More information
Description
The project objective is to launch the production of a package of crane mechanics components to be used on vessels that support offshore wind farms, oil rigs and other offshore installations. Designs of these devices have already been developed in the R&D department of Winda-Warszawa in cooperation with the project’s Norwegian partner, ALIMAK Group Norway. The partner’s market research shows strong demand for innovative mechanical assemblies used in marine elevators which are exposed to extreme weather conditions and therefore require the most durable materials. In addition, plans by the Norwegian and Polish governments to install new wind turbines point to a coming “boom” in offshore wind farm construction. The resulting packages of mechanical crane components for service vessels serving wind farms (and, in the future, complete cranes) will be sold by the partner mainly on the Norwegian market.
The project involves the construction of a production and storage hall, the purchase of two production machines (a laser cutting machine and a press brake), and the introduction of a new manufacturing process for crane components at the company using new methods for performing strength analyses.
The technological innovation introduced under the project results in a number of benefits for recipients of the new elevators in the maritime industry. These include a reduction in the weight of the cranes, high static and fatigue strength, the life of the product extended to at least 20 years, the extension of the warranty period for the coating that protects the elements from corrosion from 2 to 5 years, the possibility of replacing individual elements of the structure thanks to its modularity, and the simplification of the execution of modernization of the cranes, i.e. reducing their downtime (in comparison with welded structures) by about 25%.
Summary of project results
The aim of the investment was to launch the production of an innovative integrated package of components of lift mechanics that can be used on vessels intended to operate offshore wind farms, drilling platforms or other installations on the open sea. The concept, design, and strength calculations of lift components were developed in cooperation with the Norwegian company ALIMAK Group Norway, which has the experience and knowledge necessary to execute orders from the maritime and offshore sectors.
The Applicant is the only manufacturer of such lifts/components in the country. The planned project will be implemented in partnership with ALIMAK Group Norway.
The project is in line with the goal: to increase the competitiveness of entrepreneurs operating in inland and marine waters through activities leading to the production of lift components that will be used in the maritime and offshore industry.
Another aim of the project was to implement a product innovation - including the development of new or significantly improved designs of key components influencing the strength of the entire lift and which are not available on the market in a form that meets the design assumptions. There will be produced new innovative lift components and lifts equipped with these elements. Process innovation will also be implemented, which includes a change in the production process of elements compared to those previously offered on the market. To achieve the planned goals, it is necessary to purchase new fixed assets – a laser cutting machine and a press brake, which will be placed in a newly built production hall. The introduced innovations will contribute to the development of the Applicant’s business activity, particularly the increase in revenues and profits.
The implementation of the project will also contribute to strengthening bilateral cooperation between Poland and Norway.
As a result of the project, innovative products were created - production of lift component packages. The package includes elements of new or significantly improved designs of key components affecting the strength of the entire lift, which are not available on the market in a form that meets the design assumptions. These are a set of cabin elements, a set of cabin frame elements, a set of counterweight frame elements, a set of power unit foundation elements, a set of overhang cable tensioner elements, a set of counterweight guide brackets, a set of cabin guide brackets and a set of suspension elements for support ropes. For example, a feature of the new floor is the complete elimination of welded joints in the case of marine lifts, and as a result, reducing the volume of the so-called welding fumes generated under the influence of high temperature and welding arc radiation. This is of great importance in terms of the impact on the natural environment. The elimination of welding work is additionally associated with another critical issue. The use of disjoint – screw connections allows for a certain modularity of the structure. As the analyses and tests carried out have shown, the floor made in such a structure provides much greater strength compared to standard structures. Another advantage is the possibility of replacing component parts without the need to disassemble the entire structure.
Process innovation involves a change in the production technology of elements compared to those previously offered on the market. During the design works, it was possible to eliminate metallurgical profiles, which required many operations during the processing phase, considerable labour input and generated a large volume of waste.
The introduction of innovative products into the market is of great importance for the solution recipients.
- The structural changes made in the design process resulted in a weight reduction compared to conventional solutions - the most advanced on the market available on a global scale. This made it possible to use electrical units with less power, which results in reduced demand for electricity.
- A construction with high static and fatigue strength has been developed. The obtained results meet the requirements of even the harshest sea conditions prevailing in the seas of the Northern Hemisphere, where more and more offshore wind farms are being built, which require special vessels equipped with lifts to operate them.
- The performed fatigue analyses allow for estimating the product''s lifetime at least 20 years. This eliminates the need for frequent replacement of lifts, the worn-out elements of which would become waste.
- The design of the lifts provides for the possibility of making any coating protecting the elements against corrosion. The complete elimination of closed profiles and welded joints enables a trouble-free operation of the hot-dip galvanizing process. The design process includes various variants of surface protection (paint coating, galvanizing, galvanizing + paint coating), which will be determined by the target customer based on the analysis of the conditions in which the devices will operate.
- The applied design, in which closed profiles and welded positions are eliminated, facilitates the execution of the galvanic coating. Due to its durability, it will be possible to extend the warranty period of the coating from 2 to 5 years.
The construction based only on split couplings ensures the possibility of replacing individual elements. This shortens the time of possible downtime of the lift, the failure of which makes it impossible to use it to transport goods and people to operate, among others, offshore wind farms. The modularity of the design facilitates also the modernisation of the devices by replacing only the necessary components. The modularity of the design also makes it possible to easily modernise the devices by replacing only the necessary components. The reduction of lift downtime caused by damage to the elements included in the package, compared to welded structures, is approx. 25%.
Summary of bilateral results
The technical knowledge of our Partner was most beneficial in terms of durability calculation for our new components solution. Due to our experience as a company working solely in the lifts sector, our Partner could have a key cooperant in lifts project design team. Our cooperation is for sure going to be continued, we have several projects ongoing with a very good perspective for year 2025. Our partnership agreement does not have a specific due date, it is being and will be continued in the future.