2012-5 ivormatie.pdf

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ormatiemagazine

Ivormatie is a publication o Iv-Groep | Volume 27 | February 2013

Engineering Company with a Passion or Technology

Expansion o Steenwijk water treatment plant | A Sports Bowl

stadium in Nigeria | Sea lock at IJmuiden | New guy-wiredantenna mast

Magazine



February 2013, Volume 27, Number 1

Editorial sta Iv-Groep, Marketing & Communication

department

Ivormatie

A publication o Iv-Groep:

Iv-Oil & Gas

Iv-InraIv-Industrie

Iv-Consult

Iv-Water

Iv-Bouw

Escher Process ModulesMuzada

Iv-AGAIv-Consult Malaysia

Iv-Inra USA

Iv-Caribbean

Nevesbu

Editorial oce

Iv-Groep b.v.

P.O. Box 11553350 CD Papendrecht

[email protected]

www.iv-groep.com

Copyright © 2013 Iv-Groep. All rights reserved.

Reproduction in whole or in part requires written

permission.

Cover: New guy-wired antenna mast

Inside page o the cover: Malt transport line Heineken

Zoeterwoude

2 IVORMATIE MAGAZINE FEBRUARY 2013


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ormatie

A multiunctional health centre that enhances the healthcare

experience

Iv-Bouw commissions De Prinsenho in Gouda22

C o n t e n tThornton Bank

4Iv-AGA assists in the design o a new injection pumping station

Rapid growth in North Dakota's oil production8

12EnQuest Producer, a third lie or the Dirch Maersk tanker

16Iv-Water prepares ROW or 37 km o water mains

pipeline

18BCFS-reactor as a centrepiece o the Steenwijk water treatment

plant

New guy-wired antenna mast at Hoogersmilde (303 m)

24Iv-Consult designs roo o new Sports Bowl stadium in Nigeria

28IHC-Iv Malaysia

IHC-Merwede and Iv-Consult establish Malaysian joint venture, IHC-Iv Malaysia,

to reduce cost o detail engineering in shipbuilding32

Successul delivery o two Flare Packages or Enerfex Ltd.

10

Design o the new sea lock at IJmuiden in the Netherlands

38

Heineken Zoeterwoude opts or sustainability with its malt

transport line34


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Thornton Bank

The Thornton Bank oshore transormer station is part o the wind arm development by

C-Power. This Belgian company is responsible or the development and realisation o a arshorewind arm on the Thornton sandbank, which is located approximately 30 kilometres oshore

rom the Belgian shore. C-Power awarded ABB the contract or the Design, Engineering,

Construction and Installation o the complete electrical inrastructure and the topside o the

oshore transormer platorm. ABB has in turn awarded HSM Oshore the contract or the

construction and installation o the topside. Iv-Oil & Gas executed the engineering and design

o the topside steel structure, including the workshop drawings and all their utility systems.

HSM Oshore started the construction activities in January 2011. On Saturday, the 3rd

o March2012, the construction o the Thornton Bank topside was nished suciently to allow an open

day. A lot o people made use o the opportunity to visit a platorm o this kind. Five days later,

the load out o the platorm took place. On the 19th o March the installation o the platorm

was completed.




To transer the generated electrical energy in the most economical

way, it is necessary to transorm the energy to a higher voltage,

so that energy losses will be limited. The Thornton Bank oshore

transormation station is used to collect, transorm and transer the

energy generated by the wind turbine generators (windmills).

The wind arm comprises o 54 wind turbine generators with

capacity ranging rom minimum 5 MW to maximum 6 MW.

The generated energy o the wind arm is collected at the

transormer station. The medium-voltage electrical current is

increased in voltage with a transormer and cultivated, such that

the electricity can be released into the Belgian grid without urther

treatment. The electricity will be transported to shore by two

150 kV high voltage cables o approximately 37 km length. At the

Grid Connection Point in Oostende, the two 150 kV high voltage

cables link the wind arm to the Belgian electricity network.

The Normally Unattended Installation (NUI) is controlled and

operated rom shore. When maintenance to the station is necessary,

it is possible to stay overnight or a short period o time. For

situations like these, a shelter or maximum six persons is included.

Roo Deck

Only small equipment is placed on the Roo Deck. I required,

the main equipment (transormers and shunt reactors) can be

lited through the roo deck onto a barge. The Belgian rules

require a bird migration monitoring system to be installed on all

installations like Thornton Bank. On this station, this system is

located on the Roo Deck along with several weather systems.

In case o an emergency, helicopter winch operations allow

sae evacuation o personnel rom the Roo Deck. In normal

situations, the transportation o personnel to and rom the

station will be by boat landing at jacket level.

Mezzanine Deck

Due to the size o the main transormers, these pieces o

equipment stick through the Mezzanine Deck. Four shunt

reactors are placed on the Mezzanine Deck.

Main Deck

The two main transormers are placed on this deck. This type o

equipment transorms the collected energy rom 33 kV to

150 kV. This transormation is necessary to minimise the losses

while transporting the electricity over large distances. The

smaller transormers on this deck support the larger ones. In

addition, this deck houses Gas Insulated Switchgears in three

large rooms.

Cable Deck

Electricity is collected rom several windmills and will enter

the station through high voltage cables. These cables arrive

at the Cable Deck o the station. The Cable Deck is the lowest

deck and is provided with staircases or the two boat landings

at jacket level, which gives access or personnel. In this station,

approximately 50 km o cable is allocated to connect the

windmills with the oshore transormer station. Two cables o

approximately 40 km in length connect the oshore transormer

station with the Belgian electricity grid onshore.

Rigardo Kautz

Project Manager, Iv-Oil & Gas

Oil & Gas


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Thornton Bank

Technical Details

Main dimensions : 20 x 30 x 17 m (lxwxh)

Weight Topside : Max 2,150 mT


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Figure 1: Fracking involves racturing the rock using chemicals and small underground explosions, a method o extracting oil rom the state's

Bakken Shale ormation.

50-200 eet 15.240 metres - 60.960 metres

1000 eet 304.800 metres

3000 eet 914.400 metres

1 Mile1609.344 metres

7500 eet 2286 metres

2 Miles3218.688 metres


Iv-AGA assists in the design o a newinjection pumping station

Rapid growth in North Dakota’s oilproduction

The use o ‘racking’, has greatly increased production o shaleoil and has promoted producers to expand the oil transportinrastructure as quickly as possible.



Michael J. Russo

Manager Electrical & Instrumentation, Iv-AGA

Oil & Gas

9

Currently a new injection pumping station as part o an existing

pipeline, which transports crude oil to the renery, is being built

in Mandan, North Dakota, USA. The objective is to integrate this

Johnsons Corner Injection Station into the pipeline's existing

monitoring and controlling system.

The Electrical & Instrumentation (E&I) division o Iv-AGA was closely

involved in this project, achieving excellent perormance and

meeting all requirements within the agreed time schedule.

Iv-AGA provided detailed E&I design and engineering services to

support the installation o two Variable Speed Drives or motor

driven, positive displacement pipeline injection pumps.

Improving eciency with modular design

Iv-AGA produced a design in association with Project Consulting

Services (PCS). PCS is an engineering company specialised in

pipeline design. PCS entered in a contract with Iv-AGA to provide

Electrical & Instrumentation engineering support. The design

incorporated a modular Motor Control Center (MCC). The MCC

building houses all the electrical distribution switchgear and

equipment required to operate the Johnsons Corner Injection

Station. The modular design allows the MCC to be quickly

disassembled and moved to another site when required.

Enabling remote operation

Iv-AGA’s E&I team also provided systems integration engineering

to enable the Johnsons Corner acility to be operated remotely via

SCADA VSAT connection to the operations center.

Continuation o the Project

An Electrical Connection was made to the Saddlebutte pipeline

site acility as well. This permits two or more pipeline companies

to utilize the Johnson Corner Site. The second phase o the project

is expected to start this year and could entail the addition variable

speed pumps to accommodate additional anticipated pipeline

volume and pipeline connections.



Successul delivery o two arepackages or Enerex Ltd.

Escher Process Modules (Escher) has successully delivered twoFlare Packages including Flare Tips and Ignition and ControlSystems or Enerex Ltd.



Computational Fluid Dynamics study results detailing the internal and external ow distribution in

the Sonic Multi Arm HP Flare Tip

Ignition test o the Pilot Burners beore installation on the Flare Tips

Thomas Lassus

Project Leader, Escher Process Modules

Mark Gelderblom

Process Engineer, Escher Process Modules

Oil & Gas

11

As a background, Sonic Multi Arm Flare Tips are generally selected

due to the good and smokeless combustion and because it

causes less heat reduction due to stier and more stable ames.

Furthermore, a sonic are tip requires a smaller diameter and lighter

weight are compared to conventional open pipe are tips. As a

result o the higher noise level, the Sonic Multi Arm Flare Tips are

less oten applied or onshore applications. For thinly populated

areas (e.g. in desert like areas), or in cases where height restrictions

are applicable (e.g. oshore environments), it has proven to be a

good alternative. For instance, on oshore platorms, sonic ares are

the standard solution.

To design the sonic are tip, Escher has applied leading are

sotware, Flaresim. Computational Fluid Dynamics (CFD) simulations

were perormed to model the internal and external ow distribution

and occurring pressure drops. Lastly, a combustion simulation

was perormed or quality assurance and design success. Special

attention was required or the eight arms, and or the center

burner (reer to gure on the bottom). On the one hand, a better

understanding o the (sonic) ow patterns o the gasses and the

ame was necessary, and on the other hand it was needed to ensure

that the pressure drop was calculated within valid design standards.

From a mechanical point o view, the verication was ocused on the

internal pressure assessment concerning the selected thicknesses

and branch connections. Based on the results, a stress model has

been prepared, taking into consideration all possible loadings to

ensure the ultimate sae disposal o natural gas.

Escher has been designing, manuacturing and supplying

Flare Systems or six decades and in 2011, Enerex Ltd. awarded

Escher with a contract to design, manuacture and supply

Flare Packages to be installed or an international project. The

project is completed; the design and manuacturing o the Flare

Packages was completed on schedule and the delivery occurred at

the end o 2012.

Escher was tasked with providing two Flare Packages, including are

tips and control systems (high energy ignition type).

The Flare Packages design scope covered ull process, mechanical

and piping aspects. Enerex requested two types o are tips: a

conventional open pipe or the low pressure (LP) are and a sonic

type or the high pressure (HP) are.

For both tips, the selected construction material was heat resistant

310S stainless steel. In addition, Escher has selected a pilot ignition

based on High Energy Ignition, because this type adapts better

variations in the gas composition; it is a less complicated design

and it allows or easy installation. The open are tip is a standard,

turnkey Escher product. This allowed or quick response to the

requests by Enerex. The sonic are tip was more customised and

thereore required more eort in the process engineering aspect in

the project.



EnQuest Producer, a third lie or theDirch Maersk tankerIn the rst quarter o 2012 the Uisge Gorm Floating Production Storage and Ofoading (FPSO)

vessel was acquired rom Bluewater Energy Systems by EnQuest PLC. The FPSO was renamed the

EnQuest Producer and is to be deployed in the Alma (originally named the Argyll eld – the very

rst oil eld to be developed in the UK) and Galia oileld development. However, beore the ship

can be deployed it must undergo extensive modications.



The vessel is about to enter a third lie, not to be conused with

‘le troisieme age,’ the French term or retirement. On the contrary,

the EnQuest Producer is expected to service in the British sector o

the North Sea or at least another 10 years.

The ship’s rst lie was as a tanker or the Danish company Maersk.

In 1996 it was acquired by Bluewater Energy Systems and converted

into an oil production and storage vessel or use in the Fie eld in

the British part o the North Sea.

Maritime

The ship’s mooring system

The EnQuest Producer will be kept in position using an internal

turret mooring system, which allows the vessel to turn and adopt

the direction o least resistance against waves, winds and currents.

Between 12 and 16 chains and anchors extend to the seabed rom a

central point in a radiating pattern rather like a spider’s web.

In act, the central hub is known as a spider, which hangs on a

rotating turret. In practice, it is not the turret that rotates but the

ship which rotates around the turret. Alongside the mooring lines

are exible pipelines and cables, which connect the vessel with the

wells on the seabed. Because the turret remains static in relation to

the seabed, these pipelines can never become entangled.



Kees van Roosmalen

Managing Director, Nevesbu

Internal turret mooring

On the EnQuest Producer, the turret is secured to the vessel itsel by

means o bearings at the deck and the bottom. This method entails

constructing a vertical cylinder rom the the keel to the deck, which

contains bearings and allow the ship to revolve around the turret.

This option is requently employed in areas with extreme weather

conditions and is most appropriate when there are a large number

o pipelines and risers connecting the vessel to the seabed, each

carrying a dierent product ow. A large number o ows will result

in a particularly complex swivel stack construction. Access can be

improved by means o the internal turret arrangement.

The turntable is located at the upper part o the turret. Here gas and

uid ows rom the risers are led to the swivel stack.

The new turret

Nevesbu is responsible or the integration and engineering or the

new turret. The picture below shows a typical Finite Element Model

which we use to calculate the structural engineering requirements

during the design phase. Finite Elment Modelling oers the only

way o analysing the structure in adequate detail.

The turret deckhouse

In addition to the structural design and installation o the turret

itsel, Nevesbu has also been awarded the contract or the design o

the turret’s deckhouse. This structure, 18 m in height, protects the

swivel stack against wind and waves. The deckhouse also contains

the various pipes and cables which run rom the ship, via the turret

to the seabed. The upper side o the swivel stack is supported by the

deckhouse. Below the structure are the chain pull-in winches which

serve to pre-tension the anchor lines. Each winch has a maximum

pulling orce o some 250 t, requiring extremely solid oundations.

Once this project is completed, EnQuest’s development o Alma and

Galia will allow the EnQuest Producer to start at least another

10 years o service producing oil in the North Sea.



Iv-Water prepares ROW or 37 kilometreso water mains pipeline

In late 2011, Iv-Water acquired a ramework contract with Vitens, one o the leading water

suppliers in the Netherlands. Under this three year agreement (with possible extension to

ve years), Iv-Water and ve other engineering companies will provide technical advice on

underground resh water inrastructure and above ground installations. Project leader Ronald

Schuilenburg and department head Paul Kloet ocus on the ROW (right-o-way) part o a

pipeline project.

Vitens water corporation supplies resh water to industries and residents in Overijssel, Flevoland,Gelderland, Utrecht and Friesland (the Netherlands), including the Wadden Islands (the

Netherlands). With 5.4 million residents and companies as customers resulting in a network

totalling 47,500 kilometres o pipeline, it is by ar the largest drinking water supplier in the

Netherlands.

Vitens now outsources part o its engineering activities to the six parties mentioned earlier. The

huge area is divided in regions and Iv-Water is the designated company or most o the projects

or underground inrastructure in the province o Gelderland. Depending on Vitens’ exactrequirements, projects in other regions may be awarded on the basis o competition between

the companies who have signed the ramework agreement.



Transport by pipeline

The Province o Gelderland has granted Vitens a permit to extract

groundwater. However, this permit restricts the annual amount

o water to be extracted. Upon recent renewal o the permit, this

amount was reduced. To maintain a steady drinking water supply,

Vitens thereore reviewed its water mains network, location o

extraction sites and pumping stations. As a result and together

with the Province o Gelderland, an important document named

‘Covenant or Sustainable Drinking Water Provision in Gelderland’

was signed.

Under this covenant it has been decided that the pumping station

at Zutphen is to be dismantled in 2015. To saeguard resh water

supplies, a new pipeline must be constructed rom the pumping

station at Epe to Zutphen, via Apeldoorn. This is an excellent

alternative since underground pipelines oer a highly ecient

way o transporting uids rom one place to another. They requirelimited maintenance and have a high rate o availability. They

are not visible and, provided they are designed and constructed

properly, they have a very long operating lietime.

Land owners and leaseholders

The route o the new pipeline has been decided and approved by

Vitens. It’s now Iv-Water’s task to acquire all necessary ROW’s or the

land that will accommodate the pipeline. In law, these rights are

written down in contracts that are signed by both the land owner

and Vitens, drawn up by a notary. This notary then registers these

contracts at the Land registry named 'Kadaster'. In the contract, one

can nd rights and obligations o landowners, leaseholders and

Vitens. It also claries the exact position o the pipeline and the

space that must be kept clear on the surace to provide access when

required. For practical reasons, Vitens wishes to have the pipeline

constructed along the shortest possible route, this reduces the line

resistance and saves on pump energy and associated costs. Vitens

must also have ready access to the pipeline in case o maintenance

or an emergency. Thereore, any building or construction directly

above or in the vicinity o the pipeline will be prohibited.

Water

Right o way

Iv-Water acilitates the entire process o acquiring ROW’s or

the complete pipeline. On behal o Vitens, Iv-Water negotiates

with landowners and lease holders to ensure that all necessary

documents are available in time or the notary public. The rst step

was consulting the land registry to sort out who owns the land in

which the pipeline is projected. This resulted in approximately

400 lots and some 300 stakeholders such as land owners, lease

holders, provincial authorities, local authorities, water boards,

et cetera. Iv-Water bases its negotiations on the standard

compensation amounts determined annually by the Dutch

Federation o Agriculture and Horticulture (LTO). This process

demands a combination o legal expertise and technical knowledge

since there must be someone who can explain to the stakeholders

why a certain routing is chosen, the impact o diversions rom

the ideal routing and the inuence o geological actors. The

consultants who are to procure the ROW’s on behal o Vitens haveconsiderable experience in these areas. As always, it is essential

to have the right people with the right knowledge on the job. In

this case, the technical experts o Iv-Water are in direct contact

with their counterparts at Vitens. Since everyone speaks the same

'language', Vitens knows it can ully rely on Iv-Water.

Inormation package

To provide inormation and, at the same time create understanding

or the plans, Iv-Water compiled an inormation package or

landowners. It explains exactly what the project entails, includes

drawings o the routing on each lot o land. The package also

contains a drat contract to inorm landowners what they are being

asked to sign. The intention is to provide ull transparency about

the rights and obligations on both sides, and to allow everyone the

opportunity to prepare and ask any questions. Iv-Water’s experience

was that the majority o landowners greatly appreciated this

approach.

Engineering

Having acquired the necessary ROW’s, Vitens’ next step is to open a

procurement tender or the pipeline materials. This is a part o the

engineering phase executed by Iv-Water, implicating ne tuning

o the exact routing, construction sites, engineering o trenches,

horizontal directional drillings or intersections with roads, railways,

waterways etcetera. Various environmental actors must be

considered as well, such as the presence o valuable ora and auna,

groundwater, geology and potential hazards such as old explosives.

In a nutshell, Iv-Water’s task is to acilitate the process and make it

transparent or everyone involved. The team aims to carry out every

aspect o this project to the ull satisaction o Vitens.

Paul Kloet

Department Head, Iv-Water

Ronald Schuilenburg

Project Leader, Iv-Water



BCFS-reactor as a centrepiece o Steenwijk water treatment plant

Iv-Water provides technical consultancy

services to clients in the sewage water

treatment market segment. Much o its

advice relates to newly build and renovationprojects or industrial users and public water

authorities. One such authority, Waterschap

Reest & Wieden, asked Iv-Water to advise on

the expansion o its wastewater treatment

plant in Steenwijk to include a new biological

‘BCFS-reactor'. Project Managers Geert-Jan de

Wit (Reest & Wieden) and Iwan Ramtahalsing

(Iv-Water) explain the metamorphosis that

Steenwijk has undergone and the role that

Iv-Water played in the process.

Project: Biological expansion o Steenwijk

wastewater treatment plant

Client: Reest & Wieden Water Board

Consultancy and

project management: Iv-Water

Civil engineering: Elja Beton- and Waterbouw, Rijssen

(the Netherlands)

Mechanical engineering: Aan de Stegge, Goor (the Netherlands)

Electrical engineering: Moekotte, Veendam (the Netherlands)

Construction costs: Over €13 million



In late March 2011, the Steenwijk site was ull o activity. The

project involved all aspects o construction: demolition, renovation

and new build. All work ocussed around the construction o a

new biological water purication reactor that has a diameter o

approximately 70 m. We met Jan van Egten in the control room

who has been monitoring operations at Steenwijk since 1975. He

is ‘the last o the Mohicans’. When the Steenwijk site rst opened,

it had a sta o six employees. Jan is now the only person working

there ull-time. “Over the years, we simply needed ewer people,” he

explained. “Everything is now automated and most maintenance is

outsourced.” It is not clear whether there will be anyone at all on the

site in the uture.

What will change?

“Steenwijk has been expanded several times in the past,” states

Project Manager Geert-Jan de Wit, “in 1997 and 2005 or example.

With each expansion, we adapted the installation to meet the

higher capacity requirements and the stricter water quality

norms. In the late 1990s, a BCFS-system was integrated into the

existing plant. The abbreviation stands or Biological-Chemical

Phosphate and Nitrogen removal. In order to continue meeting

the quality norms, we had to expand the biological component,

which entailed a new BCFS-reactor. Some components are

decommissioned altogether, others replaced or included in the

process in another way.” The BCFS-reactor in Steenwijk is the th

that was commissioned by Reest & Wieden at its various wastewater

treatment plants.

Iv-Water: a new ace

In late 2008, a European tender was opened or the nal design,

specications and project management o the latest expansion at

Steenwijk. “Iv-Water produced the best proposal,” recalls

Geert-Jan de Wit. “This was something o an eye-opener or us since

we had never done business with the company beore. We didn’t

quite know what to expect. But the design and specications met

with everyone’s complete satisaction and our contacts with sta

were always very pleasant. It was decided that Iv-Water should also

become responsible or project and construction management.

The company also oversaw the European tender and contractor

selection process, as well as advised during the permit application

phase.”

Iv-Water’s involvement in the project was managed and coordinated

by project manager Iwan Ramtahalsing who, supported by a team

o colleagues, also took on the role o construction manager.

A mix o old and new

The Steenwijk water treatment plant has a mix o old and new

equipment. The pre-sedimentation and pre-thickening tanks,

although ully unctional became redundant. Paradoxically, the

problem was that they worked too well, removing too many

contaminants rom the inuent. For the BCFS-reactor to work

properly, the water had not to be too clean to begin with. The

bacteria on which the process relies on are more eective in

dirtier water. The plant’s anaerobic tank and sludge ermentation

tank (with its combined heat and-power generator) are alsodecommissioned.

A new operations centre is built. It is very well insulated and smaller

than the current version, with just enough room to accommodate

the control and monitoring equipment, and the minimum required

number o sta. In addition, the raw water intake system is replaced

and expanded to include new bar and mesh screens, a sand

chamber and a sand-washing unit. Also replaced are the blower

housing, the P-stripper, the sludge buer tanks, the chemicals

storage and dosing system, the sludge return pump and the

lava lter. Some components remained including the three post-

sedimentation tanks and the sand lters (which provide a nal stage

o purication beore the ultra-clean efuent is discharged rom the

plant).

Iwan Ramtahalsing, Project Manager Iv-Water

Geert-Jan de Wit, Project Manager Waterschap Reest & Wieden (Reest & Wieden Water Board)

Water



The heart o the process: the BCFS-reactor

All new components are overshadowed by one very remarkable

structure, which was put in place one wall panel at a time: the BCFS-

reactor itsel (see inset). To provide the necessary rm oundation, a

concrete oor with a diameter o approximately 70 m was poured in

just one day.

"Its surace is as smooth as

ice. It is certainly a ne piece

o work,” says De Wit, “and a

great achievement with 150

truckloads o concrete poured in one day. Many o the people

involved had never seen

anything on this scale beore.”

The pouring process was careully monitored by civil engineer

Bas Paardekooper o Iv-Water. The oundation supports 355 preab

concrete wall panels, each 5.55 m high, 1.515 m to 2.365 m wide,and between 165 mm and 200 mm thick. At intervals along the

concrete wall are apertures or the channels through which the

inuent water is passed into the various process basins. Some o

these channels are enclosed with concrete sheets to reduce smells.

On the base o the basins there are a total o 198 aeration elements,

installed at strategic points. These introduce the oxygen, which

allows the bacteria to do their work. Other basins are ‘anaerobic’

and contain bacteria, which thrive in a low-oxygen environment.

The water is gradually circulated around the basins by mechanical

impellers. The reactor has a capacity o 2500 m3 per hour (Rain Water

Supply).

Reclaiming energy and saving

The existing sludge ermentation unit didn't orm part o the new

purication system. “The residual sludge was transported to Echten,”

explains Geert-Jan de Wit,“ where the Water Board commissioned

a new and sustainable sludge ermenter. The sludge rom all our

treatment plants is brought here and converted into biogas. ”

The water authority has set itsel the target o reducing energy

consumption by 2% year-on-year. Following the expansion project,

the Steenwijk water treatment plant certainly made a contribution

to this objective. Both the design and the construction process have

devoted considerable attention to sustainability.

Perect coordination

“One o the most signicant challenges in this project was ensuringthat the old plant remains ully operational and accessible

throughout,” says Iwan Ramtahalsing, Iv-Water’s project manager.

“There were many construction activities going on at the same time,

sometimes within metres o each other. This calls not only or good

technical knowledge but also or considerable creativity in order

to keep the risks, costs and time requirement in balance. But that is

what makes our work so interesting and enjoyable.”

The BCFS-reactor is at the heart o the uture purication process

and was also the key ocus o the construction project. All

subcontractors were very much dependent on each other to ensure

eective coordination o their respective activities. In act, the

project proceeded extremely smoothly.

Geert Jan de Wit: “Everyone seemed to be on top o things. The

reactor itsel was in place at the end o April 2011, whereupon all

the high-tech connections and equipment were installed. There are

thousands o cables criss crossing the site. It is a wonder they didn't

get tangled! But I had every condence that everything proceeded

in the same highly ecient and ordered manner. That is largely

due to the close involvement o Iv-Water. The primary work was

nished in the beginning o 2012, and we switched over the entire

plant rom the old state to the new within one day. That was a tense

moment, but also very gratiying or everyone who had contributed

to this project.”



Discharge into protected nature area requires extra clean euent!

District Water Board o Reest & Wieden serves the south-west and central parts o Drenthe and northwest Overijssel, a nature reserve with

an area o 137,500 hectares with relatively ew inhabitants. The authority manages 202 km o pressurized drainage pipelines, 123 sewage

pumping stations and eight wastewater treatment plants, o which Steenwijk is the second largest. The plant was built in the early 1960s and

stands alongside the Steenwijker Diep waterway, into which the efuent is discharged. Because the waterway ows directly through a national

park, De Weerribben-De Wieden (the largest low-lying peat bog complex in north-western Europe), the efuent must meet the highest

standards o purity. Steenwijk thereore has an additional purication phase in the orm o a sand ltration unit.

The BCFS-process

BCFS is a patented water treatment and purication process. The abbreviation stands or Biological Chemical Phosphate and Nitrogen

Removal. A complete BCFS-conguration comprises ve steps: AN-KB-ANOX-Exchange-OX. The process also involves a P-stripper in the AN

zone, parallel to the anaerobic zone. The presence o bio-P creates a risk o minor sludge ormation, so the process also includes a contact

basin. Because there is some ingress o ats in the inuent which passes into the pre sedimentation tank, the sludge is saturated with

phosphates, some o which must then be removed by a chemical process. The P-stripper is there to ensure that the active sludge contains

no chemical contaminants. Water which is rich in phosphates is continually ed into the pre-thickener where the phosphates are chemically

removed. The chemical sludge passes directly to the drier and is not introduced into the AT. A complete BCFS-conguration ensures that

treated water meets the very highest quality standards.

Interview and text by Suzanne Doeleman

Water



A multiunctional health centre that

enhances the healthcare experienceIv-Bouw commissions De Prinsenho inGouda The company Zorgpartners Midden-Holland operates 18 residential care acilities in the

western Netherlands and is looking to extend its services in Gouda. This new acility,

named De Prinsenho, will oer residential accommodations including 130 private

bedrooms, each with its own bathrooms and communal lounges that are shared by

seven residents. The centre will also oer a wide range o care-related services to the

local community; such as meals on wheels, domestic help, tness acilities,

physiotherapy and shops.



Following the completion o the building in September 2011,

Iv-Bouw spent another six months detailing the electrical

engineering components. The ocial opening was on 16 April 2012.

The interior has been completed and the next step is to design the

garden area. Iv-Bouw has completed the landscaping plan and has

selected the suppliers and service providers. The trees and greenery

are scheduled to be sown in the autumn o 2012 and by spring

2013, the garden will be ready or exhibit.

Sustainability

De Prinsenho has a geothermal heating system. A series o ground

source heat pumps is used to exchange energy between the air

in the building and the ground system, which draws heat rom

underground aquiers. This is a highly ecient system which is not

only environmentally responsible but considerably reduces the costs

to the client. Underoor heating and cooling ensures a comortableinterior climate at all times o the year.

'Experiencing Gouda'

The centre, designed by architect Hans van Egmond o Noordwijk,

has now been operational or several months. Its curved, elliptical

orm is unique or a building o this type, and is a visual reerence to

two nearby apartment buildings designed by the same architect.

The underlying concept o De Prinsenho is ‘experiencing Gouda.’

The interior walls are adorned with photo-murals o local scenes,

rom the wide open spaces around the city to its narrow shopping

streets. The ground oor decorations eature the city centre and

historic city wall. The design and nishing strives to create a warm,

homely atmosphere.

Residents, neighbours and visitors have all commented on how

attractive and welcoming the centre seems.

To bring this vision to ruition, Zorgpartners Midden-Holland

collaborated with Iv-Bouw rom design to implementation. Iv-Bouw

oversaw the project and was involved in all phases o development,

including the preliminary and nal designs, specication, tendering

and procurement, construction management and atercare.

Iv-Bouw assembled a team o subcontractors including

BVR-Groep (construction), Wolter & Dros (mechanical engineering)

and HVL (electrical engineering) to ensure the successul

commission o the De Prinsenho.

Building a new acility can be challenging, especially during an

economic downturn. Construction projects are typically subject

to design modications in order to better address the evolving

client requirements. In addition, legislative requirements in terms

o room size, accessibility, climate control and security add to the

complexity. From a development standpoint, Iv-Bouw aced the

ollowing challenges:

• Delivering the project with reduced budget: The economic

conditions can change drastically during the long liecycle

o construction projects. The project was conceived during a

time o relative prosperity but experienced budget cuts over

the course o the project. This led to the reduction o land

availability by 800 m2.

• Change in scope: To better address the needs o patients, the

client included in the scope to also accommodate patients with

dementia, a tness centre and an out-patient acility or local

residents.

• Minimizing noise and disruption to neighbouring residents.

In order to complete the project within its entirety but with reduced

budget, Iv-Bouw implemented creative solutions such as:

• More ecient use o required space (double unctioning o

space).

• Optimization o spaces by investigating the requested space in

relation to the use o space.

The inclusion o patients with dementia meant that new saety

requirements had to be considered. This was addressed by ensuring

that a dierent set o security measures was incorporated in the

plan.

De Prinsenho is located in a residential neighbourhood. To

minimize the disturbance to surroundings, the team inormed the

local residents about the planned work on a weekly basis and a ‘no

radio’ rule was introduced on site.

In addition, the success o project can be attributed to the

cooperation within the team. Communication among the groups

was eective and problems were solved quickly and eciently.

Buildings & Structures

Marcel van Houdt

Project Manager, Iv-Bouw



New guy-wired antenna mastat Hoogersmilde (303 metres)

The transmitter mast in Hoogersmilde provides television and radio

coverage in the northern part o the Netherlands. On 15 July 2011, a re

in one o the eeder cables caused the Hoogersmilde guy-wired antenna

mast to collapse, causing service disruption to the region and damage

to part o the concrete tower. The goal o Omroepmasten B.V. was tominimize the disruption by replacing a new mast on the concrete tower

by August 2012.

This project was carried out as a mutual eort among Iv-Bouw, Iv-

Consult, the client and other stakeholders that resulted in a new design

and appearance o the Hoogersmilde antenna mast.

Iv-Bouw was responsible or the project managment and

communication among the stakeholders and Iv-Consult was responsible

or the technical aspects and structural design o the new mast.





Opportunity

Considered a great achievement at the time, the mast was originally

designed by 'De Vries Robbé' in the 1960s or the purpose o

broadcasting television. In the later years it was modied to include

the broadcasting o more FM radio and digital television. In order

to improve coverage and better meet capacity demands o current

and uture users, the ollowing modications to the existing design

were incorporated:

1. The height o the mast was increased to 303 metres.

2. An open lattice structure with a triangular cross section was

adopted, compared to the original tubular section with a

diameter o two metres. Expected advantages were as ollows:

• Reduction o re risk

• Open space and room or uture changes and antenna

arrangement modications

• Eliminate internal moisture problems

• Increased space at the mast base or the eeder cables

• Compliance to saety regulations

• Fast and easy manuacturing and construction

Challenges

Guy-wired masts o this scale are classied as one o the most

complex structures in structural engineering. Due to the national

importance the mast was designed or Consequence Class 3 (CC3),

in accordance with the Eurocodes. From a design to commission

point o view, the construction team aced the ollowing challenges:

• Meeting the tight deadlines: Approximately three months wasallocated or both the design and steel abrication, and two

months ater the start o abrication, the erection o the mast

was scheduled to start.

• The wind loading: Wind loading is very signicant or this

structure thus considerations to the shape, solidity ratio,

wind patch load area and dynamics must be taken to account

careully.

Solution

To mitigate the tight deadlines, Iv-Consult and contractor Volker

Wessels Telecom completed a parallel ast track design in order to

meet the scheduled mast erection date.

For a mast design, the design

according to CC3 is signicantlymore severe than one according to

CC2. This design will better address

the increased wind load actor and

consequence o a guy rupture (the

latter being experienced in the

original mast as a result o a 'very

close y by' o a jet ghter, shown in

the picture to the right). The wind

load also implied that more weight

and bearing capacity had to be

added to the existing anchor blocks

at the base structure.

25



Test or possible rupture

The Conservative Procedure (EN 1993-3-1: 2006 §E.3) has been

applied to determine the eect o the possible rupture o one o the

guys. For the top guy rupture, results according to the Simplied

Analytical Model (EN 1993-3-1: 2006 §E.2) have been considered.

Comparison is shown in the gure below. In addition, the dynamic

behaviour o the whole structure in case o rupture o one o the

top guys has been analysed by means o a dynamic analysis (direct

time domain numerical integration). From this analysis the dynamic

amplication actor, against which the mast sections and its

connections should be designed, could be determined. By adopting

this design approach, the envelope o the governing orces could be

determined.

Completion o the mast

Once the mast was able to broadcast again, the structural outtting

o the mast commenced. Platorms were installed at the our-guy

level; a crew shelter added at the second guy position; and a new

top cabin was placed at the concrete base.

The erection o the mast was completed in two weeks by a

specialized helicopter installation company. Special tools and

procedures were designed by Volker Wessels to ensure the success

o the delicate operation, which included the installation o more

than ty elements and the guy wires that were own in position

and hooked up in special devices.

Results

The new design o the mast allowed or improved coverage and

increased capacity to address the demands o current and uture

users.

Wouter Visser

Manager Structural Design department, Iv-Consult

The abrication o the standardised steel sections was done by

Voortman Staalbouw.

The nine metre tall oundation and rst section was the biggest

and most dicult one to produce. The total mast load passes

through this base point which is designed as a pinned rocker

bearing support.

All steel parts were hot dipped

galvanised and painted in a standard

Dutch 'sky grey' color. The size limit o

the galvanize bath gave the condition

that the mast sections just tted.

The guy brackets had to be attached

aterwards.




Iv-Consult designs roo o new SportsBowl stadium in Nigeria

In early 2011, Iv-Consult designed a new roo or a sports stadium in the Nigerian city o Port

Harcourt in association with Hollandia and ArcelorMittal. Together with its representative in

Nigeria, ArcelorMittal Projects o Dintelmond, the Netherlands, accepted the contract to design

and build the stadium together with Iv-Consult and Hollandia. The Sports Bowl is part o an

entire sports village called the Garden City Community Sports Centre. It is being nanced by the

Nigerian province o River State as a git to the community.

Source: ArcelorMittal




Iv-Consult was responsible or the design o the roo structure and

the ollowing boundary conditions were applicable:

The Sports Bowl measures around 275 m x 190 m (l x w). The stands

are made o preabricated concrete elements with heights o up to

roughly 16 m.

Figure 1: Tekla model view o block 1

A steel awning was placed above the stands with a span o

approximately 40 m, with a central support midway along the

stand. The roo as a whole is made o eight rotationally-symmetric

sections, each section with its own stabilizing orce. There are our

sets o blocks (numbered 1-5, 2-6, 3-7 and 4-8). Each block has

columns placed at regular intervals coupled to latticed trusses.

Figure 1 shows a view o block 1-5.

The roo trusses and couplings are made o angle steel. The purlins

consist o HE and IPE sections. The elements were chosen so as to

allow on-site bolted assembly like a big Meccano structure. This can

be seen in the trial assembly in gure 2.

Figure 2: Test assembly by Hollandia.Source: Hollandia

Overview o the Tekla model


29



The design was as ollows:

• The curved sections have a smaller column distance than the

straight ones. This would have resulted in the truss ends nearthe inner ring being too close to each other to work optimally

and thus, a dierent system was adopted (see gure 3).

• The intermediate truss was removed in the curves and the purlin

span was maximized by adding sections. These sections go rom

the bottom girder o the main truss to the purlins (see gure

4). This creates a statically indeterminate structure capable o

distributing its orces optimally.

To ensure access immediately below the roo or maintenance work

on the lighting and sound systems, the design included two ring

walkways in combination with our radial walkways reachable by

step towers.

On completion o the Tekla 3D-models, the roong supplier in

England (Arval, part o ArcelorMittal) set to work. The roong

required accurate dimensioning. The models were thereore

exported in AutoCAD 3D. These models were used to determine the

layouts and acilities necessary to assemble the roo slabs correctly.

Figure 5 provides an impression o the conguration.

Some o major challenges in this project included:

• The many parts, and tonnes, o steel required accurate

management o the assembly o trusses.

• The individual parts had size restriction due to transport per

container rom the Netherlands to Nigeria.

• There were many parties involved and thus proper coordinationwas paramount.

To address the challenges the ollowing solutions were

implemented:

Optimizing the design: the basic design o the roo was evolved with

the objective to optimise the structure rom a number o parts, and

a total mass point o view. Two engineering principles were applied

that resulted in the weight and the number o parts to be reduced

by about 20%. This saving was achieved by using dierent designs

or the straight sections and or the curved sections. Every two

trusses in the straight sections have one column and the columns

are spaced approximately 12 m rom each other.

Figure 3: Original lay-out (top)Figure 4: The middle girder has been replaced by the system o diagonal beams to reduce the purlin span

(bottom)

Figure 5: Method o the Ondatherm roong.

Source: ArcelorMittal




Block 1-5 (top) Block 2-6 (bottom)

Sea transport required that all parts had to t into containers o 12

metres, which meant that the modelling o the roo had to be ne-

tuned to ensure compliance. With this in mind,Iv-Consult started producing the workshop drawings or this project

in February 2011. The implications were as ollows:

• None o the parts could be longer than 11.8 metres.

• The stadium roo would need to be made o numerous parts,

which would be bolted together. There were a total o 54,298

parts and to interconnect all the structural elements it required

a total o 68,636 bolts built within the 3D Tekla model. The

starting point was the straight parts designated as blocks 1

and 5 ollowed by the curved parts o blocks 2-6, 3-7 and 4-8,

including stairs, gutters and walkways.

Successful teamwork: the steel structure was scheduled or

completion by year-end 2011 and there were many stakeholders

involved in its commission. Iv-Consult managed the manuacturing

schedule and logistical requirements in the workshop models in

close consultation with Hollandia. The successul alliance allowed

or good coordination and eedback among engineering, detailing

and workshop. In addition, Iv-Consult’s experience in working

across cultural dimensions enabled Iv-Consult to successully work

alongside the Nigerian national authorities and local population.

The parts were all set down in drawings, resulting in 101 overview

drawings and 4,369 mono drawings. The entire structure weighs

approximately 1500 t. Design and commission o the roo was

completed on time. The design was optimized to achieve a 20%

reduction in weight and number o parts, thereby allowing or sea

transport. In addition, the successul teamwork among the dierentstakeholders enhanced eciency without compromising quality by

minimising rework and slack.

Stadium, under construction in 2011


Henno Vlieg

Manager Detail Design department, Iv-Consult

Wouter Visser

Manager Structural Design department, Iv-Consult

31



IHC-Merwede and Iv-Consult establish Malaysian joint venture, IHC-Iv Malaysia, to reduce cost o

detail engineering in shipbuilding

Expanding the business and reducing costs

For more than 12 years Iv-Consult Malaysia, the Malaysian arm o

Iv-Consult, has been producing workshop drawings or steel

structures at a competitive price. A new department, Steel Design,

was created last year and is now expanding at a rapid pace.

The cost reduction, made possible by perorming detail engineering

work in Malaysia, has enabled Iv-Consult to oer products and

services at a competitive price. IHC-Merwede took the opportunity

to oshore some o its detail engineering work in Asia in order to

take advantage o the cost-savings. The opportunity also allowed

IHC-Merwede to leverage the increase in capacity to mitigate the

shortage o engineers in the Netherlands. The objective o

IHC-Merwede is to grow by 50% in the coming years. They envision

the oshoring o engineering activities to assist in this objective in

two ways; the exibility enables the company to better respond tovariable demand and supporting internationalisation o the rm by

placing engineers or partner yards in the Far East.





Solution to capacity problems

By diversiying its activities (expanding the Kuala Lumpur site to

include shipbuilding know-how) Iv-Consult is able to hedge against

the volatile steel construction market. The joint venture also serves

as a sta pool or IHC-Merwede and Iv-Consult, allowing companies

to absorb periods o engineering over- and undercapacity.

About IHC-Iv Malaysia

The rst 12 employees started work on 1 June 2012 and

immediately let or the Netherlands or three months. During their

stay they received urther training at the IHC-Merwede training

centre. They visited IHC-Merwede yards to learn more about how

the company works at a hands-on level.

The Malaysian company is managed locally by two Dutch experts.

Day-to-day business is run by Schalk van Zyl, who serves as Manager

o Projects. On behal o IHC-Merwede he is responsible or projects

in terms o time, money and quality. Robert van der Waal o

Iv-Consult Malaysia serves as Oce Director and looks ater general

matters such as nance, accounting and human resources.

The building adjacent to Iv-Consult Malaysia’s oce has been

converted into an attractive oce with the potential or urther

expansion. All the necessary IT acilities are now in place, and an

IT system connected to the Dutch network o IHC is up and running.

The employees have returned to Malaysia in the meantime and have

enthusiastically embarked on their rst project, the ‘Beagle 4’.

During this initial project they will continue to receive intensive

training rom experienced IHC-Merwede shipbuilders in

Kuala Lumpur. The impression o the trainers ater three months is

that the Malaysian colleagues are capable and, importantly,

highly-motivated shipbuilders.

Independent uture

IHC-Iv Malaysia’s goal is to be nancially sel-sucient in two years’

time and capable o independently providing high-quality detail

engineering services or dredgers and oshore industry vessels.

All work is being perormed with the Nupas-Cadmatic 3D ship

design sotware, and the company is able to work or IHC Dredgers,

IHC Oshore & Marine and IHC Parts & Services. IHC-Iv Malaysia is

working hard on generating growth and is planning to have a team

o 24 expert employees on its payroll by the end o 2013.

Arie Lanser

Managing Director, Iv-Consult

33



Heineken Zoeterwoudeopts or sustainability with its malt

transport line

Heineken wishes to reduce CO2

emissions in both its production and logistics processes. One

important step in achieving this objective is the implementation o the ‘Malt by Ship’ project at

its brewery in Zoeterwoude (the Netherlands). Malt, a key ingredient o beer, has traditionally

been transported o Zoeterwoude by truck. Bringing it by barge will greatly reduce the number

o transport movements required and hence reduce pressure on the Netherlands’ busy road

network. Rather than 7,125 road movements each year, in the uture the brewery’s malt

requirement can be met with just 350 barge movements. ‘Malt by Ship’ is part o Heineken

Zoeterwoude’s own sustainability program, and in addition will help to achieve the localauthority’s ambition to become a ‘role model’ or sustainable enterprise. Additionally, the

creation o the malt harbour will help to revitalize the Oude Rijn River, restoring its unction as an

important transport route or local companies.




The new transport line was required to convey the malt rom the

dockside into the brewery itsel. It connects a new riverside harbour

and Heineken’s own site, crossing an industrial estate and the Hoge

Rijndijk, a busy through-trac road.

Malt is unloaded rom barges by crane and deposited into a hopper,rom which it is evenly placed (‘dosed’) onto the conveyor belt o the

transport line. The conveyor belt is entirely enclosed and has a lter

system to prevent the escape o any dust or particles into the air. At

the brewery end, the malt is deposited into the existing silos. The

conveyor belt is supported by a steel ramework which incorporates

an accessible walkway to allow inspection and maintenance,

eliminating the need or scaolding or elevated platorms.

Iv-Industrie designed the steel main support structure or a new

malt transport line, 290 m in length and incorporating

220 t o steel, at the Heineken brewery in Zoeterwoude. Iv-Industrie

was also responsible or the oundations and some inrastructural

modications.

The scope included the nal design and oversight o both the detail

engineering and implementation phases. The involvement started

in 2008 and ended in mid-2011 with the completion o the main

support structure.

35



Figure 1: Beam cross-section original design

Figure 2: Beam cross-section o the Iv-Industrie optimised design

Design optimisation

Heineken approached Iv-Industrie with a preliminary design that

required renement. Once this stage had been completed, the

intention was to open a tender or the construction work itsel.

However, the costs o ollowing the original design exceeded

Heineken’s budget or the project. Alternatively Iv-Industrie

suggested an alternative design by using a Nabla’ girder. This

would greatly reduce the overall weight o the structure without

any signicant modications o the original design’s appearance.

This was important, since that design had already been submitted

to the local authority or planning permission. (Later, the local

authority stated that it had actually ound Iv-Industrie’s design a

distinct improvement). In view o the potential cost reductions,

the tendering procedure was deerred to give Iv-Industrie an

opportunity to rene the alternative design. As a result, it proved

possible to reduce the steel requirement o each 48 m section by

17% (approximately 5,000 kg).

Following a critical analysis, Iv-Industrie was also able to reduce

the number o diagonals required within the Nabla structure, with

remaining diagonals in a lighter orm, and to design ve o the

portals (arch supports) in hinged rather than xed orm. This meant

that the high-maintenance slide assemblies (used to reduce riction

at critical joints) were no longer required. The steel rame lattice

supports between the bunker and the rst portal, which could be

replaced by a simple bridge structure, with two main I-beam girders

linked by cross-beam trusses and a wind bracing or stability.

The steel construction

In the construction the Nabla girder demands the main role. The

ratio between span and structural depth is 16, which gives the

structure a remarkably slender orm. One particular requirement

or the Nabla structure was the maximum allowable horizontal

movement o only 50 mm, in addition to the limits which apply

to the conveyor belt itsel. The hinged portals are designed

to withstand the vertical loads and the horizontal wind orces

(directly perpendicular to the line itsel ). Each xed portal consists

o three columns, while the hinged portals have two columns

supporting a mesh ramework, hinged at the top and at the bottom.

The xed portals stand on each side o the Hoge Rijndijk road.

Their special design is in line with the client’s demand that they

should be ‘aesthetically pleasing’. A structural engineer would,

rom a structural point o view, preer entirely straight columns

to ensure even distribution o the orces. Because these columns

are curvilinear, there is a convergence o orces at the apex o thecurve. Moreover, having two xed portals (which was necessary to

create a second, redundant load path or saety reasons) meant that

contraction and expansion orces had to be taken into account in

the structural design. The angled section at the dockside end relies

on the simplest and most ecient girder bridge design option,

since no aesthetic requirements are applicable.

Expansion and contraction

Being outdoors, the entire steel structure is subject to expansion

and contraction caused by uctuating temperatures. At the point

where the conveyor belt reaches the malt intake building, the

design had to allow or a dierence in length o up to 76 mm. The

ree space between the steel structure and the building is thereore

determined to be 100 mm. At the dockside end, there is 70 mm

ree space between the Nabla structure and the ree-standing work

gantries. The conveyor belt is attached to the steel structure and

thereore expands and contracts in the same magnitude.




Peter de Bliek

Lead Engineer, Iv-IndustrieFigure 5: Transer rom crane 1 to crane 2

Figure 3: Example o a hinged portal Figure 4: Example o a xated portal

Industry & Energy

37

Assembly The components o the steel structure were brought to the site

by special transport. The assembly o the central section posed

particular challenges. Due to the dicult terrain it was not possible

to transport all the girders to their exact nal location by truck.

Some sections were thereore lited into place by two cranes. A

stability triangle was used when transerring the components rom

one crane to the other, as shown in gure 5.

Conclusion

Iv-Industrie has produced various intricate structural designs or

Heineken in the past, including several production areas with

column-ree oors. In this design-optimization project,

Iv-Industrie helped Heineken to achieve a signicant reduction in

the construction costs o its new malt transport line. We can look

back on a very successul project and are pleased to have made our

contribution to Heineken’s sustainability objectives.

Other modifcations The preabricated concrete wall o the malt intake building had

to be modied, with an aperture created to allow the malt to pass

directly rom the conveyor belt. Some o the wall elements and their

steel supports were removed. Once the upper section o the wall

had been modied to assure the load-bearing unction, a number o

the concrete elements were replaced.

Heineken made several modications to the inrastructure o the

harbour itsel. The dockside whar was raised and made suitable or

the barges which will moor here. Suraces were repaved and a ence

was erected around the site.



Design o the new sea lock at IJmuiden

in the Netherlands The IJmuiden complex on the North Sea coast (see Figure 1) consists o our locks, a drainage

sluice and a pumping station. The complex provides seaaring vessels access to the Port o

Amsterdam. The drainage sluice and pumping station control the water level in the North Sea

Canal and the Amsterdam-Rhine Canal (which is xed on 0.4 m below Amsterdam Ordnance

Datum). The complex also orms part o the primary ood deense system, so it must be

capable o withstanding severe storm surges rom the North Sea. The complex urther serves asa trac link between the northern and southern banks o the North Sea Canal.

The largest sea lock o the present complex is the Noordersluis, which is 400 m long,

50 m wide and allows a 15 m water depth. The lock dates back to 1929 and is technically likely

to require replacement, at the latest by 2029. A larger lock is required to handle larger vessels

and to cope with the expected growth o sea cargo. From a unctional perspective, earlier

replacement is necessary because the existing lock complex is likely to reach its maximum

capacity beore 2020. Figure 2 shows the IJmuiden complex including the location o the new

sea lock, which will be Europe’s largest to date with planned dimensions o 500 metres long, 60,

65 or 70 m wide and allowing a 17 or 18 m water depth.

gure 1: Location o the IJmuiden lock complex Figure 2: IJmuiden lock complex, including intended location o the new lock



Figure 3: Intermediate design o mitre gates and sector gates

Figure 4: Three diferent lay-outs o the new sea lock: straight rolling gates (top), mitre gates (middle)

and sector gates (bottom)

Challenges

The limited amount o space available or the large new sea lock

within the existing complex prompted the question as to whether

such a lock could be built and still meet the requirements, with

respect to reliability/availability and swit and sae use o the lock,

while staying within budget. The apparent lack o space or the use

o straight rolling gates was one o the major issues, as these gates

are the proven reliable solution or locks o such a large width.

In 2011 the Directorate-General or Public Works and Water

Management commissioned Iv-Inra and DHV to carry out the

planning study or the new IJmuiden sea lock. The most important

task was to demonstrate the easibility o building a lock o these

dimensions, which would also satisy the dened requirements

(‘Proo o Concept’). In addition, the environmental impact o the

new lock on its surroundings also was identied, a social cost/

benet analysis was carried out or the new lock as well as an in-

depth reliability and availability analysis o the existing Noordersluis

and the other assets in the complex.

Solutions

For dierent lock widths (60 m, 65 m and 70 m) total solutions

were produced and compared according to location, type o gate

(including operating mechanism), lock bay, chamber wall and

levelling system. A selection was made and was worked out to the

level o a preliminary design. Space-saving solutions or the gates,

nautical simulations, availability analyses and cost estimates played

a crucial role and were ully elaborated. Iv-Inra was in charge o

designing the gates and their operating mechanisms, and also

conducted the quantitative availability analysis o the lock. The

availability required or the lockage process imposed stringent

requirements on the maintainability and reliability o the gates and

their operating mechanisms. This was to ensure that the downtime

caused by scheduled maintenance (or example the periodic

replacement o the gates) and sudden breakdowns (or example

due to a collision or due to any internal ailure in the total operation

process) is minimized. Among other things, the technical easibility

o both sector gates and mitre gates were demonstrated. Mitre

gates have never been used or locks wider than 30 m.

Conclusion

Based on nautical simulations combined with the design o straight

rolling gates, it was eventually concluded that straight rolling

gates ater all were easible within the space limitations or all o

the dierent lock widths (60, 65 and 70 m). Only acceptable minor

concessions were needed in terms o the procedure or vessels

entering one o the existing locks immediately next to the new lock.

The results o this study made it possible to press through with thecall or tenders and the construction o the new sea lock (under a

Design, Build, Finance & Maintain contract). The plan calls or work

to start in 2015, with the rst ship due to pass through the locks in

2019.

Wouter van der Wiel

Project Manager, Iv-Inra

39

Inrastructure & Ports

2012-5 ivormatie.pdf

Documents

Transcript of 2012-5 ivormatie.pdf