Dynamics builds brain of Jan De Nul's hybrid dredger

Dynamics’ control centre controls Jan De Nul’s plug-in hybrid dredger. Less emissions and noise, more efficiency - with Siemens technology.

Noise and CO2 emissions from dredging in ports will soon be a thing of the past. Dredger Jan De Nul Group’s latest trailing suction hopper dredger is a plug-in hybrid: specially designed to operate on an Energy Storage System (ESS) in small ports. The control comes from Dynamics. Managing director Mathias Deloof: “Through TIA Portal, we were able to build the IMC transparently and reliably.”

Smart dredging with minimal emissions and noise

Jan De Nul Group has been making its dredging operations sustainable for years. To further reduce their carbon footprint, they ordered a plug-in hybrid trailing suction hopper dredger. Just as with a hybrid car, you charge it with a cable and continue to run on fuel when the battery runs out. It is the first plug-in hybrid in the fleet as well as the smallest trailing suction hopper dredger. It is therefore specially designed for operations in and around ports, where lots of people often live. Especially for small ports such as marinas, this is a real asset. The vessel can dredge for about four hours on the ESS, resulting in a drastic reduction in emissions and noise.

“Our Integrated Monitoring & Control system or IMC controls all dredging operations and monitors the entire process, from suction head to hopper,” says Mathias Deloof. “In port, the vessel dredges emission-free, outside port it switches to generator power. That hybrid interplay requires perfect control.”

About Dynamics and Jan De Nul

Menen-based Dynamics is a machine builder and system integrator that develops complete automation solutions for various industries and maritime applications. As a Siemens OEM Partner, the company couples technical expertise with a pragmatic approach.

Jan De Nul Group is a world leader in dredging, offshore and construction activities with a focus on sustainable innovation. Based in Aalst, the family business is working towards a greener maritime future with low-emission and now plug-in hybrid ships.

In port, the vessel dredges emission-free, outside port it switches to generator power.

Mathias Deloof, Managing Director, Dynamics

Five hundred pages of specifications

Jan De Nul Group and Dynamics have been working together since 2006. Until now, they mainly realised smaller projects - think measurement and control systems for dredging cranes or rock installation units. “We are not the same company we were in 2006. I wanted to prove to Jan De Nul Group that we can also handle projects of this magnitude. So we were very happy with this opportunity.”

“We were sent more than 500 pages of specifications,” Mathias laughs. “We analysed that at record speed and, together with Siemens, translated it into something feasible. Our speed, flexibility and no-nonsense mentality made the difference.”

Moving project

Dynamics’ IMC coordinates all subsystems on board: dredge pumps, suction and discharge mechanisms, valves, measurement systems, position sensors, etc. “The hardware and software integration was complex,” explains project manager Steije Maertens.

“Such a ship involves dozens of parties, spread across different countries. We had to communicate with each party and our system had to talk to each of their systems, while everything is built at the same time. That’s a big difference from building machinery on land, which runs in phases. Here we had a project that is constantly moving.”

A second challenge was the limited space on board. The control boxes are completely full. The team even had to use the side of the cabinets. “On land, you leave space,” says Steije. “On a ship, there just isn’t any space. Certainly not on a comparatively small dredger. The spaces and facilities are all smaller, but we control the same number of things.”

Everything was built at the same time. Quite a challenge when your system has to be able to communicate with all the others.

Steije Maertens, project manager, Dynamics

Fuel consumption monitoring in real time

Dynamics’ IMC is crucial in Jan De Nul’s pursuit of sustainable operations. “We continuously measure fuel consumption and energy efficiency,” Mathias explains. “That data is forwarded to Aalst, where Jan De Nul can report and analyse it. Thanks to this project, we may roll out the reporting system to the rest of their fleet.”

Communication is via Siemens SCALANCE routers, which deliver the data to the ship’s communication system. “This gives the head office real-time insight into performance and fuel consumption. This is not only sustainable, but also economically interesting: less consumption means lower costs.”

Operator stays at the helm

Although the system can run almost completely autonomously, the operator remains central. “We noticed that operators like to be in control. We also built the control stations. Two, because everything is fully redundant. The operator can operate the dredge, but the helmsman can intervene equally well at a smaller control station.”

Each interface had to look identical to those on other Jan De Nul ships. “The operator has to be able to move from one ship to another without training,” says Maertens. “That required customisation: many technology objects we developed from scratch. We could not get them from a standard library. The development environment, TIA Portal, was a huge advantage here tho

eptance Tests during the development phase.”

Siemens technology as backbone

At the heart of the IMC system is a redundant Siemens architecture. From PLC to visualisation, everything works together:

SIMATIC S7-1517-PLCs
SIMATIC ET 200SP-remote I/O modules
SCALANCE routers and switches for network communication
WinCC client-server environment with redundant data storage

Delivered on time

The project forced Dynamics to refine its project management. “Working in parallel with so many parties was new for us. Because everyone was working at the same time, we did have to park things until there was clarity, while the deadline kept ticking. We have learned to stay calm, but at the same time steer tightly to schedule.”

It paid off: the IMC project was delivered well on time - a feat Jan De Nul was obviously counting on. And the future? “This opens doors to new collaborations with major industry players,” Mathias concludes. “Jan De Nul is not just another customer; it is a reference in sustainability. We helped build a ship that dredges more quietly and cleanly than ever. We are proud of that.”