This thesis presents the design process of an active wire rope tensioner, a device designed for cranes, that serves two primary functions. Firstly, it increases the tension in the wire rope during spooling, ensuring neat and tight winding on the drum to reduce damage to the wire rope and cutting-in problems. Secondly, it reduces the required lower block weight, thereby improving the crane's load curve.

The research has commenced with a study of relevant background information and working principles. A thorough literature and patent review has followed, revealing a gap in the state-of-the-art of tensioning devices that both prevent cutting-in and reduce the required lower block weight. In the conceptual design phase, seven innovative concepts have been generated based on the literature review and current principles. These concepts have been assessed for their capability to meet the requirements and their performance against the key performance indicators (KPIs). Consequently, five concepts remain, with the clamping track concept emerging as the most promising.

The clamping track concept utilizes a chain drive with clamps attached to it that press on the wire rope. By applying force to the chain, the tension in the wire rope can be manipulated. Detailed development of the clamping track concept has yielded a conceptual design with three potential deployment scenarios, each requiring a slightly different version of the active wire rope tensioner and offering distinct advantages and disadvantages. Scenario 1 offers the greatest possible lower block weight reduction but comes with the cost of a more complex and riskier system. Scenario 3 does not allow for any lower block weight reduction but is simpler and safer. Scenario 2 strikes a balance between the two.

This research presents a novel approach for real-time stress state estimation in steel bridges using Fiber Bragg Grating (FBG) sensors and image recognition techniques. The methodology involves creating a digital model of the bridge, comprising a global finite element model (FEM) and detailed sub-models of critical areas. A database of precomputed load cases is generated, and real-time sensor data is matched to this database using the developed fingerprinting method. Image recognition is employed to detect multiple load scenarios, enhancing the accuracy of stress estimations and ensuring linear scalability for multi-load situations. The accuracy of the developed model was tested using a scaled setup using a 3 meter long aluminium bridge, proving its effectiveness in real-world conditions. The results demonstrate the feasibility of this approach, with reasonable accuracy achieved in both single and multi-load scenarios. Future work should focus on improving model accuracy, enhancing image recognition algorithms, and optimizing computational performance for large-scale applications.

This thesis presents the optimization of chord-bracing connections (tubular joints) in lattice boom structures using Wire Arc Additive Manufacturing (WAAM). The research aims to enhance the static and fatigue performance of critical joints, with a focus on the 1600mt LEC crane boom, which is used for offshore wind turbine installation. Through the integration of topology optimization and WAAM, the study seeks to improve structural efficiency by optimizing weld geometry and material distribution.
Finite Element Analysis (FEA) was employed to identify high-stress regions within the tubular joints, followed by topology optimization to refine their design. The study also investigates the impact of WAAM on material efficiency, fabrication flexibility, and the overall mechanical properties of the joints. The results demonstrate that the optimized tubular joints exhibit significant improvements in fatigue life and static strength compared to traditional designs, providing a more robust and cost-effective solution for lattice boom applications.
The findings of this research contribute to advancing the use of additive manufacturing in structural engineering, particularly in enhancing the performance and sustainability of offshore crane systems. The proposed optimization framework and design methodologies offer valuable insights for future applications of WAAM in heavy-duty structural components.

With the European Union targeting a 55% reduction in greenhouse gas (GHG) emissions by 2030, the shift to renewable energy sources like offshore wind is crucial. Another consequence of the 55% reduction goal is the new upcoming registration and levy on carbon emissions. Since there is a noticeable lack of research on the emissions from the installation offshore wind farms, and marine contractors will have to pay for those emissions in the near future, there is a need for a framework to predict those emissions prior to the installation process. This thesis aims to develop such a framework to predict GHG emissions during the installation process using Wind Turbine Installation Vessels (WTIVs).

The study starts with a review of current methods for calculating maritime GHG emissions, following the EU Emissions Trading System (ETS) guidelines. It then looks at the steps and technology involved in offshore wind farm installations, pinpointing the main energy consumers. Using a physics-based approach, the model estimates fuel consumption and the the GHG emissions for the installation of wind turbines for an offshore wind farm.

For the complete installation of 50 wind turbines, the model predicts a total effective energy requirement of approximately 408,000 kWh, leading to GHG emissions of around 312,533 kg CO2.
The results highlight the significant impact of activities like vessel transit and auxiliaries on total emissions. The sensitivity analysis performed identifies critical parameters influencing the model's accuracy, such as vessel speed, jack-up height, and crane efficiency. The model's validation through a real-world case study for the crane part of the developed model shows its accuracy in predicting emissions.

The thesis ends with suggestions for improving the model and finding ways to reduce emissions in offshore wind installations. This involves the validation of the other aspects of the model, technology upgrades, and checking if feedering might me an interesting solution to reduce the impact on the environment even more.

Overall the developed model for the prediction of greenhouse gas emissions proves to be a stable framework that could be used in the future by marine contractors when negotiating contracts and installation costs, including the predicted costs of the carbon levy.

At a dry bulk terminal, coal and iron ore are transported in the open air by conveyor belts and handled by large (mainly automated) equipment. The dry bulk material is rough and the equipment is installed in the harsh environment of the harbour. With vessels continuously being unloaded by quay cranes and outgoing vessels and trains being loaded, the conveyor belts make lots of operational hours. With more than 27 kilometers of conveyor belts running at 4.5 m/s it is important these systems are maintained well.

To reduce downtime and maintenance cost, a new maintenance strategy will be created. Therefore, different maintenance strategies and methodologies will be explained and the current situation will be investigated. A new maintenance strategy will be created by using the FMECA method (Failure Modes, Effects and Criticality Analysis), where malfunctions of the conveyor belt systems will be prioritized according to their criticality. Malfunctions happening during the period of this thesis will be investigated and used as an example to proof the new maintenance strategy works. This strategy is applicable to other equipment and other terminals as well. In the end some future remarks will be discussed to further improve the new maintenance strategy.

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.

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.

This research investigated the feasibility of designing an on-board system for the installation of fully assembled Tension Leg Platform Floating Offshore Wind Turbines (TLP FOWTs). The study aimed to identify a potential design that would enhance the overall feasibility of such installations, which required a combination of a literature review, a design methodology, and a concept evaluation.

The main research questions guided the study, focusing on the essential design elements and systems needed for the installation process. Key insights from the literature review helped form a basis for answering the first four sub-questions, while the subsequent sub-questions were addressed through concept development and analysis. The most crucial design decisions revolved around the connection between the installation deck and the ship and the selection of the actuating system.

Multiple concepts were developed, all incorporating a three-beam parallelogram configuration. A load analysis established an installation method and indicated three critical scenarios during the whole procedure. Force analysis, based on the load analysis, revealed two designs as the most feasible. This analysis provided crucial information on the direction and magnitude of forces within the system, guiding further refinement. Further specification of these designs addressed critical parameters, including the dimensions and structure of the beams, the size of the actuating system, and the integration of water ballast.

The study identified two potential solutions. One concept featured an additional framework within the three-beam configuration, optimising force distribution and introducing compressive forces in the actuating system, making a hydraulic cylinder the best choice. The other concept consisted of a simpler three-beam configuration, where the actuating system faced only tensile forces, making a winch system the most suitable solution.

The design methodology structured the development of these concepts, with analyses providing critical insights for further refinement. This iterative process highlighted the advantages and challenges of each concept.

In conclusion, this thesis contributed significantly to the current understanding of TLP FOWT installation by proposing potential solutions for the on-board installation system and identifying future research directions. Through its systematic approach and iterative design process, this research laid the groundwork for further advancements in the installation of TLP FOWTs.

The increasing automation in various industries has underscored a notable gap in the airline catering sector, where predominant manual transport of airline catering trolleys within facilities results in substantial costs and physical strain. This paper addresses these challenges by proposing an automated solution for the transport logistics of airline catering trolleys within catering facilities.
The suggested solution involves implementing a Unit Load Device (ULD) designed to securely carry multiple airline catering trolleys. This ULD is engineered for compatibility with various transport systems, including Automated Guided Vehicles, highloaders and conveyors.
The paper outlines the design process for a ULD within an airline catering facility. To formulate a comprehensive design, several design problems are identified, and potential solutions are presented. Subsequently, multiple viable load plate prototypes are constructed and tested on an Automated Guided Vehicle and highloader, resulting in the identification of a single viable all-purpose ULD for the entire process. Additionally, an in-house ULD emerges as a cost-effective alternative to the all-purpose ULD.
In this context, this paper introduces a comparative analysis of three possible future airline catering facilities: utilizing 1 ULD, using 2 ULDs, and employing no ULDs (or maintaining the current status quo). The comparison reveals minimal cost differences between facilities employing 1 or 2 ULDs, both facilities however show significantly more cost efficient compared to using no ULDs.

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.

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.

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.

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.

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.

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.

In this literature study the buckling of frames is investigated. Two frames are considered, where both consists of two columns and a girder. The first step was looking at the behavior of a single column under an compressive load. This results in so called effective lengths for different sets of boundary conditions on the column. Because in a frame the multiple columns and girders work together, the buckling mode also depends on the frame itself and the neighboring beams. There are two types of frames according to their buckling mode, a sway and a non sway frame. For determining the effective buckling lengths Eurocode 3 is studied for general rules for frames and calculation methods for effective lengths. Also the method from the AISC standard is described shortly. After that, it is investigated what methods the FEM programs use. Beside these methods, another method has been found and will be demonstrated on both situations. In the last chapter the results are summarized and a final conclusion and recommendation are made.

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.

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.

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.