Over the years the introduction of new Computer Aided Engineering (CAE) software into the design process allowed engineers to significantly shorten the time necessary to produce finished designs. There seems to be an agreement that using CAE tools shortens the time of the design process and improves the quality of finished products. Although, oftentimes in research it is the improvement in quality, which is focused on when presenting new tools. However, in an industrial setting, what also matters and is frequently the main concern are the improvements in time efficiency. It would be undesirable for the newly incorporated software to elongate the process. In this study, the effects of incorporation of a new CAE tool on the design process is researched in an industrial setting. The opportunity, which allowed for this research is the incorporation of a new post-processing software for the finite element analysis Jan De Nul Marine Engineering and Design Department. In order for the new tool to be implemented, its effects on the design process should be tested. In order to do that, the methods of design were researched in order to find what is the current design methodology and its structure. This is done based on a case study, a draghead gantry for a trailing suction hopper dredger vessel. In this case study the equipment is designed according to the methodology used in the department. Based on the first design, the methodology of design used in the department was codified. Then, problems which were found in that process are addressed and a new design methodology is proposed based on the solutions, literature and adaptation to the new software. Next, the new design process is presented. Lastly, the results of both approaches are shown and compared.

As a result of the need for higher productivity ship-to-shore container cranes, seven concepts are composed that can simultaneously transfer 4 Twenty Foot Equivalent Unit containers. All concept can be built on a standard ship-to-shore crane structure. These concepts are based on working principles found in (patent) literature. The concepts are compared based on multiple objectives, after which one concept is chosen to realize a concept design. A ship-to-shore crane with two trolleys turns out to be the most suitable concept. The two trolleys consist of a rope towed trolley and a semi rope trolley, which are combined with a continuous rope support system. The design of the trolleys is based on an existing trolley. For all wire ropes to run adjacently, the sheave diameters and positions on both trolleys deviate from the existing trolley. The sheave positions have consequences for the trolley frame design. To validate the adjusted trolley frames, a finite element analysis is performed.

Offshore contractors use special cable laying vessels (CLV’s) in order to install subsea power cables, which transport offshore generated energy. Workability studies are performed to evaluate whether operations can be performed or not. These workability studies are subsequently a combination between operability assessments (performed in OrcaFlex months prior to operation) and forecasted weather windows. During the operability assessment, eventually limiting sea states are defined which are expressed in significant wave height (Hs), wave peak period (Tp) and incident wave angle relative to the vessel heading (a). If the forecasted weather windows exceed the predefined limiting sea states, operations cannot be executed. These current workability assessments are based on 1D JONSWAP spectra. This thesis contains an exploratory study of implementing a motion-based forecasting (MBF) method into workability studies, based on 2D wave spectra. This is done by focusing on the motions at the chute of the CLV, as this is where the subsea power cable leaves the CLV. Before MBF can be implemented, however, at first a specific limiting motion predictor needs to be identified that covers the cables integrity limits. Furthermore, this limiting motion needs to be quantified as well in order to compare this essentially composed new cable limit with MBF predicted chute motions. Subsequently, all cable integrity criteria need to be converted into this limiting motion to preserve the subsea power cables integrity. For normal cable lay operations, eventually all mechanical properties and cable limits are covered by three main cable integrity criteria. These are minimum bending radius (MBR), minimum bottom tension (BT) and maximum top tension (TT). By means of modelling a lot of various environmental loading conditions, the research described in this thesis shows that the chute z velocity is eventually indicated as a proper limiting motion predictor. Out of all investigated chute motions, chute z velocity (which represents the vertical velocity of the chute) shows the best correlations with the aforementioned cable integrity criteria. To determine workability by implementing motion based forecasting, this limiting chute z velocity needs to be quantified. The chute z velocity needs to account for all three main cable integrity limits, hence these limits are essentially converted into one single chute z velocity limit (which is essentially a new introduced cable limit). To quantify this limiting chute z velocity not the entire relation is of interest, but only the range close to breaching the cable integrity limits. Therefore, a percentile line method is introduced which is constructed on the 90th-percentile values per bin. Based on this research, it was found that binwidths must not exceed values of 0.5m/s to obtain robust results. However, no minimum amount of data points per bin was established as this varied for all assessed subsea power cables. Finally, workability studies of the current 1D JONSWAP (based on a single Hs −Tp sea state) method was compared to a 2D superimposed JONSWAP accounting for both swell and wind wave contributions. This comparison indicates that when determining workability based on more detailed 2D spectra, the workability study provides more smoothed results. This means, the higher chute z velocity peaks from the 1D total sea state are downscaled when simulating a 2D spectrum, whereas the lower chute z velocity peaks from the 1D total sea state are upscaled when implementing a 2D spectrum. The obtained motion-based chute z velocity forecasts indicate that optimization is possible by splitting the total sea states into both swell and sea waves contributions and accounting for wave spreading.

Mammoet is developing a new type of system for the transportation of offshore power cables. With this system the cables can be spooled, stored, and transported both on land and on heavy transport vessels in a more efficient way. There are a few uncertainties for the system, mainly about the loads on the carousel and the behavior of the cable stack. These uncertainties resulted in some assumptions that have been used for the proposed design. Furthermore, there are a few challenges for the system that need to be addressed to compete with the current offshore power cable transportation methods. The main challenges include the structural strength and stability in combination with the self-weight, the used cylinder stroke of the hydraulic SPMT cylinders and other issues with the SPMTs. In this study these uncertainties and the challenges for the current design of the system are investigated, which resulted in more insight in the uncertainties and a new concept with improved performance against the challenges.

Wind loads acting on STS cranes are an important design parameter to be taken into account when designing STS cranes. Current calculation standards such as the EN13001-2 overestimate wind forces. The goal of this research is to propose an improvement on current calculation standards. Wind tunnel tests were performed to assess the results of standard calculations. Computational fluid dynamics were validated against the wind tunnel and used to investigate the root cause of this difference. This research proposed the use of the shielding coefficients found in the DIN 1055 standard for horizontal elements in conjuncture with the EN13001-2 standard for more accurate calculations.

For years, ESI Eurosilo have successfully stored several, mostly low-density, non free-flowing bulk materials in their silo’s. Recently, demand has arisen whether bulk materials outside their current range could be stored using the same reclaim screw system. Unfortunately, the theory behind the screw dates from the 1980s and assumes fine powdered bulk material, making it difficult to predict the reclaim screw performance. This paper demonstrates the effects of bulk materials on the scraping process of a reclaim screw by modelling its mechanics using DEM, as scraping is most prone to external influences like consolidation. The reclaim screw has been simplified to a single linearised flat disk, which is still able to exhibit a behaviour similar to the screw. The effects of bulk parameters have been investigated using the DEM model by a comparison to the analytical model to see whether the simulation results agree, a screening process to find the most significant bulk parameters on the scraping process and an optimisation to find the optimal screw design of a low- and high-density bulk material.

Maintenance of complex machines or assemblies is an essential part of machine-building companies. Besides building and designing machines, they are responsible for replacing components and restoring the machines to maintain good operational conditions. An optimal maintenance plan ensures that customers spend less on maintenance and remain satisfied. Also, for the machine builders, an optimal maintenance plan shows efficient use of the service mechanics, trust in the machines and the quality of the knowledge. This research aims to create a maintenance framework that leads to a suitable maintenance plan starting from experience-based maintenance. The framework proposes steps in which initial data points are collected, calculates the maintenance intervals and estimates values for a failure distribution to obtain knowledge of components, while it is still manageable (practical) for the service department. Eventually, this paper shows the benefits of the proposed maintenance framework relative to maintenance based on experiences like reactive maintenance. A simulation model has been developed, showing the KPIs of the framework and results from the framework. In addition to the simulations, this project provides guidelines for the service department to implement the framework.

This thesis focuses on a vertical farming system designed for growing crops. The system’s deficiencies were identified during a company visit where the system was operating. An analysis was conducted to see when all deficiencies would be resolved. It revealed that the vertical farm robot had to be redesigned to grab seven benches deep to eliminate the system’s shortcomings and significantly enhance its performance. Thus, a literature review was conducted to determine possible solutions. As a result, various alternatives were devised based on the requirements and constraints considering the available design space and a morphological chart. These alternatives were scored with a weighted criteria method, and the best view was elaborated in more detail. Subsequently, a computer-aided design of the best overall-looking design was created. After ordering all materials, a design prototype was built inside a climate cell in the research centre, and all sensors and drives were wired and controlled by a programmable logic controller to fully automate the prototype. A proof of concept was successfully obtained from the test results. Therefore, this redesign of the system’s performance was enhanced, and this thesis was successful.

Wind turbine industry is growing and future predictions are promising. However, a shortage of installation vessels could influence this growth in offshore wind industry. Commonly, wind turbines are installed in components using a jack-up vessel. Occasionally, wind turbines are installed fully assembled. The center of gravity of a fully assembled wind turbine is relatively low and thus lifting above the wind turbine is not necessarily for fully assembled wind turbine installation. Wind turbines can be installed fully assembled using cranes in twin lift configuration to reduce required lifting capacities. The flexibility and scalability of the vessel depends on the location of the cranes on the vessel. Different vessels can install wind turbines with their advantages and disadvantages. To identify these solutions, principles are proposed and compared with state-of-the-art vessels for wind turbine installations. A morphological analysis is used to identify promising solutions for fully assembled wind turbine installation. Eight concepts are compared in a scenario comparison with varying distance between nearby marshalling ports and the wind turbine park location. Several solutions show subsequent improvement in installation rates. One new concept, the PWT installation vessel, shows overall improvement in installation rates. This solution, developed by the author of this report, is proposed for flexible and scalable fully assembled wind turbine installation.

Erosion of the seabed around offshore structures, due to current and waves, is a common occurrence. Scour protection by rock placement can be done in order to limit erosion and its consequences. Tideway Offshore Solutions will use the multipurpose vessel ’Living Stone’ to execute such rock placement operations. Aboard the Living Stone a newly designed inclined fall pipe system will be installed to transfer the rocks through shallow and possibly high current water towards the seabed. The goal of this thesis is to design a concept of a rock handling system to feed the inclined fall pipe system aboard of the Living Stone. The concept requires to be capable of handling armourstone with gradings up to 60-300kg and continuous mass flows up to — tonnes per hour. With the use of the VDI 2221 design cycle the function, principle and solution structures were created to realise a morphological overview. Multiple concepts were created and evaluated on criteria including the maximum allowance of peak production, proven technology, maximum solvability, minimum required space and minimum costs. Thereafter, a preliminary layout was created for the concept ranked highest. In order to be sure the concept is capable of generating the demanded mass flows in terms of capacity and accuracy, discrete element modelling was used. With the use of EDEM-software the performance of the in Solidworks created model was studied. After calibration of the simulated material, the performance of the concept was studied by varying the outlet area and the feeders’ velocity. This resulted in the associated mass flows and their fluctuations. The accuracy of the mass flow was defined as a percentage of the mass flow in which the flow fluctuated. The configuration was studied and set for further simulations, using Box-Behnken design of experiments and Minitab-software. The mass flow, depending on the installed shear height and the velocity of the feeder, was validated with empirical theory for apron feeders. This work demonstrated that the ratio between the outlet area, defined as the outlet diameter but realised by the shear height and feeder width, and the maximum particle diameter is of great influence on the mass flow. The smaller the ratio, due to an increase of particle size and/or decrease in outlet area, the less accuracy of the simulated mass flow. The difference between the simulated and theoretical mass flow increases exponential with the decrease of the ratio between outlet diameter and maximum particle diameter.

Dust emissions developed during the handling of dry bulk products pose increased risks for health, safety and the environment. Legislation drives bulk handling facilities to face the challenge of maintaining dust emissions within limitations. At the bulk terminal of Verbrugge multiple bulk products are handled, making the dust control problem even more difficult. The aim of this research is to improve the dust control methods of bulk handling equipment handling various dry bulk products to further reduce the dust emissions. A dust control strategy is developed based on the knowledge gathered through theoretical and practical research concerning the formation and control of dust emissions. The strategy provides a structural approach to identify the most suitable dust control methods, applicable for all types of bulk handling operations and bulk products. It incorporates the specifications of the dust source, investigates the feasibility of dust control measures, and creates and evaluates combinations through a weighted multi-criteria analysis. The decision-making tool is implemented at three dust sources at Verbrugge and proposes dust control methods to improve the reduction of dust emissions. The strategy suggests providing transfer chutes between two conveyor belts with a flex-flap system to avoid dust dispersion within the installation. The proposed method offers a safer, more reliable, less expensive, and maintenance-friendly solution as opposed to the currently applied dust collector. The implementation of the dust control strategy at the transfer between a grab and hopper offers the valuable insight that the design of wind screens need to be optimised in order to improve the extent of dust control. The ship loader is best equipped with a cascade chute and dust skirt, as suggested by the strategy. This study shows the developed dust control strategy not only substantively proposes the most suitable dust control methods, but also offers valuable insights into potential issues, provides possible solutions or improvements, and significantly reduces the time and effort invested in the decision-making process. To further enhance the findings of this research, it is recommended to include the effects of organisational dust control measures and a design aspect in the dust control strategy. Additionally, a more reliable assessment of dust control measures can be achieved by quantifying the generation and control of dust emissions.

Ship to shore (STS) cranes handle millions of containers every day. One of the latest products from Stinis is the Split-Headblock. This device allows its user to work in tandem operation in which up to two 20ft or four 40ft containers can be lifted at once. In order to further increase the performance, it is important that it can be accurately positioned. Due to wind, trolley driving, and possibly other factors, the Split-Headblock starts to skew. This motion makes it very difficult to enter a cell on a ship or place the containers onto truck trailers. Reducing the skewing motions can therefore increase the cranes performance. Several attempts have already been made to control this motion from the crane. This research proposes a method to control the skewing motion from the headblock. A solution is proposed where horizontally movable sheaves are controlled with a PID controller to control the system. Tests are performed with a Simulink Simscape simulation model. The solution has been tested on a variety of load cases, hoisting heights and external disturbances. Out of the 124 cases tested, 86 showed a successful outcome where the anti-skew system is an improvement compared to not using the system. Taking all results into account, the anti-skew-system can improve the number of MPH and total throughput up to 6% in least favourable conditions and up to 17% in most favourable conditions.

Increasing global parcel shipping volumes and just-in-time delivery force distribution centers to handle increasingly larger volumes of greatly varying parcel types. Automated material handling systems are essential to achieve these challenging requirements. A push divert sorter is one of these systems. This system uses a series of sliding plastic blocks to divert items from a main conveyor onto specific lanes. The performance of a push divert sorter is highly influenced by the design of components interacting with parcels. The shape and materials of these components influence the locations, directions and magnitude of forces acting on parcels, which influences their dynamic behaviour. The influence of the design of these components on the system performance is analyzed in the study. Moreover, based on these insights, an improved design is proposed and assessed.

The intermodal transportation transport is used to ship goods from A to B all over the world using different modes of transportation. The intermodal freight relies on the use of standardized containers for this transport. All empty containers need to be shipped back to the areas where there is a demand for empty containers. Since a standard container is the shame shape, independent of whether it is loaded or empty, all nodes in the intermodal system have a significant portion of empty container moves. Holland Container Innovations saw a solution to this problem of empty container repositioning, in the form of a 40ft foldable container, which can save on relocation costs of empty containers. HCI wants to expand its portfolio with a 20ft foldable design as well. Therefore, in this report the design process for the design of a viable 20ft foldable container is described. The end result of this project will be a concept that is adaptable to a full commercial design. The same folding method of the 40ft design is applied to the 20ft design, since it has already been proven to be viable. In addition, this opens up possibilities for synergies between the 20ft and 40ft design, as well as faster acceptation by other stakeholders, due to similarity with the already proven design. A critical design problem for applying the 4fold design to the 20ft container is the folded container height. The new 20ft design needs to meet a five to one bundle size, meaning that the folded container needs to be one fifth the height of a normal container. The height reduction requirements let to several dimensional design problems in which the design needed to be altered in order to house the parts needed for the folding process. A number of components were redesigned to fulfil the height requirements. After solving the spatial design problems, the 20ft foldable design was evaluated based on the ISO requirements. Initial hand calculations and FEM analysis of critical components have shown that the design fulfils the ISO load cases, as well as the operational requirements outlined by HCI For further development of the 20ft foldable container, the design can be made lighter to reduce the margin of error, and in turn allow for a reduction in material to be used, by performing a full FEM analysis. Although the weight and cost requirements have passed for this design, improvements in these values will always benefit the viability of the design.

Bulk carriers load and unload large quantities of iron ore and coal at bulk terminals. The loading and unloading process on the EMO terminal is largely automated, but for the last 5% an excavator is used to remove material stuck on stairs and walls in the hold. This process takes many manhours, can be dangerous, and can cause damage. The research question is: Is it possible to clean the hold of a coal bulk carrier by machine, and have the hold be cleaned faster and with less damage? A design is made, and based on that a test is set up. The results show that higher pressures, closer distances, and certain nozzle types result in better cleaning, without causing damage. The conclusion is that a hold can be cleaned by a machine with less damage, and possibly faster.

Fatigue is typically a governing limit state for maritime structures, and weld joints are the most critical locations. Various fatigue damage criteria have been developed involving either an intact or cracked geometry parameter, incorporating local or global information. In this thesis, the effective notch stress based total life fatigue damage criterion has been used in order to improve the accuracy of fatigue lifetime prediction and reduce the workload of engineers in the early design stage. First, the Battelle structural stress calculation procedure is clarified and examined with three models. A hot spot type A, B and C mesh convergence study are conducted. In order to quantify the influence of mesh quality, several ugly mesh models are tested with their good mesh counterparts. For validation purposes of the total life model, a large scale specimen fatigue test result has been used and the mesh quality investigations are included. The DNVGL based life time estimate is provided for the sake of comparison. Finally, several conclusions and recommendations are provided for future applications.

Despite the technological improvements in the dredging industry in the last decades, there are components that have not been investigated accordingly. One of them is the bow coupling bend pipe which can be found on trailing suction hopper dredgers. In contrast to most pipelines, the specific bend pipe is not only a means of transport for the dredged material but has a structural role, as well. Currently, it provides support to the subsequent pipes, which have no other connection to the vessel than the bow coupling bend pipe. Moreover, the abrasive nature of the slurry causes severe wear in the dredging pipes, with even more damage in bend pipes. These two factors lead to the relatively frequent replacement of a large amount of material, which also translates to an uneconomical procedure. The objective of this thesis is to explore the potential of designing a new bow coupling bend pipe, which focuses on the reduction of the replaced material and the extension of its lifetime. This can be achieved by analysing the two aforementioned factors, in order to improve the management of the original material, resulting in an economical solution. This study does not only analyse the design of bow coupling but also contributes to the understanding of slurry wear in bend pipes. Precisely, the report starts with a thorough explanation of slurry transport, describing also the three mechanisms of slurry wear and the parameters that influence the wear rates in a bend pipe. Furthermore, a literature review on the wear profile of bend pipes takes place in order to determine the expected wear pattern in the bow-coupling bend pipe. A total of five different wear zones are proposed to describe the wear rates in specific areas in the bend. The lack of research on slurry wear in large-scale bend pipes necessitated the use of assumptions to adapt the literature outcome on the bow coupling bend pipe. The information obtained from that research is used for the development of various concepts, considering also other aspects that contribute to the main goal of the thesis. Several concepts are investigated and compared based on the priorities of the project. The final design is further discussed, proceeding to modifications that improve its performance. The final geometry and materials of the system are defined in the finite element analysis. To do that, company guidelines and related standards were used to define the loads on the system as well as required realistic scenarios in which the design had to prove its structural feasibility. Finally, before providing recommendations for future work, the proposed design is compared with the current one, highlighting improvements in the three aspects of the thesis objective. In particular, using almost 60% of the material required for the current design, the new solution extends the bend pipe’s lifetime at least three times. That proves the remarkable effectiveness of the new design in the management of the pipe material, which is also directly linked with economic benefit. It is estimated that the capital expenditure of the new system will be twice as high as the current case, while the replacement cost is reduced by about half.

Coal silos are often used in areas where space is scarce, or because of environmental issues. Enclosed storage reduces the impact on the environment. If enclosed storage is used, different properties are important. The material characteristics can be split up in basic properties (moisture, angle of repose, etc.) and physical properties (shape, size, density, etc.). Different equipment is used to handle coal, conveyors are specifically used in enclosed storage. The current system with an infeed rate of 2,500 MTPH is fully developed. Higher infeed rates are required due to rising industries, larger vessels and cranes. A new system has to be found to combine high infeed rates with enclosed storage. Different concepts are developed, from which one concept is developed detailed. Different situations are used to compare filling multiple silos relative to each other and the comparison is made between vessel unloading and silo loading.