Paper 83 - Smart Mechanical Drive Solutions fo Locks ...€¦ · Paper 83 – Smart Mechanical Drive Solutions For Locks ... in case of system blackout and braking system failure,

“SMART RIVERS 2013” Liege (BE), Maastricht (NL), 23-27 September 2013

SMART RIVERS 2013 (www.SmartRivers2013.org ) Paper 83 - Page 1/4

Paper 83 – Smart Mechanical Drive Solutions For Locks – Weirs – Moving Bridges

LAUNAY PY.; DUCRET X.; LESSARD F. CMD Gears (Compagnie Engrenages et Réducteurs Messian Durand), Cambrai, France – Groupe CIF

Email: [email protected]

ABSTRACT: New Navigation projects, as well as refurbishment programs, are very often coming across the need for steel structures drives: for opening/closing lock doors, for emptying/filling lock basins, for regulating river water levels with weirs, for moveable bridges or boat lifts motions. This paper will expose the various requirements related to drives functions, how various drives comply with these requirements, and develop 3 case studies, where mechanical drives are used with specific ‘smart’ features (Villeneuve/Yonne 1 & 2, Ramspol Bridge).

1 INTRODUCTION

From the approach standpoint, each project has its own specificities: heavy or moderate loads, frequent or occasional operation, low or medium speed motion, safeguard position by holding in place or lowering down, environmental or ‘climate’ requirements, skills of the local task force for operation & maintenance, availability and sustainability of ‘power’ resources…

For each specificity, there is the need for a dedicated answer. The following chapter will develop the various specificities and adequate answers, and how various mechanical drives can comply. 3 case studies will be developed to emphasize smart features that were used to comply with specific projects requirements:

- Villeneuve / Yonne 1 – Yonne River – France • Weir drives with safeguard position ‘hold

in place’ - Villeneuve / Yonne 2 – Yonne River – France

• Weir drives with safeguard position ‘let the gate go down’

- Ramspol Bridge – Zwarte Meer N50 – NL • A power consumption bascule bridge

compatible with solar panel output

2 VARIOUS SPECIFICITIES / ANSWERS

2.1 Introduction

All applications, either on new projects or refurbishments programs, have in common the need for maximum reliability, low or free maintenance, reduced TCO (Total Cost of Ownership) and NPV

(Net Present Value), and being more and more environmentally friendly. In addition to that, specific smart features are often integrated to the drives for easiness of operation, monitoring, control and protection.

2.2 Maximum Reliability

Maximum reliability is obtained, of course in the first place by using the proper design & engineering standards (ISO, DIN, AGMA, EUROCODES, DNV, IEC), as well at state of the art design, manufacturing, assembly and testing tools. It is also obtained by using the most ‘standard’ equipment (versus special ‘tailor-made’ solutions), proven technology (versus high-technology prototypes)

Figure 1: Full load testing at CMD Durand workshop with irreversibility testing (Winches on lifting bridge)



2.3 Low or free maintenance

In many cases, local task forces for maintenance are reduced; therefore this feature is particularly emphasized at the early stages of each project. It is obtained of course by working towards maximum reliability products (see §2.2), but also by using specific material (stainless steel on chains), lubrication methods (rustic splash lubrication versus high pressure forced lubrication), reinforced sealing methods (labyrinth seals, double lip seals), alternate lubricants (low quantities of semi-fluid grease versus full load of oil).

Figure 2: Mechanical jack on Sambre River, installed more than 30 years ago (Voies Navigables de France)

2.4 Reduced TCO & NPV

TCO (Total Cost of Ownership) and NPV (Net Present Value) analyses are used to support projects and planning decisions. TCO is very spread, and more and more combined with NPV, that integrates capital cost but also operating and maintenance costs for a period of time. Reduced TCO & NPV are obtained by fulfilling the requirements of § 2.2 & 2.3; also the use of the most standard equipments, casted casings, having interchangeability between various infrastructures.

2.5 Being environmentally friendly

When maximum reliability, trouble free operation & reduced maintenance is observed, of course your equipment is more environmentally friendly. Having said that, more & more compulsory regulations require that all contingency situations would not be detrimental to local fauna & flora. Therefore, equipment manufacturers work hand in hand with lubricant specialists to increasing sealing properties, spillage safeguard systems, and of course

‘ecological’ lubricants. Indeed, gear manufacturers are now able to provide ‘biodegradable’ greases and oils, or complete ‘Ecolabel’ winches. On some occasions, alternate materials like stainless steel can be used (Galle Chains).

2.6 Monitoring & Control

Water regulation requires being able to reading reach levels, but also to implementing triggers to be able to protect both the environment and the machinery. Modern drives (chain or cable winches, mechanical jacks) can integrate full monitoring and control systems:

- Position of the gate (weir, lock, bridge…) can be monitored through the use of encoders or selectors directly mounted on a drive inner geared shaft. These features can provide also triggers (Lo, LoLo, Hi, HiHi) that can be doubled for redundancy by direct sensors & switches mounted on the drive end (chain, cable, jack rod)

- Load control can be easily integrated to modern drive: load cell on a floating hollow shaft winch, strain gauge on chains and cables, flexion sensor on jack road. Continuous monitoring as well as designated switches will allow proper operation and control.

Figure 3: Modern worm gear chain winch with full monitoring & control package (encoder on low speed shaft, position switches on chain, load cell on torque arm), and full protection package (service & stand-by motors & brakes, rotating parts & spillage guards)

2.7 Protection, contingencies and safeguards

In addition to the standard ‘protection package’ indicated at 2.6, modern drives can modulate their reversibility level, from being completely reversible to being completely irreversible. This last feature can be achieved by the use of designated worm



gears properly installed through the drive kinematic. Indeed, the reversibility factor will depend on the helix angle between worm & wheel (the higher the ratio, the smaller the helix), and it will also depend on the operating speed (refer to figure 4). A worm winch will be either fully reversible (small ratio at moderate or high speed), reversible with static irreversibility (moderate or high ratio at small or moderate speed) or fully irreversible (very high ratio at very low speed). This will allow, in case of system blackout and braking system failure, to hold the gate in position, even during a started motion. Full irreversibility shall be tested at workshop to avoid complicated full scale testing (refer to figure 1 also) . This feature can be modulated to achieve for instance static irreversibility (hold in position, but dynamic reversibility achieved to let the gate go down during contingency operation). The same principles can be observed on mechanical jacks, from full irreversibility (trapezoidal screw threads) to full reversibility (ball or satellite roller screws).

Figure 4: Reducer & multiplier efficiency curve showing how a Durand ZA profile 200 mm centre distance worm gear with 50/1 ratio achieves dynamic irreversibility at 5.4 rpm input speed

3 CASE STUDIES

3.1 Villeneuve / Yonne 1 – Yonne River - France

This weir was part of a general refurbishment program lead by Voies Navigables de France to modernize old ‘Needle’ weirs on Seine, Marne & Yonne Rivers. Over 30 winches were installed using a small combination of standard worm gearboxes (primary 160MH & 200MH & secondary 315C & 400C Durand gearboxes); all winches have resilient casted steel casings, are mounted between bearings and fully tested at the factory; throughout the years the winches were equipped from standard to full monitoring and protection packages. All winches needed irreversibility to hold the weir in position in case of a motor or brake failure. Villeneuve/Yonne 1 is a 2 weirs dam, equipped with 200MHF2x400C Durand winches. Each weir is 17.5 m wide, with a 1.75 m wedge & 45 Tons load. The winches are composed of 20/57 & 18/59 helical gears & 2/31 & 1/40 worm gears; the 1/40 worm gear, installed at low speed shows static irreversibility. The worm is installed beneath the wheel to allow permanent oil film with minimum oil level & maximum sealing.

Figure 5: Worm chain winch on Yonne dam

3.2 Villeneuve / Yonne 2 – Yonne River – France

This project was carried out in 2012/2013 and was part of a second phase of the global refurbishment program of Voies Navigables de France to modernize ‘Needle’ weirs. This project beneficiated form the feedback experience accumulated throughout the years and the completion of previous refurbishment projects. This time, full reversibility was required as well as ‘state of the art’ ecological features. Villeneuve / Yonne 2 is a 3 weirs dam; each weir is 16 m wide with a 30.5 Tons load; the winches are composed of R3HC30 & R3HC42 ERmaster gearboxes, with a combination



of fully reversible 3 + 3 helical gears & high resilient steel fabricated casings. The winches are mounted between bearings, with load cell on torque arm, position switches on the Galle chain, encoder at low speed, service & standby brake motors, parking brake, centrifugal brake and display panel.

Figure 6: Villeneuve/Yonne 2 winch assembly at CMD Cambrai workshop

3.3 Ramspol Bridge – Zwarte Meer N50 - NL

This project had a very particular requirement, which was to have a power consumption for the bascule of the bridge compatible with the installed solar panel output. The bascule of the bridge is achieved through a typical Dutch solution composed of a drive with motor + coupling + spindle + pinion + Panama wheel.

Figure 7: Bascule bridge ‘Panama wheel’ kinematic To achieve this low consumption, design &

manufacturing engineers from bridge & drive companies had to work hand in hand to reduce drastically the energy losses and increase efficiency. The gearboxes, couplings & Panama wheels were designed, manufactured & tested on ‘state of the art’ machining, cutting & grinding machine, achieving a quality ISO 5 or better on

tooth. 10% energy savings were observed making the project possible.

Figure 8: Panamawheel on 3D bench after tooth grinding

Figure 9: Panamawheels during assembly at Ramspol Bridge

4 CONCLUSION

Recent projects have emphasized the possibility for mechanical drives to achieve the highest standards & requirements, trouble free operation, low or no maintenance, reduced TCO & NPV and respect for the environment. In addition, smart features can now be incorporated to comply with project specificities, whatever their complexity.

REFERENCES

VNF/CETMEF. 2008 – Vannes clapet – dossier type

VNF/CETMEF. 2006 - VN-06-03 – Amélioration de l’exploitation des barrages à manœuvre manuelle

VNF/CMD. 2002. Synthèse des opérations de maintenance et de suivi sur les treuils de vanne

Jean-Pierre BLUZAT – Philippe AUGENDRE. 1988. Moto-Vérins Mécaniques. Conférence aux Vois Navigables de France

Paper 83 - Smart Mechanical Drive Solutions fo Locks ...€¦ · Paper 83 – Smart Mechanical Drive Solutions For Locks ... in case of system blackout and braking system failure,

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