Pirate Falls – LEGOLAND Windsor Resort
Pirate Falls is a traditional flume ride located within The LEGOLAND Windsor Resort, captivating guests with its exciting water-based adventure. This popular attraction features fibreglass boats that navigate a dynamic water circuit, culminating in a splashdown. Designed to accommodate up to 21 boats, the ride offers an immersive experience with a duration of 5 minutes and 30 seconds.
Originally constructed to deliver an engaging and enjoyable ride, Pirate Falls required an upgrade to its control and safety systems to meet contemporary standards. The challenge was to enhance the legacy equipment while preserving the ride’s unique operational characteristics and ensuring a safe and enjoyable experience for all visitors.
The Pirate Falls at LEGOLAND Windsor is a flume ride in which passengers are seated in boats that travel around a water-filled trough circuit with forced flow. They enter and exit the ride via a walkway to the ride’s turntable.
Once a boat is dispatched from the turntable, it floats down the water channel until it reaches an auto-spacing conveyor situated in the graveyard-themed area of the ride. The auto-spacing conveyor then adequately spaces the boats to prevent any stoppages. After the auto spacing, a ramp conveyor pulls the boats up to the tree house section of the ride; only one boat is permitted in the tree house under normal operating conditions. Drive tyres propel the boats through the Tree House to a gravity drop section that leads to a splash zone. As the boat goes down the drop chute, the water in the splash zone decelerates the boats as they continue along the channel and return to the turntable.
Challenges
The challenge was not just technical but also involved preserving Pirate Falls’ unique operational philosophy. The existing system had to be upgraded to enhance safety and efficiency yet retain the excitement that guests have come to expect.
Outcome
Fairfield’s team undertook a comprehensive upgrade process to enhance the safety and control systems of Pirate Falls. Our approach included:
Initial Safety Review: We conducted a site visit to assess the existing control system and perform a thorough safety review.
Design Risk Assessment: Based on our site investigation, we generated a Design Risk Assessment to identify potential risks associated with the ride’s operation. This assessment was crucial for developing effective mitigation strategies.
Risk Mitigation: We documented the identified risks and recommended measures to address them. The proposed solutions were designed to improve safety by integrating advanced devices and procedures calculated to meet the latest performance standards.
Hardware Upgrades: We implemented new hardware components to enhance the reliability and functionality of the control system.
Software Development: The control software was rewritten using current standards as a reference. While retaining the existing control philosophy, we integrated additional safety functions to ensure compliance with modern leisure standards.
Testing: A Factory Acceptance Test (FAT) was conducted at our Retford office. LEGOLAND representatives were invited to observe and validate the system’s performance under simulated conditions.
Electrical Installation: We completed the electrical installation of all new hardware components.
Commissioning: The final step involved commissioning the upgraded system to ensure its seamless integration with the existing ride infrastructure.
Standards Compliance
Throughout the upgrade process, we adhered to the following key standards to ensure the highest levels of safety and reliability:
- BS EN ISO 12100:2010 – Safety of machinery. General principles for design. Risk assessment and risk reduction.
- BS EN 13814:2004 – Fairground and amusement park machinery and structures. Safety.
- BS EN ISO 13849-1 – Safety of machinery. Safety-related parts of control systems. General principles for design.
- BS EN 60204-1:2006+A1:2009 – Safety of machinery. Electrical equipment of machines. General requirements.
Results
The upgrade of the Pirate Falls control system gained several significant benefits:
Increased Reliability: The new hardware and software have improved the control system’s reliability, reducing the likelihood of operational issues and downtime.
Compliance with Standards: The system now meets current leisure safety standards, aligning with industry best practices and regulatory requirements.
Successful Testing: The FAT confirmed that the upgraded system performs correctly and reliably under test conditions, demonstrating its readiness for operation.
Seamless Operation: The transition to the new control system was smooth, with no significant disruptions to the ride’s operation. This maintained the high standards of guest experience expected at LEGOLAND Windsor Resort.