Energy chain system for shipyards: Fast and safe conversion at a height of 122 metres

• What was needed: Pre-assembled energy chain including installation service
• Requirements: Proven solution with existing references worldwide, everything from a single source and with a long warranty; functioning, low-maintenance and fail-safe cable management system
• Products: 5050RHD roller energy chain, heavy-duty stainless steel guide trough system, chainflex® TPE cable
• Industry: Shipyard, offshore wind power
• Success for the customer: Very fast conversion with qualified installation team, customised complete solution through engineering, installation and commissioning, everything from a single source ready for use within 6 weeks, functioning low-maintenance fail-safe cable management system.

The application:
The Navantia shipyard manufactures and repairs civilian ships and wind power projects. The shipyard in Puerto Real has one of the largest dams in the world. It has a shipbuilding capacity of up to 500 metres in length and two of the largest gantry cranes in Spain. The Goliath cranes used work at a height of 122 metres. They each have a lower trolley with 168 metres travel and an upper trolley with 170 metres travel.

After 40 years of operation, the old Goliath cranes needed to be repaired. The previous line rope tender system was completely outdated and susceptible to corrosion, and the cables were also showing signs of breakage and corkscrew. Maintenance costs were continually increasing and critical safety deficiencies were becoming apparent. A prompt conversion was therefore absolutely essential. With the shipyard focussing on all types of ships and offshore wind turbines, the system had to be replaced within 6 weeks. The installation had to be realised within 10 days.
Navantia had high requirements for the new system: a proven solution was expected, which in the best case would be underpinned by worldwide references. In addition, everything was to be offered from a single source and with a guarantee. The seawater-resistant cable carrier system had to guide the cable safely and be low-maintenance and fail-safe. Due to structural steel tolerances, the guide trough had to be laterally equalised. In addition, an additional load of 13 kg/m, a speed of 0.5 m/s and an acceleration of 0.3 m/s² had to be taken into account.

With our extensive global network of companies, we were able to meet these high demands. The regional branch worked closely with our engineering team. Together with the customer, we developed a customised solution. The objectives were clearly defined: The new system had to be low-maintenance and fail-safe, and it also had to have the longest possible service life. To realise this, heavy-duty roller energy chains from the 5050RHD series were used, including a heavy-duty stainless steel guide trough system. A floating moving end was installed to compensate for lateral tracking tolerances. The developed system works with large temperature fluctuations from 5 to 50 °C, weather fluctuations and high humidity. Greater system safety was realised so that nothing can fall from the crane. High-quality chainflex® TPE cables such as CF340, CF9, CF11 and CFLG were used to match the energy chain system.
In addition to the technical specifications and requirements, the installation service was realised according to the customer's strict deadlines. The complete system was replaced within 6 weeks. The installation itself took no longer than 10 days.
We were able to convince the customer with the solution across the board. The system represents a significant technical improvement and the professional installation service enabled us to meet our deadlines.