Innovative Solutions for Complex Challenges

Wireless Control Ballast System

For the Çanakkale Bridge project, the goal was clear: develop a ballast system capable of flawless remote-controlled operations. The challenge was immense—accurately ballasting large floating caissons with high precision and substantial flow capacities, all while maintaining control over the flow, the system, and its distribution.

To meet this challenge, engineers designed two 20-foot ballasting manifolds. These high-tech manifolds featured automated valves and sophisticated pipework, capable of distributing between 1200 and 1300 cubic meters of water per hour. Each manifold could simultaneously manage water distribution to 15 clusters and included a de-ballast pump with a capacity of 1000 cubic meters per hour to efficiently empty the clusters. The system even allowed for the re-distribution of water within the caisson, showcasing its versatility. Over the course of the project, the system successfully pumped a total of 120,000 cubic meters of seawater.

Both the hardware and software were meticulously designed to achieve this high level of performance. The entire ballast system could be controlled remotely through a RAYANT network system. By interconnecting the manifolds—both in terms of pipework and data—a fully redundant system was created, ensuring continuous operation even if one part of the system failed.

Transport and handling of the system were streamlined thanks to its container-sized design. This allowed for easy movement using standard lifting equipment and trucks, facilitating quick and efficient deployment.

This project not only met its goal but also highlighted the power of innovative engineering solutions in overcoming significant operational challenges.

Remote Controlled Tunnel Immersion

Immersing tunnels is a complex process that requires highly accurate survey systems and precise control of movements and forces to place tunnel elements within tight tolerances. To enhance safety and efficiency by limiting manual operations within the tunnel during immersion, a remote-controlled immersion system was developed for the Busan Geoje project in South Korea.

The core of this system was to centralize critical operations on a single command vessel, the main immersion pontoon, from which all essential systems could be operated remotely. This innovative approach allowed for seamless control over several key aspects:

• Ballast Water Management: The distribution, pumping, and de-ballasting of ballast water were controlled using actuators, valves, pumps, and level gauges.
• Survey Systems: The use of taut wires, distance sensors, and pressure sensors ensured precise placement and monitoring.
• Winch and Wire Operations: Control of winches and wires, including reel control and load sensors, was managed from the command vessel.
• Visual and Data Control: Cameras provided visual monitoring, while single-screen data outputs and real-time logging facilitated comprehensive oversight.

This remote-controlled system significantly reduced the need for manual intervention within the tunnel, enhancing safety and efficiency during the immersion process.

The successful implementation of this system in the Busan Geoje Fixed Link project demonstrated the effectiveness of remote-controlled operations in complex engineering tasks, setting a new standard for tunnel immersion techniques.

External Positioning System

The successful immersion of tunnel elements depends on the precise positioning of these elements in relation to their theoretical alignment. This task becomes particularly challenging in extreme conditions, such as large depths, high winds, and strong currents, often leading to significant operational cancellations and downtime.

To address these challenges, an External Positioning System (EPS) was developed. This innovative system consists of two portal-shaped “legs” that are attached to the roof of the tunnel element. Once the element is roughly placed on the seabed (gravel), the hydraulically operated legs are activated, allowing for autonomous fine-positioning.

This system ensures that tunnel elements are positioned securely and with high accuracy within the set tolerances, even under design wind and current conditions. The EPS significantly reduces downtime and operational cancellations, ensuring the successful and efficient immersion of tunnel elements in challenging environments.