exsantol - simulation team...2016/04/21 · exsantol experience santos container terminal...
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EXSANTOL Experience Santos container Terminal Operations & Logistics
Agostino Bruzzone
Simulation Team
MITIM DIME Genoa Via Opera Pia 15, 16145 Genova, Italy
Email [email protected]
URL www.simulationteam.com
Logistics Node Santos Container Terminal
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EXSANTOL Experience Santos container Terminal Operations & Logistics
Request to develop a logistics plan for extending an existing port
facility located in Santos, Brazil, Atlantic Ocean; it is necessary to address
setting of logistics processes and design of port plant as well as its
configuration and equipment design; the plant is titled EXSANTOL a
Container Terminal,.
The EXSANTOL Terminal project is divided into four main phases:
development, ramp-up with initial reduced productivity (Lo-O about 12
months), full productiviy (RO for at least 18 months) plus an eventual
optional phase of high productivity (Hi-O may be destined to endure); the
terminal will work 24 / 365 (daily, 24 hours a day) on regular oceanic ships
(see Fig. 1) with approximately 50% of 5000 transported TEUs to be
unloaded and the same to be loaded in the analyzed plant; such flows are
characterized by the values and compositions shown in table I, where
import means the flow of containers (fig.1b) from international shipping lines
within the region while the opposite is intended for exports.
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EXSANTOL Santos Container Terminal
The expected final layout for EXSANTOL (see Figure 2) includes a
1500 meters dock with 20 meters of draft, a railway terminal with 8 parallel
tracks, a gate with 40 opening doors that provides trucks access to the
terminal from the network road; these trucks are intended to be
loaded/unloaded directly into the yard (square stock).
The configuration and the type of the expected flows for the EXSANTOL (i.e.
balanced imports and exports, reduced rate of transhipment from ship to ship)
provides a desired level of extra handling (for accessing to containers locked
in the storage by others non-handling) that is 15% in the case of vertical
access means (i.e. transtainer loaders) use and 30% in the case of cranes
with front access (i.e. reach stacker). For the portainer times, the extra
activities (i.e. hold opening) are assumed to be included in the auxiliary
phases computed in the average operational time of the crane (i.e. as average
around two hours for each ship mooring on the dock).
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All import and export flows provide storage in the storage areas of the yard; in
this regard it is expected that the average time spent by the containers in the
terminal is about 15 days with a standard deviation of 40 hours. The handling
process of the containers will be carried out on the quay by cranes portainer
(PT, Fig.3); it is expected to use Wheel transtainer (WT, Fig.3b) on the yard,
while on the rail terminal rail transtainer (RT, fig.3c) will be used. It is
hypothesized a connection between the vectors originally based on washers
(or drive trailer - TT fig.3d). The crane models available to equip the terminals
are characterized by the data reported in Table II. It is assumed also to
consider the possible use of cranes such as reach stackers (SR, Figure 3e) to
manage peaks, emergencies and / or special practices.
EXSANTOL Santos Container Terminal
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Container: TEU & FEU
Container 20’ feets
A 6.08 m
B 2.50 m
C 2.50 m
Container 40’ feets
A 12.16 m
B 2.50 m
C 2.50 m
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Crane: Portainer
The Portainers (known also as
gantry cranes, ship-to-shore cranes)
are operating from the Dock to load
and unload the ships
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Crane: Wheel Transtainer
Transtainers are the cranes operating
on big blocks of containers on the Yard
or on Rail Terminal for handling
containers from the ground to vehicles,
trucks, or flat-cars of trains.
Transtainers can be wheeled or rail mounted
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Crane: Transtainer railroad
Transtainers are the cranes operating
on big blocks of containers on the Yard
or on Rail Terminal for handling
containers from the ground to vehicles,
trucks, or flat-cars of trains.
Transtainers can be wheeled or rail mounted
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Truks
Trucks are used in several terminals for
moving containers among the different
areas
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Reach Stacker
A Reach Stacker is a flexible
handling solution for operating in a
small terminal or a medium sized
port
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Straddle Carrier
A Straddle Carrier is an handling
device in use in some port terminals
for moving and stacking standard
containers.
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Terminal - Location
Santos
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Terminal - Layout
Ga
te d
i
Acce
sso
Zona DS Yard Storage 400 x 1500m
46’000 TEU su 5 Livelli
Zona DK Banchina 1500 m
EXSANTOL
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Transhipment
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Feeder Ships in our
Exercise
• Capacity 1000 TEU
• Length 150 m
• Braccia (numero gru banchina massime 2)
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Reference Oceanic
Ships in our Case
• Capacity 5’000 TEU
• Lenght 300 m
• Width 35 m
• Draft 9 m
• Braccia Max 5
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TABLE I - Scenarios
• Lo - O Low Productivity
• R - O Medium Productivity
• Hi - O Hight Productivity
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TABLE II - Equipments
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TABLE III – Set up Costs
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TABLE IV – Fees
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TABLE V – Scenarios
Improvements
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EXSANTOL - Question A Santos Container Terminal
A. Verify that the storable quantity in the different yard areas (45,000 TEUs
available in total, Figure 1) is compliant with the three different scenarios
flows with the current assumption of containers dwell time and by ensuring
a 10% lower risk of saturating over 75% of the spaces. Eventually assess
the enhancement to be implemented
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B. For the scenarios Lo-O, R-O and Hi-O, size the vectors number and type
(PT, WT, RT, TT, RS) in order to ensure the annual flows requirements. It is
also required, since the end of the 6th month from operations starting point,
to complete in less than 48 hours, the process of loading / unloading of a
reference ship (by considering your total including the 2 additional hours
due to carious set up operations), even if there is a damaged quay cranes.
Since the operative 6th month it will be possible to load and unload four
reference trains (40 containers to be handled for each train) in parallel in
less than 4 hours (considering also the 30 addditional minutes due to the
staff operations for each train preparation)
EXSANTOL - Question B Santos Container Terminal
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C. Define the processes and the related total costs for imports and exports of
each container type in the R-O scenario based on the data summarized in
Table III and the set equipments (considering both the operating cost per
hour as well as the vectors maintenance and mortgage costs).
D. Determine the configuration set to above the maximum annual handling
capacity and the minimum time required for loading / unloading for the
reference ship with 5000 TEUs in optimal conditions (a single ship at the
dock) by considering the configuration at the previous point
EXSANTOL - Question C Santos Container Terminal
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E. Let’s assume to use the proposed tariff in the Table IV and to can count on
a first government funding of 150 MEuro to be amortizated in 20 years to
2% annual straight-line basis, to evaluate a configuration and an
acquisition plan of the equipments and a develment plan of the terminal in
oredr to cope the various scenarios within the temporal development of the
initiative (assume that Hi-O takes over after 18 months from the operational
starting point) maximizing the return on investment. Reproduce on this
hypothesis a timetable (Gantt chart or Milestone) with the dates of
installation of equipment and prepare a chart showing the cash flow of the
plant project.
EXSANTOL - Question D Santos Container Terminal
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F. Based on the previous hypothesis and considering the experts assessment
about possible critical development scenarios (see Table V), define the
expected average value in term of revenue during the first ten years,
prepare a synthetic contingency plan to face the different risks
EXSANTOL - Question E Santos Container Terminal
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Up to You to Handle
the Problem
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Agostino G. BRUZZONE
President International Master MIPET of Genoa Univ.
Director of M&S Net (34 Centers WorldWide)
Director of the McLeod Institute of Simulation Science
Genoa Center
President of Liophant
General Chair Simulation Team (16 Partners in 5 Continents)
Full Professor in
DIPTEM University of Genoa
via Opera Pia 15
16145 Genova, Italy
Email [email protected]
URL www.itim.unige.it
DIPTEM
References