South African Bulk Terminals (SABT), a business unit of BidFreight, has installed a 140m opposing Energy Chain system from igus to improve the management of cables used in the operation of two of its massive ship loaders.
Carrying an 11kV power supply as well as control and fibre optic cables, the new cable management system is proving its worth by significantly as boosting productivity and availability of the loader as well as providing safer work environment for workers on the machine. Made of specially developed igus polymers, the Energy Chains are strong with the ability to withstand millions of bend cycles while carrying and protecting the cables with little need for further maintenance or servicing. The design and layout of the energy chain system also prevents accidental damage to the critical cable and its no-lubrication requirement eliminates the risk of contamination of the bulk foodstuffs loaded and offloaded from ships every day.
According to SABT’s Houzair Dawood the opposing Energy Chain configuration ensures smooth, controlled travel over the full 140m length. Energy chains are like moving conduits and instead of dragging across walkways as the old system did the cables are protected, guided and supported throughout the ship loader’s travel path. “The system eliminates manual handling and significantly reduces wear on expensive power and data cables,” says Houzair.
He adds that for SABT’s shipping department the change has been transformative. “Previously we needed two workers with one person required to open covers and ensure free passage of the potentially dangerous high-tension cable while the other stood at the bottom floor using separate control cables to operate the machine. It was a legacy system and was no longer efficient and was not as safe as it should have been. By contrast our new Energy Chains are trouble free and ensure ease of operation that does not require any further thought or effort in terms of moving the cables.”
The use of Energy Chains in place of cable reels or simple drag chains has also allowed improved functionality and monitoring ability allowing the addition of sensitive fibre optic and control cables which are used for CCTV cameras and allows immediate control and reaction to events observed on the cameras. The cameras also provide visual checks, confirmation and record keeping of loading events.
This has translated to measurable operational gains according to Houzair. Faster repositioning of ship loaders translates directly into improved vessel turnaround times. “It’s a lot more efficient and more productive and we can offer our clients a more efficient service and quicker ship turnaround times.”
According to igus technical sales consultant, Vishay Sudamma, SABT had 11kV cable that used to drag onto a walkway. It was unwieldy and potentially dangerous and plans were discussed to replace the system with igus’ safe and trouble-free system. SABT was already familiar with igus technology having successfully implemented an energy chain system on another machine in 2018. This had operated reliably for years without the need for constant maintenance and was identified as a potential solution.
To find the right system igus collaborated with the team to understand their requirements, expectations and operating parameters. “So, for this application, the design incorporated our very reliable 4040CR series e-chain, for what is one of the longest opposing systems of its kind globally. The roller links enable reduced pulling/pushing forces while also increasing the operating life of the e-chain system. It was designed to manage the cables in a controlled system with the ability to add cables and other infrastructure as needed.”
igus managing director Ian Hewat explains that after the Energy Chains were commissioned the impact was immediate. “Previously if you wanted to start the machine you had to get people on various posts to oversee the cable. Now you put on the siren, press go and within 30 seconds or so, the machine is operational.”
He says the project shows the ability of engineered cable management solutions in heavy industrial environments such as demanding port environment. What was once an ongoing operational headache has become a global benchmark with long cable runs protected by opposing Energy Chain systems protecting critical power and data infrastructure while enhancing both safety and productivity.
