automating container terminals safer, greener and … container terminals – safer, ... solutions...

© ABBSlide 1November 2, 2015November 2, 2015

Automating container terminalsSafer, greener and more productive

Fredrik Johanson, ABB Ports October 2015


§ ABB today

§ ABB Ports history in brief

§ Automation

§ Remote operation

§ Control room design

§ Training with simulator

Automating container terminals – Safer, greener and more productive


ABB today


Power and productivity for a better worldABB’s vision

§Update

A leader in addressing powerinfrastructure and control needsfor utilities, industry and transport& infrastructure

A leader in operational asseteffectiveness – uptime, speed,yield – and efficiency

Contributing to decoupling growth from environmental impact

§ Less energy per unit GDP

§ Less pollution per unit energy


Shaping the world we know today through innovationPioneering technology since 1883

§Say hello to YuMi!


§Our aspiration: #1 or #2 in all businesses

Well positioned in attractive marketsLong-term market growth drivers intact

Renewables

Grid automation / digitalization

Microgrids

Smart upgrades

Electrification penetration

Energy storage

Productivity

Energy efficiency

Automation penetration

Internet of Things, Services and People

Power quality / reliability

Emerging markets

Urbanization

Data management

Electric transport

Energy efficiency

Power quality / reliability

Decentralized power generation

§Power & Automation

§Utilities Industry Transport & Infrastructure


Power and automation are all around usYou will find ABB technology…

orbiting the earth and working beneath it,

on the trains we ride and in the facilities thatprocess our water,

in the fields that grow our crops and packing thefood we eat,

in the plants that generate our power and in ourhomes, offices and factories

crossing oceans and on the sea bed,


ABB Ports history in brief


1883 Elektriska Aktiebolaget is established in Stockholm.

1890 Merger with Wenströms & Granströms Elektriska Kraftbolagto Allmänna Svenska Elektriska Aktiebolaget – ASEA.

1988 Merger between ASEA and Swiss based Brown Boveri Company (BBC)forming ABB

World leading within power and automation130 years of collaboration worldwide


§© ABB Group

§November 2, 2015 | Slide 10

§

1969

History of innovationsSolutions for cargo handling since 1897

Founding fathers

1897

Direct Torque Control

ASTAT Technology

Load Position Sensor

STS with auto landing

100 STS and 100 RTG systems

First fully automatedstacking crane Unmanned yard cranes

First crane installed

1966 1983

Multilane chassis guide

2000 2002

19881992

DC converter

1987

1996

1883

AC drive for STS crane

PLC, GPO, Cabin View

1997

2005

Dual hoist and remotecontrol of STS cranes

2010


ABB Ports offering

Crane automation for container and bulk

Terminal electrification OCR and process automation

Service and Support


The new landscape of container terminal operationsChallenges

….safety

Source: Constructiondigital.com


§ The terminals can not just add equipmentand staff based on the growing peak needs

§ To keep total cost for the transport chain theterminal must be flexible for volumevariations by having:

§ more dense stacking

§ less interruptions during operation

§ smooth integration with hinterlandactivities

How can terminal operators achievehigher productivity and better utilizationof resources?

How does this affect the role of theof the equipment operators?

New challengesA new level of terminal capacity and productivity is needed

Source: OECD/ITF based on Jansson and Shneerson (1982)


Automation


Automation is the solution – safer, greener and more productive

Automation:

§ Predictable production

§ Just in time

§ Steady smooth pace


Automation is the solution – safer, greener and more productive

Source: APM Terminals

Source: SSA Marine

Source: ABB

MIT Panama APM Terminals Lazaro Cardenas

SSA Tuxpan


The terminal operator’s roleDriving yard productivity with automatic stacking cranes

Improved stacking capacity based on:

§ Stacking 5/6 high with wide cranes

§ Optimum path in trolley and gantry directions

§ Optimum distribution of work load between thecranes in the block

§ Minimizing empty travel by double cycling

§ Fully automatic cycle including automatic containerpick-up and landing on road chassis

> 600 Automated and unmannedstacking cranes with ABB automation


Introduction of automatic stacking cranes in an RTGterminal like MIT Panama

§ First automatic stacking cranes in Latin America now inoperation in an “RTG terminal”

§ Automatic landing on terminal chassis and guided landingon road chassis

§ Remote operators do exception handling as well as TOSplanning

The terminal operator’s roleUpgrading terminals - automation step by step


Improved STS productivitybased on:

§ Automation - sway/skew/path control

§ Automatic/guided landing on lashingplatform/vehicle/quay

§ Automated handoffs by means of OCR, vehicleidentification and process integration

§ Tandem/double hoist operation

§ Double trolley or other means ofdecoupling with vehicles

§ Higher hoist/trolley speeds

§ Remote operation

The terminal operator’s roleDriving quay side productivity

75 STS cranes with ABB remotecontrol in 7 terminals worldwide


Remote operation


The equipment operator’s new roleThe new “office”

New officeNo cabin


§ From driving and being in continuous control ofthe machine to supervisionand exception handling

§ STS cranes: Automatic operation ofwhole cycle except landing on ship andsupervised landing on manned vehicles.

§ Automatic stacking cranes: Fully automatic cycleincluding automatic container pick-up/landing onroad chassis

§ Intermodal cranes: Same process as ASC.

§ Unified process for all crane types

§ Multi-skilled team enables assignment of staffbased on present needs

The equipment operator’s new roleA new way of working based on Intelligent automation


The equipment operator’s new roleRemote Control Station – modern and ergonomic working environment

§ Built-in crane operation knowledge

§ Superior visibility of the process compared to theviews from a crane cabin

§ Attractive working environment for the nextgeneration port staff

§ Larger pool of candidates in terms of age andphysical abilities

§Modern design with focus on operatorergonomics, adjustable to each operator’sspecific needs


The equipment operator’s new roleRemote Control Station – modern and ergonomic working environment

§ Automation and control system for alltypes of container handling cranes

§Modern and ergonomic RemoteControl Station for operators


The equipment operator’s new roleSafer, healthier…

§ Safer working environment – humans separated frommachines

§ Improved occupational health

§ No exposure of operators to vibrations andbraking/acceleration

§ Reduced or eliminated headaches, pain in the neck andback

§ Team work and collaboration

§ Located outside the gate - (ISPS)

§ No special clothes or safety gear

§ No transports in terminal

§ Flexible operation, the team can select longer orshorter working slots and breaks


Control room design


The terminal operations teamPeak performance requires collaboration

The key to handling of operational peak situationsis to utilize all equipment and all staff

§ All located together

§ Trained to perform at least 2-3 roles

§ The team environment provides attractive workingconditions and opportunities to continuously developpersonal skills.

§ Time efficient and continuous operation of all cranes

§ Any crane in operation within seconds

§ Easy shift/meal breaks

§ Lighting and noise control solutions


Training with simulator


Simulators for operator training

Training packages

Maintenance training

RemoteConventionalMaintenance Training Unit

Maintenance training

ü Base

ü Advanced

ü On site

ü Factory


Simulator trainingCustomer’s voice from Vietnam

“We never thought that simulatortraining would be so efficient.Bringing an ABB CS800 cranesimulator to Vietnam, was thesmartest thing we have ever done”

Rob Baigrie (Project responsible SSA/SSIT)and Frank Birkenbach (Training responsibleSSIT)


CS800 crane simulatorOne software – two training environments

Conventional STS, RTG & MHC Remote STS

§ No accidents during training

§ Less damage on goods and equipmentwith well trained operators

§ Training in the operational teamenvironment prior to operating realequipment

§ Assessment of operator candidates

§ All automation functions and TOS workorder interface

§ Graphics adopted to your crane


ABB CS800 conventional crane simulatorIn 40’ HCDD

§ When doors are closed it is a seaworthy shipping container

§ Double door-container gives access from both ends

§ Company logo and exterior color on request


Remember, your employees are yourbiggest asset and they will perform safer,greener and more productive supportedby automation

Finally


Thank you for your attention.

automating container terminals safer, greener and … container terminals – safer, ... solutions...

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