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Energy supply system on shipyard crane: Functionally reliable despite typhoon storms

Shanghai: Energy supply systems for shipyard cranes successfully in use for 6 years

At the southern port of Shanghai's Pudong region, at the mouth of the Yangtze River, Waigaoqiao Shipbuilding Co. Ltd. (SWS) is situated just opposite the Changxingdao port area. The Chinese shipbuilder SWS is one of the ten largest worldwide. Three shipyard cranes are currently in operation in this huge industrial area, the dimensions of which correspond to those of 30-storey high-rise buildings. The energy and data supply to the gigantic lifting elements is implemented with plastic energy chain systems from igus.

Shanghai: Energy supply systems for shipyard cranes successfully in use for six years

At the southern port of Shanghai's Pudong region, at the mouth of the Yangtze River, Waigaoqiao Shipbuilding Co. Ltd. (SWS) is situated just opposite the Changxingdao port area. The Chinese shipbuilder SWS is one of the ten largest worldwide. Three shipyard cranes are currently in operation in this huge industrial area, the dimensions of which correspond to those of 30-storey high-rise buildings. The energy and data supply to the gigantic lifting elements is implemented with plastic energy chain systems from igus.

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Case study brochure: Robust and smart

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Robust and smart – How digitally networked energy chains boost STS cranes in the port of Rotterdam

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Problem

Waigaoquiao Shipbuilding Co Ltd (SWS) was faced with the task of finding a suitable solution for supplying power and data to the gigantic lifting elements for three shipyard cranes. Due to the special location, the expectations and performance requirements for a solution were particularly high. The huge dock, which is located at the mouth of the Yangtze River, directly opposite the Changxingdao port area, is subject to weathering effects such as rain, as well as mostly uninterrupted lashing winds and the influence of salt water. These extreme effects are accompanied by a two-month rainy season every year, which harbours an additional risk of corrosion and poses a particular challenge for the solution of an energy supply system. In order to avoid system downtime, the aggressive environmental conditions had to be countered with a particularly functionally safe and reliable solution.

Solution

After energy chain systems from igus were installed on over 180 metres of travel in 2001, they have been running smoothly ever since, something that even a typhoon a few years ago could not change. The shipyard cranes and the 32-tonne material crane are supplied with energy and data via low-friction roller energy chains in igus guide troughs made of steel. The chains are designed for high cable loads and long travels, even at high speeds.
chainflex cables are used in the energy chains. Thanks to their highly wear-resistant TPE outer jacket, they can withstand even extreme conditions. The cables are resistant to UV radiation, corrosion caused by coolants, lubricants and bio-oil, and can withstand temperatures from -35°C to +100°C. Our
  system for push/pull force detection (iSense EC.P)  was also installed in this large facility. Also known as the "PPDS" (Push/Pull Force Detection System), it monitors the displacement forces of the energy chains online in order to prevent damage to the system and failures due to preventive maintenance or remote intervention.

Since its delivery, the igus energy supply system has been running smoothly and required only minimal maintenance. As a result, we have saved enormously on labour and materials.

Zhang Quan

Head of the SWS development department

Energy chain
Energy chain

Spare parts on call

SWS is also very satisfied with the ongoing on-site support provided by igus. Zhang Quan: "The service engineers contact us regularly to check that the system is working properly." SWS keeps virtually no igus spare parts in stock in order to save the capacity and costs of maintaining its own warehouse. They can be found in all sizes in the 3,000m2 igus warehouse in the Waigaoquiao free trade zone, just 20 kilometres from where the cranes are used. Zhang Quan: "If we need something, all we have to do is call igus or send an e-mail."

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