44 n SERVICE AND REPAIRS September 2024 www.drivesncontrols.com Retrofit gives Dutch container crane a lift Cranes are often used in demanding environments where they must withstand heavy loads, harsh weather conditions and rigorous usage. These operations can be energyintensive, and finding a balance between energy efficiency and environmental resilience can be a challenge. Nedcranes is a Dutch company that specialises in port cranes and their drive systems. Its activities range from inspections and repairs, to the complete overhaul of cranes. In a recent project, it was tasked with modernising an overhead crane system at the Rail Port Brabant rail terminal in Tilburg, Netherlands. The project would involve dismantling an old crane, reducing its track width from 41m to 27m, adjusting its beam length, and turning its cab around to give the operator a better view of containers, trucks and trains. About 500 containers can be stored under the refurbished crane which is the port’s first container crane; previously, containers were handled by reach stackers. The crane’s electrical installation has been completely redesigned and fitted with Schneider inverters with the ability to recover energy. The installation’s mediumvoltage supply has has also been renewed, including a 10kV transformer. To improve efficiency and performance, Nedcranes decided to replacing the existing DC motors with AC motors, powered via VSDs (variable-speed drives). It was expected that the conversion would result in precise speed control, reduced maintenance and enhanced reliability. By varying motor speeds, the VSDs enable smoother operation and better performance, while also allowing for more flexible and efficient power management. Four 30kW motors were used for crane movements, two 22kW motors to power trolley movements, a 7.5kW motor for lifting duties, and a 170kW motor to power a winch. All of the motors, except for the winch machine, were equipped with gearboxes and mechanical brakes that are a standard safety requirement for cranes. WEG supplied all of the IE3-efficiency motors are from its W22 series. The motors have a ventilation system that results in low noise levels – an important consideration because the rail terminal is located near a residential area. The system also achieves a good distribution of air flow over the motor, reducing hot spots on the surface and increasing reliability. n A crane at a Dutch port has been refurbished to give it a new lease of life as a container-handling system. The overhaul included converting the previous DC drive system to a series of efficient AC motors and drives, thus improving performance and reducing noise levels. Overhauling the crane at the Brabant rail terminal has improved its performance and efficiency Custom-built motor replaces 50-year-old cooling pump drive A 50-year-old motor that drives a cooling tower pump in a CHP (combined heat and power) plant in Cologne, Germany, has been replaced by a new 1.65MW squirrel-cage modular motor which has been customed designed and built to make the substitution easy. While the original motor was still running reliably, the utility that operated it wanted to replace the machine to avoid possible future problems. However, it couldn’t find a suitable standard replacement motor on the market. It therefore called in the German motor-maker Menzel Elektromotoren, which specialises in designing and manufacturing custom-built machines to replace old motors. It configured a new three-phase squirrel-cage motor in a 630 frame size, equipping it for vertical flange mounting and providing IP23 protection and type IC 01 open-circuit ventilation. The high-power-density, low-weight 6kV motor has a torque rating of 31.897kNm. The original motor’s connection dimensions, terminal box locations and instrumentation were copied on the replacement machine, which complies with the latest standards and operates with a higher efficiency. Menzel also installed a coupling supplied by the utility, thus ensuring easy replacement of the motor, and speedy recommissioning of the cooling tower pump.
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