siwertell news - spring 2013

CUSTOMER MAGAZINE Spr ing | 2013

On the rise: road-mobile

unloaders

Siwertell

news

4

6 10 22 One machine, two bulk cargoes handled efficiently

Breakthrough order from the steel industry

Successful unloader upgrade in Norway

2 Siwertell News | Spring 2013

Contents

4-5 News

6-9 Biomass and coal handling

10-15 Breakthrough order: steel plant opts for dedicated coal unloading

16-17 Unusual upgrade

18 Events

18-19 Refurbishment in Indonesia 20-21 Service visits in Asia

22-24 Upgrade in Norway

27 Representatives worldwide

Steel industry buys into large-scale

savings10

6

2016 22

Siwertell News is one of Cargotec’s customers magazines Distribution: 1200 copies Publisher: Cargotec Sweden Bulk Handling AB, P.O. Box 566, SE-26725 Bjuv, Sweden Editors: Malin Pekberg / Emily Cueva Layout: Emily Cueva Proofing: Shipwrite Editorial, UK Printed: Tryckaren Engelholm AB. The opinions expressed by the authors or individuals interviewed do not necessarily represent the views of Cargotec. The content of the magazine (with the exception of photos) may be reproduced provided that the source is mentioned.

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Siwertell

news

Siwertell News | Spring 2013 3

Dear reader,

Last year was a tremendously good year for Siwertell; we received a large number of orders and ended the year in a strong market position, leading us to expect continued success in 2013. We were right; in fact this year has started off even better.

Initially we secured a contract from Brazil for a barge unloader for handling grain at a large soya bean processing plant. This order was quickly followed by a pre-engineering contract from the Ukraine for three loaders, also designed for handling grain. We are experiencing a noticeable rise in interest in Siwertell road-mobile unloaders, demonstrating this segment’s growth capabilities. As a result of these enquiries, orders for road-mobile units keep rolling in and we have already secured several new contracts in Turkey and Trinidad. This is not surprising given the road-mobile unloader’s reputation for flexibility and reliability.

Another growth area is the biomass industry. In the previous issue of Siwertell News I mentioned our continuing success in this market and highlighted a contract we secured with Danish power company Dong Energy. This order is coming to fruition and will see a new Siwertell ship unloader handling both biomass and coal at the highly-efficient Avedøre multi-fuel power station near Copenhagen (see page six). Success in this market was further strengthened in April when we secured another contract for handling biomass and coal at a power station in the UK. These orders bring us another step closer to our aim of being the number one supplier in this field.

Demands for ever higher efficiencies are also driving operators to look at the advantages of having separate unloaders for bulk cargoes with significantly different properties – such as coal and iron ore for the steel industry – even if the traditional approach has been to use a single discharge method. Last year we received a breakthrough contract from Formosa Petrochemical Corporation for two dedicated coal unloaders. These will deliver huge costs savings to its new Vietnamese steel plant; other steel industry operators are now keen to see what dedicated Siwertell coal unloaders can offer (see page ten).

I am sure that our ongoing efforts to continuously improve existing Siwertell technology, along with developing new products and exploring new markets, will safeguard the success of our company for a long time to come. Read on to find out more about this and our other achievements.

Per Karlsson

President

Siwertell is a global market-leading brand in dry bulk handling. Customer-driven Siwertell engineering and service solutions for the dry bulk handling industry are used in import and export terminals worldwide. www.siwertell.com

About SiwertellSiwertell dry bulk handling equipment consists of environment-friendly and efficient ship unloaders, road-mobile unloaders, ship loaders and bulk terminal solutions. All conveying systems are totally enclosed, reducing dust emission to a minimum and eliminating spillage completely. Virtually any dry bulk material can be handled by Siwertell systems.

Ship unloaders Road-mobile unloaders Ship loaders Bulk terminal solutions


Reputation for reliability earns new road-mobile unloader order

Cargotec has secured a new order for a Siwertell 5 000 S, trailer-based, diesel-powered road-mobile unloader with double bellows system and dust filters. It is destined for operation by Muhammet Gümüstas, in the Black Sea coastal city of Trabzon, Turkey.

A Turkish customer has returned to Cargotec for a second Siwertell road-mobile unloader following the performance and reliability of its first machine

In 2012, the cement services company commissioned its first Siwertell unit, a 10 000 S road-mobile unloader. Both units are dedicated to cement handling at a rated capacity of 300t/h.

News

“Muhammet Gümüstas ordered a second unloader because of its favourable experience with the first unloader, and because of Siwertell’s reputation for delivering one of the most reliable unloading systems available on the market today,” says Jörgen Ojeda, Sales Director for Siwertell Mobile Unloaders. “The unloader’s flexibility and capacity, combined with low operational and maintenance costs, also had a major impact on the client’s decision.

“With more than 400 units delivered to the market since 1974, 100 of which are mobile systems, we have positioned ourselves as the market leader in bulk material handling.

“The unloader’s flexibility and capacity, combined with low operational and maintenance costs, also had a major impact on the client’s decision”- Jörgen Ojeda

“Its unique design makes the Siwertell unloader one of the most environmentally-friendly shore-based ship unloading systems available,” adds Mr Ojeda. “Dust-free handling and low energy consumption, along with minimal exhaust and sound emissions mean that it can be used in sensitive sites and those close to populated areas, such as Trabzon”.

The new unloader was built in Bjuv, Sweden; delivery took place at the end of May 2013.


News

Siwertell unloader ordered for soya bean processing site in BrazilLeading Brazilian food production company, Cargill Agricola S/A, has signed a contract for a Siwertell ST 790-M barge unloader. It will be installed at the company’s Santarém soya bean processing facility in Para State, Brazil and is scheduled to start operations in February 2014.

Components for the new unloader will be built in Sweden and China and will be combined and commissioned on site. It will support the company’s existing operations at Santarém, predominately handling soya beans, at a rated capacity of 1,500t/h.

“Siwertell systems have a well-proven track record in handling delicate cargoes, such as grain and soya beans,” says Douglas Wichers, Siwertell Sales Manager. “We also offer the highest capacities on the market for continuous grain unloading. These were two of the main reasons that Cargill opted for a Siwertell unloader. The absence of dust and spillages means the unloader will have no impact on the local environment; this was another important factor in Cargill’s decision.”

Cargill Agricola, based in Sao Paolo, Brazil, is a subsidiary of the US corporation,

Cargill, a large privately-owned enterprise, providing worldwide food, agricultural, risk management, financial and industrial products and services.

Two more road-mobile unloaders head for TurkeyCargotec has secured a new contract for two Siwertell road-mobile unloaders from Medcem Global Pazarlama AS, in Turkey. This is the second order from Turkey in less than a month. The 10 000 S trailer-based, diesel-powered Siwertell ship unloaders will be built at the Siwertell fabrication plant in Bjuv, Sweden and the delivery is scheduled for October and November this year.

The unloaders will be used to discharge cement at a rated capacity of 300t/h. Each will be fitted with a dust filter and double bellows system for loading trucks for onward transportation by road.

“With more than 100 road-mobile unloading systems delivered worldwide, they have earned a high profile reputation as state-of-the-art unloading equipment. This was one of the reasons that Medcem Global Pazarlama chose this particular system,” says Jörgen Ojeda, Sales Director for Siwertell Mobile Unloaders.

“Other advantages that influenced the client’s decision include the flexibility and high capacity that these systems offer, in combination with low operational and maintenance costs. As there is no need for any preparatory on-site engineering works, the mobile unloaders are available to start operations immediately upon delivery,” adds Mr Ojeda.


Unique and innovative:

biomass and coal handled by one unloader

Innovation


A Siwertell unloader can handle coal and biomass efficiently, safely and with minimum environmental impact, making it ideal for the emerging generation of power plants

Siwertell News | Spring 2013 7Siwertell News | Spring 2013 7


Siwertell multi-purpose unloaders are capable of handling almost any type of bulk material. This makes them ideal for both coal and biomass intakes for the emerging generation of power plants and industrial processes seeking to reduce their environmental impact in the move towards sustainable, carbon neutral operations.

“When it comes to large scale projects, whether for power generation or for industrial processes such as steel and cement production, there are compelling arguments for turning to Siwertell high capacity screw type unloaders”- Lars-Eric Lundgren

Furthermore, their totally enclosed design minimises the impact of unloading operations on the local environment, while safety systems – originally developed for the safe handling of sulphur – have been adapted to address the significant risks associated with biomass operations.

Lars-Eric Lundgren, Regional Sales Manager for Siwertell at Cargotec, explains the role of biofuel and how Siwertell solutions can help operators optimise their associated bulk material handling arrangements. “Biomass can be used in a number of ways. In some cases you find separate power generation systems on the same site: one burning coal, one burning biomass. In others, there is a single power generation system which can burn either coal or biomass. Co-firing biomass with coal represents a third option; this means burning a mixture of coal and biomass.”

Biomass has been used as a fuel source on a relatively small scale since the beginning of the century; large scale applications are

only now really getting started. Some small scale operations use grab cranes for coal and pneumatic unloaders for biomass.

“Siwertell has supplied its road mobile unloaders for some of the smaller biofuel projects and they remain an ideal solution, especially where barges are used with lower capacity requirements,” says Mr Lundgren. “However, when it comes to large scale projects, whether for power generation or for industrial processes such as steel and cement production, there are compelling arguments for turning to Siwertell high capacity screw type unloaders.”

A good example of Siwertell dual-fuel capabilities will be demonstrated by Denmark’s leading power company, Dong Energy, this year. Dong Energy is one of Northern Europe’s largest energy groups and it ordered a Siwertell type ST 790-M

ship unloader from Cargotec last year. The new unloader will be used to ensure the efficient, clean delivery of wood pellets and coal to the company’s combined heat and power station at Avedøre, discharging ships of up to 12,000 dwt at a rated capacity of 800t/h.

Dong Energy is majority owned by the Danish Government, and says that the Avedøre multi-fuel power station, situated just south of Copenhagen, is one of the world’s most efficient of its kind, achieving fuel efficiencies of up to 94 percent.

“Our Siwertell unloader will be an extension of this highly-efficient operation,” says Mr Lundgren. “It was chosen for its environmental credentials, which include high levels of efficiency and totally-enclosed bulk transfer for dust-free operations. Our long experience with bulk handling systems was also an important

Biomass productsThe development of the biomass market is driven by the need to secure new energy sources – now and for the future – via a carbon neutral cycle. Most biomass, including wood, is composed of roughly 50 percent carbon by weight, 40 percent oxygen and 5 percent hydrogen. In addition there can be about 0.3 percent nitrogen, 0.1 percent sulphur, 0.1 percent chlorine with trace quantities of minerals such as calcium, potassium, silicon, phosphorus and sodium. Industrial biomass pellets can be produced from a wide range of energy crops and other sources.

EXAMPLES OF PRODUCTS• Agri pellets: grain waste • Rice pellets: rice husk and waste • Peat pellets• Industrial pellets: quick growing Salix• Waste pellets: non-recyclable papers and plastics • Straw pellets: from sources such as sugar cane, corn, grain, jatropa• Nut shells: crushed and dried • Kernels: crushed, dried and sieved (for example olives, dates, citrus) • Briquettes: square or round – up to 200mm long (for example peat, wood)


factor in winning this contract.”He continues: “Biomass comes in many different physical shapes and sizes and is derived from a very wide range of combustible constituents; nevertheless, they can all be handled efficiently and safely by Siwertell unloaders, which are optimised for multi-purpose operation as well as for unloading a single material.

“Siwertell already has considerable experience of handling all kinds of biomass. And of course we have comprehensive, market leading knowledge of handling all types of coal. Our totally enclosed, continuous conveyor system extends from the cargo pick up in the ship’s hold all the way to the receiving facility ashore. The highly manoeuvrable arm system picks up the cargo layer-by-layer all the way out to the corners of the hold as well as underneath the hatch coamings. This provides not only the most efficient but also the best environmental unloading solution available.

“We can discharge the most common varieties of wood pellets at between 800 to 2,000t/h, depending on the density. Coal is denser than biomass so any particular Siwertell machine will be able to deliver a higher discharge rate for coal.”

There are significant risks associated with biomass handling and storage, including fire and dust explosions. Mr Lundgren explains how a Siwertell unloader addresses these dangers. “Siwertell unloaders are the only mechanical, continuous unloaders used for the large scale handling of hazardous cargoes such as sulphur. Throughout the world these systems are equipped with our 4S system, designed to detect and take care of any kind of fire or explosion within the unloader conveying system. “We have adapted our 4S expertise and transferred it, in whole or in part, over to other projects that involve handling hazardous materials such as wood dust and wood pellets.

“Our totally enclosed, continuous conveyor system extends from the cargo pick up in the ship’s hold all the way to the receiving facility ashore” - Lars-Eric Lundgren

“Other aspects of our unloader technology automatically deliver additional safety benefits. Cargo pick up by successive layers virtually eliminates the risk of cargo avalanches and the ensuing dust clouds. The screw technology is also noted for its remarkably low level of cargo damage, again resulting in minimal dust creation.”

There are major economic benefits linked to handling both coal and biomass with the same unloader. Jetty occupancy in the port is minimised, while the annual intake over the jetty is optimised. Less capital investment is required when one unloader can handle all the materials delivered to the jetty and this is also true of the associated shore based conveying system.

“Our customers operate in all dry bulk trades and appreciate the reliability, efficiency, safety and economic advantages of our products, along with their unrivalled environmental credentials. Existing customers moving into biomass, as well as new enterprises, recognise the cogent arguments for investing in Siwertell unloaders for their multi-fuel handling needs,” he adds.


In November last year Cargotec secured a breakthrough contract that has the potential to change the way that major steel plants receive their raw materials. The Formosa Petrochemical Corporation (FPC),

part of the Formosa Plastics Group, has ordered the two largest Siwertell unloaders delivered so far, for unloading coal at the Group’s newly-built Ha Tinh steel plant in Vietnam’s Son Duong Port.

FPC’s two new ST 940-DOB unloaders will have the capacity to discharge vessels of up to 205,000 dwt and will be supplied on a turn-key basis. They will have a rated capacity of 2,400t/h – giving a combined capacity of 4,800t/h – with a guaranteed average unloading capacity of 70 percent of the rated capacity. They will both be rail-mounted, with a travelling length of 350m.

Currently, large steel plants use the same unloading equipment for the iron ore and coal needed in the steel production process.

However, due to significant differences in the material properties, this means the equipment provided is not optimal for either commodity.

Per Karlsson, President of Siwertell at Cargotec explains: “Traditionally there are two methods for unloading iron ore and coal; grab cranes or bucket chain unloaders. As neither is dedicated to a specific cargo, the properties of which vary considerably, their efficiency levels in the steel plant context are not very high.

“Furthermore, as iron ore is a very dense commodity, a vessel used for transporting iron ore will be much larger than a vessel used to transport a similar volume of coal. This means that on many occasions the

Vietnamese steel plantset to benefit from huge efficiency savings

Cargotec will deliver two large Siwertell coal unloaders to the Taiwanese conglomerate, Formosa Plastics Group; this is the first time that a major steel plant will feature permanent, large-scale separate intake systems for coal and iron ore

New industry


This is a comprehensive description of what we do. Any questions?

Dry bulkhandling

www.siwertell.com Siwertell is a Cargotec brand

http://www.siwertell.com/

12 Siwertell News | Spring 2013 12 Siwertell News | Autumn 2012

unloading equipment will be oversized for coal unloading. As a result of this over sizing, huge investments are often needed on the coal intake berth as it needs to be designed for the ‘wheel and corner loads’ based on the jetty’s requirements for iron ore intake.

“From this it should be clear that separate, dedicated unloading systems for iron ore and coal will deliver a more efficient operation and significant cost savings. However, to our knowledge, this is the first time that a major steel plant of this size has been equipped with permanent large-scale separate intake systems for coal and iron ore,” he says.

It might seem that the plant could have been equipped exclusively with Siwertell screw-type unloaders. Mr Karlsson explains why this is not the case: “The problem with iron ore is that sometimes it has a high moisture content, in excess of four percent, which can make it very sticky. In these circumstances it cannot be unloaded using a screw-type unloader.”

It is the scale of the cost savings that leads Mr Karlsson to believe that this contract may well be a trend setter for the steel industry.“Siwertell systems can deliver huge cost savings – in the region of $2.5 to $3 million per year for this particular operator – in comparison to traditional systems, because ships will spend much less time at the unloading berth,” he explains. “Until now the industry has been reluctant to invest in separate intake systems for coal and iron

ore, however, savings on this scale cannot be ignored and we are confident that this order will start a trend that sees more steel plants using Siwertell continuous ship unloaders for dedicated coal unloading. In fact, we are already having ongoing discussions with other steel plants.

“The following gives an idea of the time and cost savings that the Siwertell coal unloaders will deliver. In the contract we have guaranteed a through-vessel capacity equal to 70 percent of the rated capacity, meaning a discharge rate of 1,680t/h per unloader, or 3,360t/h for both. On average it will take about 60 hours to unload a 200,000 dwt Capesize vessel.

“In contrast, a grab unloader with the same capacity, but with an efficiency factor of only 55 percent, will take about 75 hours to unload a similar vessel. The plant’s annual coal intake will be around 7.8 million tones, meaning that it will receive 39 coal carrying vessels every year. The savings will be around 15 hours for each of the 39 vessels, which equates to 585 hours or about 24 days each year.

“Based on a dispatch value of US$100,000 per day, the savings will amount to around US$2.4 million per year. There are additional factors that will also save money, including the reduction in equipment operating time and the associated maintenance requirements, along with the cost of drivers and other personnel.”

In this example all these advantages were delivered with no added investment costs.

“The high annual intake of coal meant that there was a need for additional unloaders in any case,” he explains.

The two new unloaders provide significant operational flexibility. Depending on the occupancy of the jetty, the operator can use two unloaders in one vessel or it can discharge two vessels simultaneously using one unloader in each vessel. “One major benefit with the Siwertell unloader is that it offers almost the same efficiency rates for both Capesize and Panamax vessels,” notes Mr Karlsson. “This is a dramatic advantage compared with the two other types of unloaders, as they are designed for the much larger vessels and as a result they will have a significantly lower efficiency when discharging the smaller Panamax vessels.

“Siwertell systems can deliver huge cost savings, in the region of $2.5 to $3 million per year for this particular operator”- Per Karlsson

“There are other operational advantages when compared to grab cranes, including a much cleaner operation, minimal cargo loss and less risk of damage to the ship’s structure. Taking the example of cargo loss, a typical estimate is that a grab operation loses about one to two percent of the cargo handled. If 7.8 million tonnes of cargo is processed every year, this equates to an average annual loss of between 78,000 and 150,000 tonnes of coal, multiplied by the actual cost of coal. If this is extrapolated



over the lifetime of the plant, say 20 years, this could mean that a Siwertell unloader saves the operator around US$80million to US$160 million; and that is based on a today’s relatively low coal price.”

“We can build unloaders with even greater unloading rates so long as the receiving systems can handle the increased capacity. The limiting factors are more to do with restrictions on the belt conveyor side”- Per Karlsson

Mr Karlsson adds: “The main reason for the higher efficiency for our type of equipment compared with a grab crane is that at the beginning of the unloading operation, the grab only travels a very short distance. However, the more bulk material that is unloaded from each cargo hold, the greater the distance the grab has to travel and therefore the lower the efficiency.

“For all types of equipment, the clean up phase is the one that needs the most attention,” he says. “Both grab and Siwertell unloaders need the assistance of excavators or payloaders for the final clean-up. However, for barge unloading, we have developed a new inlet device that needs no assistance at all.”

Siwertell will also introduce a new screw-type unloader by the end of this year. With a rated capacity of 3,000t/h, it will be able to handle vessels of up to 200,000 dwt. Mr Karlsson says it has been developed to meet rising world coal demands and the consequent use of ever larger vessels, supported by the expansion of the Panama Canal. Considering larger unloaders he says: “We can build unloaders with even greater unloading rates so long as the receiving systems can handle the increased capacity. The limiting factors are more to do with restrictions on the belt conveyor side.”

FPC’s Siwertell unloaders will be totally enclosed, right from the inlet device, which draws coal from the vessels’ holds, up to

the three transfer points on the owner’s jetty conveyors. The Ha Tinh steel plant’s jetty will have six conveyors, three to handle coal and three for iron ore.

“In terms of operating the unloaders, on this particular equipment we have several redundant system integrations and safety factors,” explains Siwertell’s Contract Manager, Per Hansson. “The travelling machinery is designed to function with a loss of power if one or more drives should fail. This is also the case for the slewing machinery, which can be manoeuvred even with a unit loss. “In case of a failure in the unloaders’ power supply during unloading operations, we have equipped the machines with an emergency operation system, allowing the operator access to all motions in order to manoeuvre the machine out of the vessel and park it in a safe manner. This system is integrated into both the electrical and hydraulic systems.


“Many of our installations also have redundant PLC systems; however these are implemented through customer requests and were not required for this particular project.

“In terms of operating the unloaders, on this particular equipment we have several redundant system integrations and safety factors”- Per Hansson

“On top of this, Siwertell unloaders are equipped with a number of sensors indicating the operational health of the equipment. While this is not redundancy per se, it is nevertheless an excellent aid for the operator. Knowing the machines’ operational well-being equates to higher availability rates though increased maintenance awareness.”

Mr Hansson says the Siwertell equipment delivered for this particular project will be equipped with the most durable and sturdy conveyor technology, delivering a long lifetime as well as optimised maintenance requirements. “As long as our regular

maintenance recommendations are followed, wear part maintenance should only be required every second year. These include components such as the outer diameter (OD) bearing flights, covers, lower transport tube, wear screws and bottom bearings.

“A well-maintained unloader is safer and maintains its operational efficiency. It also strengthens customer satisfaction throughout the equipment’s lifetime”- Per Hansson

“These components are typical wear parts that need to be replaced after a certain number of running hours. Naturally, the lifetime of wear components is related to the way the equipment is used and the standard of maintenance. With skilled personnel operating the unloaders and a good maintenance regime, the lifetime of components can be extended. The vertical conveyors will easily last four to five years at the plant’s planned operational pace. If maintenance is carried out properly, they will last even longer.”

He adds: “Our service department always works very closely with our clients and listens to their demands. As each installation and owner is different the service needed is usually tailored to meet their needs. This naturally ranges from larger operation and maintenance contracts to occasional wear parts maintenance, extra training or regular inspections. We try to integrate this co-operation during the course of the project to ensure that maintenance is seriously considered. A well-maintained unloader is safer and maintains its operational efficiency. It also strengthens customer satisfaction throughout the equipment’s lifetime.”

The unloaders’ main system components will be manufactured in Europe, while the steel structures will be fabricated in Vietnam. The unloaders will be erected on site and are expected to be operational by mid-2015.

The steel plant is owned by Formosa Plastics Group’s daughter company Formosa Ha Tinh Steel Corporation. Mr Karlsson says, “We have a long and successful relationship with FPC. With this new contract, we will have delivered 11 ship unloaders to the company; all of them for handling coal and the majority with a capacity of 2,000t/h or more.”


This demonstrates how much spillage you get with a Siwertell ship unloader.




Cement loader upgrade in Australia brings two-fold benefits

solution for each individual operation,” notes Mr Svensson. “Normally, the only exception is our road-mobile unloaders, which come in a range of standard sizes.”

“Starting from scratch, we design our systems from the ground up, taking into account a wide range of factors including the local topography and tidal ranges, the nature of the trade, capacity requirements, local regulations, the range of cargoes to be handled and budgetary considerations.

“The time available for dismantling the old belt conveyor arm, adapting the existing support structure and winch and installing the new loader system was limited; it all had to be done in less than a month”- Bengt Svensson

“This was an unusual project for us; it made good commercial sense for Adelaide to use as much as possible of the asset represented by its existing loader, and we were able to offer a very cost effective solution, bringing the loader into line with modern environmental expectations while improving its operational performance.

In July 2011 Adelaide Brighton Cement Ltd placed an unusual order with Siwertell to upgrade part of its cement loader; the modernised unit has now been operating successfully for nearly a year. “The contract called upon our flexibility and logistical planning skills to deliver in a tight time-frame with minimal disruption for the operator,” says Bengt Svensson, Senior Contract Manager for Siwertell.

The long-established Australian company had a cement and clinker belt-type loader at its Adelaide cement production plant. However, the loader, which had been manufactured by a competitor company, needed to be upgraded to reduce dust emissions in line with the strict local environmental regulations.

“Siwertell ship loaders, unloaders and terminal deliveries are almost invariably tailor-made to provide the best possible

Upgrade

Flexibility and good planning were vital factors in delivering an unusual loader upgrade for Adelaide Brighton Cement without affecting its commercial operations; the loader now meets the area’s environmental regulations and can accommodate larger vessels


“In addition to the design and manufacture of a screw-type loading arm to integrate into the existing loader, we had to undertake a lot of preliminary engineering work to prepare the existing structure to receive the new arm.”

The work on site was planned to coincide with a scheduled break in cement production for maintenance at various other installations in the plant. This meant that although the loader would not suffer any downtime in a commercial sense, the time available for dismantling the old belt conveyor arm, adapting the existing support structure and winch and installing the new loader system was limited; it all had to be done in less than a month.

“Our plan for the upgrade had to ensure that the work would be carried out quickly and smoothly so that the loader could be re-commissioned in time for the resumption of cement production,” he says. “To make the best possible use of the time available to us, we assembled the replacement units on the ground prior to installation. All went very much to plan; we carried out the work to upgrade and re-commission the ship loader within the allocated time frame and it resumed commercial operations in July 2012.”

In addition to meeting the environmental regulations, the upgraded loader can accommodate larger cement vessels than was previously possible. Mr Svensson explains. “Our screw conveyor technology operates perfectly well when the conveyor is inclined at an angle to the horizontal. Therefore, using the loader’s winch system, the outer, slewing screw conveyor can be elevated sufficiently to accept ships with a greater freeboard than before.”

Clinker is a highly abrasive commodity, so the screw flights are hard faced and the casings are fitted with wear liners. The rated loading capacity for cement is 900t/h; however, it is limited to 600t/h for clinker to reduce system wear. This variable rate is achieved by controlling the screw conveyors’ rotational speed by means of frequency converters.The conveyor diameter is 700mm and the new loading arm has a 25.25m-long inner horizontal screw conveyor and a 4.75m-long outer, slewing screw conveyor. The new arm is fitted to a new upper turret section that connects with the existing slewing ring tower support as well as the existing winch system.

The new loading chute with its specially-designed loading spout can be positioned directly onto the opening in a ship’s hatch cover or dedicated loading point; its length is automatically adjusted during the loading process. A dust collector maintains negative air pressure to eliminate dust emission. The system is controlled by the client’s PLC and HMI systems, either from the fully equipped operator cabin or from the portable radio control unit that allows the operator to get the best possible view of loading operations.

Commenting on concerns about the polluting nature of bulk cargo operations, Mr Svensson notes that relevant regulations across the world are becoming very much tighter. He

says the totally enclosed design of Siwertell systems means they perform excellently in this respect. “And there are real commercial benefits to be made from clean operations in addition to meeting environmental rules and providing better working conditions for the personnel. Eliminating dust and spillage means that there is no requirement to clean the vessel, loader and surrounding areas and there is no penalty for lost cargo.”

With ship loaders and unloaders based on screw, aeroslide or belt conveying technologies Siwertell can design and supply the most appropriate solution for handling cement at any annual throughput. Global market demands have pushed cement shipping to higher volumes and operators favour larger vessels requiring increased handling rates. The common terminal configuration until the late 1990s was geared to handymax vessels. Many terminals can now accommodate Panamax tonnage and they want to ensure quick turnarounds by providing enhanced cargo handling capacity.

“We have the knowledge, technology and expertise to meet these demands, while also maintaining clean, quiet, safe bulk handling operations,” he adds. “For vessels up to Panamax size, we have already delivered cement loaders with capacities as high as 1,000t/h and cement unloaders achieving up to 1,500t/h.”


Cargotec has introduced a new method for supporting the substantial loads involved when partially dismantling its Siwertell loaders and unloaders when replacing their slewing bearings. “Previously, we had to use two large cranes during the dismantling process, but with the new method we use smaller cranes in combination with purpose built service towers,” explains Kari Leppänen, Senior Surveyor for Siwertell at Cargotec.

“This new approach is particularly valuable in cases where the nature of the jetty imposes weight and space limitations. For customers faced with these issues, this is an ideal solution. It also saves money on crane hire; whether the method is cheaper overall will depend on the local cost of fabricating the service towers and this will vary, case by case.”

It employs two customer-built service towers, for which Cargotec provides the detailed engineering drawings. “The towers take some of the weight, so we don’t need to use such big cranes. This is the general principle,” says Mr Leppänen. “However, Siwertell loaders and unloaders are tailor-made for each application, so each set-up is different; we will always have to fine tune the process for individual sites and systems.”

“The unloader had operated for more than 52,000 hours, which is a very high figure; its generally excellent condition is a great testament to the company’s maintenance and service regimes”- Kari Leppänen

The new bearing replacement method was successfully employed on a 1996-delivered VST-940/D-type unloader operated by Indonesian company, PT Holcim. “This was our first ever VST-940/D-type unloader delivery,” he notes. “The customer asked Siwertell surveyors to inspect and, if necessary, replace the unit’s worn slewing

Alternative approach toslewing bearing replacement

Events You will find Siwertell representatives at these events during the second half of 2013.

24-27 June, The Netherlands

1-3 July, Germany

3-6 September, Russia

22-24 October, Brazil

4-6 September, China

Refurbishment

Cargotec has developed an alternative approach for replacing the slewing bearing on its Siwertell loaders and unloaders; it overcomes many issues related to limited space and weight restrictions and may also deliver cost savings

BULK MATERIAL &

HANDLING EXPO

11-13 November, Jordan

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bearing. The unloader had operated for more than 52,000 hours, which is a very high figure; its generally excellent condition is a great testament to the company’s maintenance and service regimes.

“Due to the limited size of the jetty and its load restrictions, it was not possible to use the traditional method employing two large cranes to perform the lift to replace the bearing. Therefore we used two service towers, a 100-tonne crane and a 25-tonne crane. The larger of the towers was built in two sections to make it easier to handle and install. The smaller tower supported the outer end of the horizontal arm.”

In this particular installation, a belt conveyor runs along the jetty directly under the unloader gantry. Its rollers were removed and the belt lowered in order to make room for the service tower’s lower horizontal beams.

Alternative approach toslewing bearing replacement

Mr Leppänen says that following an inspection the new bearing was fitted and the unloader was re-assembled. “The whole process went smoothly without any problems, and the unloader was ready for work again within 21 days.”

“The whole process went smoothly without any problems, and the unloader was ready for work again within 21 days”- Kari Leppänen

A spokesperson for PT Holcim says the company’s response to the new method has been very positive and it gained valuable new knowledge regarding unloader maintenance during the project. “Drawings supplied for the construction of the towers were easy to understand. The spare parts were delivered on time and the step-by-step method for replacing the slewing bearing was clear. There was also good co-operation between Cargotec and PT Holcim.”

Customer Pt Holcim IndonesiaLocation Cilacap, IndonesiaEquipment Siwertell VST-940 D-type ship unloader Material handled Limestone


Managed maintenance costs and

long-term reliability A Siwertell operation and maintenance agreement for a replacement coal unloader minimises the risk of downtime and helps with financial planning at a New Hampshire power plant

Service



The owners of a Siwertell ship unloader supplying coal for a New Hampshire power plant are benefiting from the operational security provided by a Siwertell Care (STC) agreement on operation and maintenance level.

“With its long experience of operating its first Siwertell unloader, Public Service appreciates the importance and value of a well planned and implemented maintenance programme”- Tom McDonough

In 2010, the US Northeast utilities company, Public Service of New Hampshire, bought its new Siwertell ST-790D ship unloader to discharge coal from vessels supplying the company’s Schiller Station electricity generating plant. The unloader – which was installed and commissioned during the first and second quarters of 2010 – replaced an existing Siwertell unloader that began operations in 1983.

“With its long experience of operating its first Siwertell unloader, Public Service appreciates the importance and value of a well planned and implemented maintenance programme.” says Cargotec project engineer Tom McDonough. “Consequently, when a new unloader was commissioned in 2010, it invested in an operation and maintenance agreement to ensure that the unloader will be kept in good conditions and sustain its designed high unloading performance.”

The decision to buy a new Siwertell ship unloader was taken after balancing the costs and benefits of a replacement against the cost of refurbishing the 1983-built machinery.

“The replacement of major machinery on this scale requires careful planning to minimise downtime, inconvenience and the impact on the local community and environment,” says Mr McDonough.

“Dismantling and removing the redundant Siwertell unloader was carried out in parallel with the assembly of its replacement. The dock at the power plant is not used exclusively for handling coal, so it was necessary to minimise occupation and the disruption of its other activities. Therefore, work was also carried out, whenever possible, at a private dock three miles downstream on the Piscataqua River.

“We have had nothing but positive feedback for the services that we provide to the New Hampshire plant”- Tom mcDonough

“It is worth noting that although there are a number of up-market communities located on the banks of the river near to the plant, the extremely quiet operating characteristics of the Siwertell unloader mean that there is no problem with continuous 24-hour operations. The Siwertell unloader is a very good neighbour to these waterside communities,” he says. “We have had nothing but positive feedback for the services that we provide to the New Hampshire plant. Our current STC contract with Public Service of New Hampshire extends to 2015, and we hope it will then be renewed for a further period. So far this has been a win-win project for everyone involved; our customer, Siwertell and Cargotec.

“Investing in one of our operation and maintenance or service agreements gives you optimised equipment availability and planned preventative maintenance, which improves your terminal’s availability and avoids the potentially high costs and expensive downtime incurred by emergency repairs,” notes Mr McDonough. “We can offer various levels of Siwertell Care (STC) agreements, designed to fit precisely with your particular needs, requirements and budget.”

Public Service’s agreement is handled by Cargotec’s office in New Jersey, US. Siwertell service manager, Anton Ekberg, who is stationed in Houston, Texas, US, supervises the operation and maintenance works together with the New Jersey based Cargotec crew.

The five year contract makes provision for three-days of Mr Ekberg’s services, three times a year, along with cost estimates per vessel to help with budgeting. This makes it easier for the owners to calculate their annual maintenance costs.


A long-term service strategy minimises maintenance costs and means that operators can plan for larger renewals in a way that reduces or even avoids disruption to commercial operations. Norwegian operator, Yara, employed this approach after its initial investment in Siwertell technology in 1980. “Planning when an essential element of an operator’s production chain can be taken out of action for major upgrades or repairs is typically more profitable,” says Jonny Pedersen, Mechanical Manager at Yara.

Established in Norway in the early 1900s, Yara is a global fertiliser production company, listed on the Oslo Stock Exchange and has its headquarters in Frogner. Yara has two major production sites in Norway in addition to its Yara Praxair (industrial gases) joint venture and various other support operations. The production sites are located in Glomfjord, close to the Arctic Circle, which has four production units, and in Porsgrunn, which is in the county of Telemark and ranks as the largest industrial site in Norway. Yara’s Siwertell unloader serves the Glomfjord site.

Incremental upgrades lead to greater profitability

In 1980 Siwertell delivered the upper part of Yara’s ship unloader, along with the horizontal and vertical arms and tower section; all of these elements were installed on an existing gantry.

“Following years of reliable service, the unloader began a series of step-by-step upgrades in 2004 and has received frequent Siwertell visits and inspections,” explains Kari Leppänen, Senior Surveyor for Siwertell. “The last renewal was in 2011, when a new gantry conveyor was installed. The new conveyor was built with a newly-developed type of end gable fitted with a special drive

Operators that take a long-term view of their Siwertell machines benefit from minimised maintenance costs and as a result, greater profitability because they plan their down-time periods; Yara is one such company

Upgrade


shaft seal. With this latest upgrade every conveyor element on the unloader is up to current standards.

“Currently, we are in discussion with Yara about planning the logistics for replacing the slewing bearing. Yara actually purchased a replacement slewing bearing in 2010. It is stored in a warehouse at the customer’s site, so that in the event of an unexpected bearing failure, down-time can be reduced to a minimum. However, a planned replacement process is naturally more convenient and cost effective.

“Replacing the slewing bearing requires more time than previous upgrades or maintenance projects, so it needs to fit well with Yara’s production schedule. To avoid interrupting the schedule, an alternative unloading procedure must be in place to ensure the supply of raw materials during the bearing replacement process,” says Mr Leppänen.

“The bottom screw was in very good condition, while the screws from another manufacturer had become extremely worn. As a result of this inspection, Yara opted to install Siwertell screws for the entire vertical conveyor”- Kari Leppänen

Reviewing the almost decade-long upgrade process, Mr Leppänen says it has been quite a journey to get to this point. “In 2004, the company purchased a new operators’s cabin, which was essentially the start of the modernisation. Then in 2005, the unloader’s vertical tubes were replaced and the vertical conveyor was aligned according to Siwertell’s instructions. At the time of this visit, Siwertell’s latest screw and conveyor developments for unloaders were discussed and this led to an order for the delivery of a complete bottom screw, with

a wear screw, in compliance with Siwertell’s latest technology with extended service time.” The bottom screw was installed in mid-2007; 2007 also saw an alignment inspection of the horizontal conveyor. A year later, an inspection of the previously installed Siwertell bottom screw and the other screws was carried out. “The bottom screw was in very good condition, while the screws from another manufacturer had become extremely worn. As a result of this inspection, Yara opted to install Siwertell screws for the entire vertical conveyor,” highlights Mr Leppänen.

In 2008 the outer part of the horizontal arm was replaced and in June 2009 a new horizontal conveyor was fitted. “This is much easier to access for maintenance as it can be opened along its full length and has the latest Siwertell standard for intermediate bearings”.


wear parts last much longer as a result of using the latest components and this translates into reduced overall running costs.

“It is certainly worth noting that the bottom Siwertell screw, which was installed in 2007, is still in operation; the lower wear screw part was replaced in 2011,” concludes Mr Leppänen. The Siwertell ship unloader continues to support the Yara production site and has been used for approximately 48,000 operational hours since its installation in 1980.

At the same time, the drive unit for the vertical conveyor was rebuilt and a Safeset device was installed. Safeset protects the vertical screw and gearbox if scrap material enters the unloader or the vertical screw experiences other shock loads. This unit can easily be restored after an emergency stop and reduces down time due to such occurrences.

“As a result of its continued investment, Yara’s regularly upgraded Siwertell unloader works as well as a considerably more modern ship unloader. It needs far less supervision and service management and experiences far fewer unforeseen stoppages. The screws, tubes and other

In 2010 a new inlet feeder device for the vertical conveyor was fitted. “This was built according to the latest standards and therefore requires much less servicing and repair work than the unit it replaced. As an example, the gearbox can be dismantled without the need to remove the conveyor screws,” he adds.

The Siwertell ship unloader continues to support the Yara production site and has been used for approximately 48,000 operational hours since its installation in 1980



This is the total capacity of the four Siwertell unloaders installed in one Korean port.

10,000t/h




NEWroad-mobile unloader film

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You’ll get a lot of this when you invest in a reliable and low maintenance Siwertell ship unloader.

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