Comprehensive electrical retrofit for Catalan industrial cranes
Company
The customer operates Catalan cranes used in critical industrial and port environments, where electrical reliability, safety, and operational continuity are essential.
These cranes, which had been in service for many years, had obsolete electrical installations that limited their performance, increased the risk of failure, and made maintenance and commissioning of new systems difficult.
The objective of the project was to extend the useful life of the cranes through a complete electrical retrofit, eliminating the old systems and replacing them with a new, modern electrical installation that is safe and aligned with current standards, without interfering with the mechanical part.
Challenge
Design and execute a comprehensive electrical retrofit on industrial cranes in operation, coordinating all phases with the client and the shipyard, ensuring an orderly transition between the old and new installations, and minimizing the impact on daily operations.
The project required precise planning, complete refurbishment of existing conduits, and a new, reliable electrical installation ready for smooth commissioning.
Problem
- Obsolete electrical installation
The existing electrical systems were outdated, lacked up-to-date documentation, and had non-standard components, which increased the risk of breakdowns and unplanned downtime. - Deteriorated conduits
The electrical conduits had accumulated years of use, dirt, and deterioration, making new installations difficult and compromising safety. - Risk during commissioning
The coexistence of old elements with new systems increased the complexity of the installation and the risk during commissioning. - Need for operational coordination
The retrofit had to be carried out in constant coordination with the customer to ensure safety, order, and compliance with deadlines.
Solution
How we do it?
A complete electrical retrofit project was developed, addressing all phases in a structured manner, from the initial study to the final commissioning.
- Technical feasibility study
Detailed analysis of the condition of the existing electrical installation, definition of the scope of the retrofit, and planning of the intervention. - Complete dismantling of the old installation
Removal of the entire obsolete electrical system, eliminating wiring, panels, and components that were out of service, while keeping the mechanical part of the crane intact. - Pipe cleaning
Cleaning, inspection, and adaptation of all pipes to ensure a safe and suitable base for the new electrical installation. - New electrical installation
Design and installation of a completely new electrical system, adapted to current safety, reliability, and maintenance requirements. - Coordination and organization with the customer
Joint planning of the work, time management, and ongoing support during installation and commissioning. - Commissioning and verification
Comprehensive testing of the electrical system, validation of operation, and delivery of the crane ready for use with the new installation.
Results
- Complete renovation of the electrical system of the cranes
- Elimination of risks associated with obsolete installations
- Pipes cleaned up and prepared for future expansion
- Greater reliability and safety in daily operation
- Extension of the useful life of the cranes without mechanical intervention
- Orderly commissioning coordinated with the customer