Case study: Zelzate bridge

RENOVATED ZELZATE BRIDGE ENSURES CONTINUATION OF SHIPPING ON - CANAL

AGIDENS INFRA IN SHORT

FOCUS: The Ghent-Terneuzen Canal connects Ghent to the Westerschelde, a direct connection to the North Sea. The canal is vital to the economy of Ghent. »»Locks The canal divides the municipality of Zelzate. Both parts of the municipality »»Bridges are connected by the Zelzate bridge, one of ’s largest drawbridg- »»Tunnels es, and by the Zelzate tunnel. »»Flood-control dams »»Pumping stations »»Railway network MODERNISATION NECESSARY FOR THE CONTINUATION OF SHIPPING OUR EXPERTISE: In 2008 the electromechanical equipment of the bridge was more than 20 years old, some parts more than 40 years old. The age of the equipment contributed to more and »»Process & Mechanical more defects. Given the importance of the bridge for shipping and the road, it was essen- »»Hydraulica tial that the bridge operated reliably. »»E&I Most importantly of all, the bridge no longer met necessary safety standards. That is »»Control why the Flemish Road and Traffic agency decided to fully renew the electromechanical equipment in order to meet current standards. Agidens won the contract to carry out this job at a value of € 3,800,000. Agidens selected Bosch Rexroth for the hydraulic system, Vandezande for the mechanical parts and RDM Smeertechnieken for the renewal of the automatic lubrication system.

REDUNDANT VERSIONS ENSURE CONTINUOUS OPERATION The control is composed of a double redundant glass fibre-ring between the respective bridge cellars and the control building. The control sequence that allows both sides of the bridge to fold synchronously is carried out by a hot redundant Schneider Premium PLC set-up in the control building. In both bridge cellars there is an identical plc set-up that is responsible for controlling the technologies. The bridge’s safety latches are monitored by one hot redundant plc per bridge cellar. The higher-level Vijeo Citect Scada-software is redundant in the control tower. In each bridge cellar a SCADA set-up has been provided for maintenance. Case study: Zelzate bridge

SCOPE FASTER, MORE RELIABLE AND MAINTENANCE- The job consisted of the renewal of the existing electromechanical FRIENDLY BRIDGE equipment of the Zelzate Bridge: The new control system and operation of the bridge are extremely »»Fully redundant PLC control with plcs for the control of the critical reliable. This a great added benefit to the customer, both in terms technical steering locks. of reliability and efficiency. Due to the rapid start-up of the plant and faster sequences of control actions, waiting time for road traf- »»Fully redundant glass-fibre ring between the control tower and fic users has been significantly reduced. Thanks to the extensive both of the bridge cellars. Separate section (1 glass-fibre ring monitoring and data capture techniques, the technologies can be via the underwater crossing, 1 glass-fibre ring via the Zelza better monitored in the maintenance module. If there is a problem, tunnel) it can be diagnosed much more quickly and this limits reaction »»Redundant SCADA operation to replace the old operation desk. time.

»»Renewal of the existing power plant in the existing control build- ing (left side of the Zelzate Canal) for energy supply for the con- PROJECT AND SYSTEM DATA trol building and for supplying the left-hand side of the bridge and its systems. Specifications Data

»»New power plant for the right-hand side of the Zelzate canal for Client Ministry of the – Roads and Traffic Agency the energy supply of the right side of the bridge and its systems. Place Zelzate »»Disassembly of the old relay room for the control of both sides of the bridge. Type of work Double drawbridge with front locking devices »»New low-voltage control panels and general service signs in Project Electromechanical renewal each bridge cellar for the control of the corresponding side of the bridge and its existing locks and systems. Date of sale November 2006 »»Full renewal of the shipping signalling system (replacement of the old coil signals with LED signals). Completion date May 2011

»»Renewal of the hydraulic system of the drawbridge mechanism Contract value 3.806.361.56 euro (part Agidens) (excluding the drawbridge cylinders. »»Project management and study Full renewal of the mechanical and hydraulic system for locking »» »»High voltage and low voltage under the counterweight »»PLC & Scada Full renewal of the mechanical and hydraulic system for locking Scope »» »»Mechanics & hydraulics (clamping) on the front of each of the 2 sides of the bridge. »»Lubrication system Renewal of the whole lubrication system »» »»Safety & hindrance free actions

Services Annual maintenance contract LIMITED OBSTRUCTION FOR ROAD AND SHIPPING TRAFFIC The biggest challenge of this project was undoubtedly the require- ment that the bridge could only be out of use for 6 weeks for road traffic, and that a limited amount of shipping traffic was still to be allowed through during this time. The nature of the mechanical work meant that the drawbridge could not lock during this period and it remained in an upright position. The bridge needed to be able to move during the electromechanical conversion.

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»»05/2016