The Falkirk Wheel

Hydraulic systems

The Challenge

The Falkirk Wheel is a major Scottish landmark that opened to traffic in 2002. This standout example of innovative and striking engineering transfers canal boats between the Forth & Clyde Canal and the Union Canal, completing the link between Glasgow and Edinburgh.

Historically, raising and lowering boats had been handled by an eleven lock gate system, so compressing this into a single structure would be no mean feat. 1800 tonnes of steelwork had to move quickly, precisely, and reliably while delivering an unforgettable spectacle for passengers.

The Solution

Based on initial concept work delivered by Bennets, Denley was approached by Butterley Engineering to provide a complete hydraulic solution to operate the wheel’s functions. This included the main rotational drive as well as the systems needed to operate the gondola and waterway gates.

Embracing the simple historical principles on which the wheel’s concept was based, a system founded on traditional tried and tested components not only provided a high level of simplicity and reliability but also delivered precise and advanced levels of control and performance.

Technical Details

Starting and stopping

10 hydraulic motor gearbox assemblies with disk brakes drive a gear on the wheel’s central shaft
A local control manifold provides hydraulic braking and overload protection
Pressure sensing for wheel load and speed control is also fitted

Auxiliary power units

Auxiliary function power units run both the aqueduct and basin end systems
These provide hydraulic supply and control of the retractable seal, latch pin, stow pin, interspace water control valves, gondola lance and fixed and gondola gates through local and remote auxiliary control manifolds
Direct control comes from the site SCADA system with local node

Perfectly proportioned

When the weight is balanced, this is achieved with minimal energy requirements, using the equivalent power needed to boil just eight kettles of water
The system achieves a half revolution operational cycle within five minutes, raising and lowering boats 35m

Opening the gates

The four gondola gate actuation systems operate with matching fixed basin and aqueduct gates
These hydraulically-operated flap-type gates hold on-board hydraulic controls
A fixed hydraulic lance extension and docking system connect the gates to a fixed hydraulic supply for gate operation

Main drive power bank

A dual-duty pump set can automatically switch to a single set for half-speed operation
The unit supplies and controls the main drive, as well as the auxiliary brake functions
An on-board control panel with a monitoring and function PLC provide movement profile, speed control, and full manual operating facilities

The annual tune-up

A proactive maintenance scheme was developed with the client to ensure maximum operational availability
This included routine replacement or refurbishment of key items and a stock of spares to mitigate unplanned events
Wheel system conditions are tested and measured to provide information including measurements, observations, and service life assessments that assist with full trend analysis and predictive maintenance

Keeping things steady

When stationary, four hydraulically operated stow pins extend and engage with the wheel to hold it in position
At both lower basin and aqueduct ends, latches engage with both gondolas to hold it in place and in-line
A U-shaped retractable seal is then extended out to the gondolas at both locations from the fixed structure to form a sealed interspace between the gates

The wheel in motion

The stow pins are withdrawn, and the wheel begins its rotational movement, accelerating smoothly to running speed
During rotation, the wheel drive is constantly monitored and controlled to maintain a smooth and steady velocity
As the wheel concludes the rotation, it is smoothly decelerated until stopping precisely in station

The balancing act

Using centrifugal pumps, the interspaces between the gates are filled with water to match water levels
An extendable lance then connects to the gondola to power their gates, lowering them fully to allow boats to freely exit and enter
Once boat loading is complete, the gates are closed and the water valves and pumps drain the interspace of water. The seal is then retracted leaving the wheel free to rotate

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The Falkirk Wheel

The Challenge

The Solution

Technical Details

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