Ice, Ice, Baby: Modernizing Controls for Polar Icebreakers

Upgrading crane and hydraulic controls aboard U.S. Coast Guard polar icebreakers to improve reliability, redundancy, diagnostics, and operator control.

When the U.S. Coast Guard installed new crane hardware and hydraulic power units aboard its two polar icebreakers, Concept Systems was selected to engineer and program the supporting crane control systems and operator interfaces.

Operating in extreme polar environments required more than standard controls. The system needed to provide reliable operation, centralized control, system redundancy, and diagnostics for mission-critical cranes and anchor windlasses.

The Problem: Mission-Critical Controls in Extreme Conditions

Cranes and anchor windlasses aboard polar icebreakers must remain operational in some of the world’s harshest marine environments. The new hydraulic power units required a control system capable of withstanding those conditions while giving operators centralized control through touchscreen HMIs at each HPU location.

Reliability was especially important. Multiple backup systems were required so critical equipment could remain operational in the event of a system failure.

The U.S. Coast Guard needed a controls architecture that combined redundancy, operator visibility, diagnostics, and flexible hydraulic control in a robust system suitable for polar operations.

The Solution: Centralized Marine Crane Controls

Concept Systems supervised the control system design, PLC and HMI hardware selection, programming, and software development for the centralized hydraulic power unit control system.

Built around Allen-Bradley ControlLogix controllers and PanelView Plus HMIs running FactoryTalk View ME, the system gives operators centralized visibility and control of the hydraulic equipment.

Through the operator interface, hydraulic fluid flow can be redirected between cranes and anchor windlasses, providing greater operational flexibility. The control architecture also incorporates backup functionality designed to maintain critical operations during system failures.

Integrated diagnostics and troubleshooting capabilities give operators and maintenance personnel greater visibility into system conditions, supporting faster identification of potential issues.

The Results

The upgraded crane control system improved the reliability, flexibility, and maintainability of critical equipment aboard the U.S. Coast Guard’s polar icebreakers.

• Centralized crane and hydraulic power unit operation through touchscreen HMIs
• Improved system diagnostics and troubleshooting capabilities
• Added redundancy to support continued operation during critical system failures
• Enabled hydraulic flow to be redirected between cranes and anchor windlasses
• Improved operator visibility and control
• Engineered for reliable operation in harsh polar environments
• Achieved a return on investment of less than 12 months

Modernize critical control systems with PLC, HMI, networking, and controls engineering designed for reliable operation in demanding environments.

Explore Industrial Controls →

 

Project Details