Panama Canal extension is largest engineering project of this century

With a total of 16 rolling gates to operate the Canal extension, the sluice gates are 30x60x10m, each weighing over 4,000 tons, with two Brevini gearboxes driving the opening/closing cycle.  Brevini faced a number of significant challenges on this project.

The gates must be opened in less than 5min, with a 43min cycle of opening/closing which is repeated 33 times per day, with only 180min of stoppage permitted per month. With a lifespan requirement of 35 years, the gearboxes need to provide 57,000hrs of operation, working in humid conditions with high levels of salinity. Reliability of function is paramount to this critical application.

To ensure the required continuous operation of the canal extension, minimising maintenance time, Brevini supplied a solution based on its Posired 2 helical range, with two gearboxes driving each sluice gate, each unit weighing in excess of 9 tons. 

The gearboxes operate a winch system with two ropes off each drum which, via a system of pulleys, allow the gate to be pulled in either direction. Two gearboxes per winch are utilised in order to have full redundancy in the system but this means that, for normal operating conditions, the bearings are lightly loaded. Without a minimum load on the bearings there is a risk that the rolling elements slide and so the bearings are specially coated with Triondur C to prevent wear and tear and fulfil the requirement for a 35yr lifespan.

To address the specific environmental issues of humidity and salinity, the gearboxes include special shaft sealing solutions and desiccant breathers. Should there be a problem with the first gearbox or motor, the second gearbox immediately becomes the driver. Similarly, there is an auxiliary motor and, in case of any problems with the power supplier, the system also includes an uninterruptable power supply. With a nominal torque rating of 483kNm, Brevini’s Posired 2 size PD67 gearboxes more than meet the extremely high torques of up to 330kNm required to move the sluice gates.

Explaining the rationale in selecting contractors to work with on this hugely-significant project, Roberto Cimolai, Managing Director of Cimolai Technology said: “My business strategy at Cimolai Technology is to always use first class brands with products that have no competition from a qualitative viewpoint.”

Renato Brevini, Brevini Group Chairman, explains Brevini’s approach to such projects, is by selling a products from a technical and commercial point of view. “We adapt the products to ensure they meet the needs of markets and individual customers.”

Within the UK, Brevini have extensive experience in a wide range of industries, including the marine and offshore sector. With world-class manufacturing capabilities and expertise in solutions-led engineering, our activities are underpinned by a commitment to engineering excellence, innovative solutions, quality, reliability and outstanding gearbox design.