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I Ship Lift Vision Port Solutions Customer Case Study TM iVisionmax - Ship Lift Control System for L&T Kattupalli Shipyard Overview L&T has set up a large world class shipyard State-of-the-art Ship Lift at Kattupalli, near Chennai,India for Country or Region: India construction of new ships/vessels and System Industry: Shipbuilding repair & maintenance of old ships/vessels. Ÿ The shipyard has a state-of-the-art Ship Customer Profile This is a ` 4,300-crore Shipyard-cum- Lift system for transfer of ships/ vessels Captive Port Container Terminal project The Kattupalli Shipyard cum Captive Port from sea to shore berths and vice versa Complex is a large shipyard at Kattupalli implemented by L&T Shipbuilding Ltd. and the ship lift platform itself always village near Ennore of Chennai built by remains available for emergency ship L&T Shipbuilding Ltd . The Shipbuilding The shipyard will build commercial ships, facility recently set up for construction of specialised cargo ships, defence ships, repair demands. high tech vessels and the facilities at the including submarines, offshore platforms, Ÿ The shiplift can lift ships/vessels weighing shipyard include prefabrication facilities floating platform-cum storage facilities and around 18,000 tonnes at its present such as shot blasting and priming , CNC heavy engineering fabrication and capacity. With a 60 m lengthwise cutting machine, semi panel line component production for ship-building. extension, it will lift a total of 23,000 fabrication, unit assembly bay, block Housed in a spacious 1,225 acres area, the assembly and a slipway to launch the tonnes. It consists of two 200-metre- shipyard will, in the current phase, handle vessels along with a jetty for outfitting long outfitting jetties supported by two ships of up to 210 m long and 18500 T jobs for the ships under construction. It piled platforms, one cross-transfer area, launch weight. offers total solutions in shipbuilding – two defence repair berths, one wash- from concept and design for ‘new-builds’ The shipyard's world-class assembly line down berth, two commercial repair as well as repair and retrofit. The shipyard includes 20 state-of-the-art production berths and two defence 'new-build' is geared up to take up construction of berths. The self weight of ship lifting niche vessels such as specialized Heavy lift shops. The total area of the production platform is about 8200 tonnes. 68 Cargo Vessels, CNG carriers, Chemical shops is 54,765 sq.m with shops of various winches of 590-tonne capacity each lift tankers, defense & para military vessels heights that exceed 120 feet. and other role specific vessels. the platform along with the vessels. “We are satisfied and proud to have a best in class system delivered by C&A for our Ship yard facility.” P R Prabhu Director - L&T Shipbuilding Ltd A ship docked using the new shiplift at the Kattupalli yard. EAIC - Control & Automation System Details: Ÿ To dock a vessel, the platform along with sensors (Load Cell + Motor Current) were a cradle are lowered into the water, and incorporated. Hoists: the vessel is moved into place over the 590 T, 68 Nos, expandable to 92 nos. TM platform. When in position, the The software iVisionmax-Ship Lift is Platform Speed: platform is raised to the shore level and developed by L&T Control & Automation keeping in mind the criticalities involved in 0.18M/Min vessel is removed from the platform using transfer system to shore berth. the operation. The important features Ship Weight: Ship Lift platform, thus, is available for provided are as follows: 18500 T, expandable to 23000 T. next operation. On completion, the 1. Speed synchronization of all hoists Platform Length: process is reversed. The Ship Lift system 200 M x 46 M, minimizes space required for launching 2. Position skew monitoring between expandable to 260 M x 46 M. ships at the waterside and the transfer hoist pairs as well as adjacent hoist system ensures maximum use of the pairs. Maximum skew allowed: shore work area away from the water 15 MM (Achieved max 5 MM) front, without polluting the waterway. 3. Maximum position skew monitoring Control System Software: between any two hoists. TM Why L&T Shipbuilding iVisionmax-Ship Lift 4. Load sharing between hoist pairs chooses C&A Drive: 5. Expected load Vs. actual load on all Control & Automation Business Unit (CA) 30 kW Closed Loop Vector Control hoists. of L&T supplied the Electrical & Control Power System: System for the ship lift system. The scope 6. Safe halting under all conditions 11kV/4 x 415, 50 Hz, 24 Pulse, 2 MVA i n c l u d e d d e s i g n , e n g i n e e r i n g , manufacturing, testing (FAT & SAT) of the 7. Centre of gravity calculation entire system and documentation, 8. Run / inch control with auto slow down. followed by Lloyds Certification. The system is operational since January 2012. The critical factors 9. Individual/pair/group/platform control The entire system development was done considered in the design: 10. Initial position calibration facility. indigenously by pooling expert engineers 1. Platform stability under from Electrical, Drives and Controls 11. Maintenance mode operation. all normal and fault conditions Departments of CA having 15 to 25 years 12. Storage of ship loading data for future 2. Robust Power System of experience. The development task involved clear understanding of use. 3. Ease of Operation mechanical system behavior consisting of 13. Monitoring of various other parameters hoists, ropes, platform and the load through condition monitoring. distribution. 14. Elaborate event, alarm and fault Platform stability under all logging system. conditions: 15. Multilevel password access for Platform stability under all conditions was operators and administrators. of primary importance. The team performed Design Failure Mode Effect 16. Redundant servers and controllers. Analysis (DFMEA) for electrical, control & Power System Design: mechanical system listing all possible faults that might occur while carrying out the CA decided to use standard squirrel cage operation. Based on the probability of fault induction motors driven by closed loop occurrence, ease of detection of fault and vector control drives in place of likely consequence, the system architecture synchronous motors. The advantages were including protection system was reviewed. obvious. As an outcome of this exercise, redundant 1. Servo like performance. Position control system (Servers & Controllers), accuracy better than 2 mm over entire redundant communication, redundant vertical travel length. position sensors and redundant load EAIC - Control & Automation About Us 2. All hoists could be started at the same and hence does not face downtime when L&T Control & Automation (C&A) is a Strategic time without the problem of inrush mains power is not available. Business Unit of L&T Electrical & Automation. It current. So, no need to stagger starting is a part of Larsen & Toubro – the multi-billion Ease of Operation: India-based conglomerate. L&T's C&A business of hoists. is market leader in delivering integrated 3. System has built-in feature to run at User-friendly GUI on operator stations with electrical & automation solutions in India and overseas. With over three decades of experience higher speeds in the field weakening elaborate diagnostic system, ease of in diverse industry segments, C&A delivers value mode for lighter loads. navigation between the GUI screens, through comprehensive solutions based on extensive fault diagnostic screen for quick varied technology platforms and incorporates 4. Power factor is better than 0.95 identification of problem are some of the the benefits of its wide-ranging experience. L&T's state-of-the-art Automation Campus at 5. Lesser maintenance for motors. features responsible for ease of operation Navi Mumbai in India has the latest testing and All the drives are fed from a 24-pulse power of the platform. Condition monitoring manufacturing equipment. It incorporates a provides early alerts for preventive modular manufacturing unit, an application system and the problem of harmonics has software laboratory and a fully networked office also been eliminated. The entire ship lift maintenance avoiding costly breakdowns. for engineering and project management. system can be run on a diesel generator LARSEN & TOUBRO Control & Automation Automation Campus, Shil Mahape Road, Navi Mumbai, India. Tel : 91-22-67226300 A screen grab showing load distribution in the shiplift system E-Mail: Rahul.Rane@LnTEBG.com CNA-marcomm@LnTEBG.com Web Site: www.LnTEBG.com Our Integrated Electrical & Automation Solutions: Cement l Material Handling l Cement Plant E&I l Automation Solution for Steel Making Energy Solutions l LV/690/MV Drive Systems l Solar PV Products and solutions l Power Management System l Availability Based Tariff System Infrastructure l Airport Baggage Handling Systems l PMS for Airports & Metro l ECS & TVM for Metro l AFC for Metro Oil & Gas l Integrated Process Control System l Pipeline SCADA l Emergency Shut Down System and Fire and Gas l Terminal Automation Power l Integrated Controls for Boilers and Turbines l Station C&I for Power Plants l E&I for main plant & BOP Systems The solution has been in use since mid-2012 and has successfully met user's expectation of smooth operation. With this proven track record, L&T is fully geared up to provide similar integrated solution to global ship yards. Control & Automation Business Unit is the part of Electrical & Automation - Larsen & Toubro Limited. The views expressed in this publication are not necessarily those of the management of Larsen & Toubro Limited. All trademarks are the property of their respective owners. We reserve the right to modify or improve the design or specifications of the products at any time without notice. The contents of this publication should not be reproduced without the written permission of the Editor.
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