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Energy-Efficiency-Package
EEP BAUER Maschinen GmbH
52,0
37,8
0
10
20
30
40
50
60
BG 30 BG 30 EEP
used
fu
el [l/
100cyc
les]
Energy-Efficiency-Package EEP PI 116 en 04/2015 2
Motivation
Reduction of energy consumption on construction sites is an ecologically as well as economically
justified objective. In addition to reducing emission of CO2 and other pollutants, reduction of
expenditures on diesel is a highly motivating factor, contributing to the efficiency of a construction
site.
A specific work result can be achieved by using different methods and equipment. Besides
choosing the best construction method, another important factor that has considerable influence on the energy consumption of a construction project is the efficiency of the used equipment.
Methods of evaluation and improvement of energy-efficiency of specialist
foundation engineering equipment are developed within the scope of the
TEAM project (development of technology for energy-efficient drives of
mobile machines).
The Energy-Efficiency-Package EEP is one actual result of the project. It combines various
measures for increasing energy-efficiency and is available as an extra for the Bauer BG
PremiumLine drilling rigs.
Research and Development
The work carried out in research and development from 2012 to 2014 is divided into the following
phases:
• Reference tests:
At the beginning of the project, a current
drilling rig Bauer BG 30 PremiumLine was
used as a reference machine for the tests. These included bench tests, winch tests and
drilling trials in order to determine fuel
consumption rates of serial equipment.
• Analysis phase: Detailed evaluation of energy flow in a
drilling rig was done on the basis of these
reference tests. Specific improvement
measures could be identified, developed and
evaluated based on these analyses.
• Implementation phase: Measures with a high potential for reducing
fuel consumption and short pay-off periods
were implemented on the demonstration
machine.
Energy-Efficiency-Package EEP PI 116 en 04/2015 3
• Practical test - use on a construction site: In order to verify the practical suitability of
the machine, it was used in normal operation
on a BAUER Spezialtiefbau GmbH
construction site for several months. The BG
30 PremiumLine achieved excellent results with its reliable operation with very high
productivity and low fuel consumption. This
proves that this new technology is not just a
"display rig" for trade-fairs and exhibitions -
but that the benefits can directly be used in
practice.
• Demonstration trials: At the end of the project, the machine was
put through the identical tests as in the first
phase. This helps determine the reduction in
fuel consumption, which allows for a direct
before-after comparison.
Measures to increase energy efficiency
Bauer BG 30 PremiumLine's Energy-Efficiency-Package EEP contains numerous modifications to
improve efficiency. The drive system of the main winch, with its significant share in energy
consumption, especially during Kelly-drilling, was fundamentally re-engineered. The new system
makes it possible to recover the energy released during the lowering of the tool. Thus, the fuel
consumption can be significantly reduced, especially when drilling deep boreholes. Further benefits
are increased efficiency during lifting, higher speed and independent parallel operation of several
functions (e.g. main winch, crowd, slewing and rotary drive).
Energy consumption by all ancillary devices, such as fan drives and pressure supply units was
optimized. This reduces not only the energy consumption, but also the noise emissions. The
already low values of pressure loss in hydraulic hoses and valves were further reduced.
Theoretical and practical tests have proven that the use of generously dimensioned components
pays off after a few months of operation.
The diesel engine control is also optimized. The RPM of the diesel engine while operating the
ancillary functions (e.g. auxiliary winch) or in standby mode has thus also been dynamically
adjusted. This makes the machine significantly quieter. A special hydraulic fluid with a favourable
viscosity over a wide temperature range further increases the efficiency. Prerequisites for the
highest energy efficiency are not only the individual measures taken, but also their optimal
coordination.
Energy-Efficiency-Package EEP PI 116 en 04/2015 4
Benefits to the user
• Reduction of fuel consumption by up to 30% while operating the main winch:
The adjacent diagram shows the fuel consumption
for 100 stroke cycles with a load of 14 t.
• Reduction of fuel consumption by 10-20% in normal operation:
The adjacent diagram shows the fuel consumption
for two identically performed drilling operations, with
and without the Energy-Efficiency-Package.
• Increased productivity through improved efficiency
• Independent control of the main winch function
• Considerably reduced noise levels achieved by optimization of the diesel engine and fans
• Cost-effective investment by focussing on measures with a short pay-off period
• Tried and proven suitability for practical application
Summary
Bauer has a long tradition of productivity and efficiency. The Energy-Efficiency-Package EEP was
developed on the basis of contemporary research and development. Besides significantly reducing
the fuel consumption, it also offers other advantages and thus shows that high performance, low
noise emission and low fuel consumption are not necessarily incompatible. Numerous tests have
proven the suitability for practical application. Your contact person at BAUER Maschinen GmbH
will gladly supply the information on availability and launch dates.
BAUER Maschinen GmbH
BAUER-Strasse 1 86529 Schrobenhausen,
Germany
Phone: +49 8252 97-0
Design developments and process improvements may require the specification and materials to be updated and changed without prior notice or liability. Illustrations may include optional equipment and not show all possible configurations. These and the technical data are provided as indicative information only, with any errors and misprints reserved.
