AREMA 2011 Manuscript Submission Northwest … · AREMA 2011 Manuscript Submission Northwest Ohio Trans-Shipment Terminal CSX Intermodal Terminals, Inc. June 15, 2011 Principal Author:

AREMA 2011 Manuscript Submission

Northwest Ohio Trans-Shipment Terminal

CSX Intermodal Terminals, Inc.

June 15, 2011

Principal Author: Richard Hisrich, Manager Terminal Development


550 Water Street

11th Floor

Jacksonville, FL 32202

P – (904) 633.1427

F – (904) 306.5467

[email protected]

Co-Author: Chris Durden, Director Terminal Development


550 Water Street

11th Floor

Jacksonville, FL 32202

P – (904) 633.1306

F – (904) 245.3717

[email protected]

WORD COUNT: 3,040 WITHOUT IMAGES

7,290 WITH IMAGES

© 2011 AREMA ®

ABSTRACT The 540-acre Northwest Ohio Intermodal Terminal, (“NWOH Terminal” or “Terminal”), is the

western anchor of the National Gateway and the cornerstone of CSX’s intermodal network. The

National Gateway is a $800M+ public-private partnership to improve intermodal service

between the East Coast and the Midwest, Southwest and West Coast.

NWOH Terminal features:

· 32.5 miles of track, including a five-mile siding, 74 #10 and 16 #20 high-speed

mainline turnouts

· Eight (8) 3000’ process tracks, served by five state-of-the-art, electric (zero

emission) wide-span cranes and four ‘One-Over-One’ shuttle carriers

· An eighteen (18) track remote control classification yard

· Locomotive fueling and servicing with railcar maintenance facilities

· Green features such as: NARSTCO steel ties, recycled plastic composite

crossings, standard LEED certified crew building

· A terminal operating system that incorporates optical scanners and railcar axle

counters to integrate all rail, crane, shuttle carrier and trucking processes

Stormwater design includes self-sustaining stormwater controls that provide runoff and water

quality control for the site. Detention basins were designed with forebays and oil/water

separators located in critical portions of the property to provide additional environmental controls

for the facility.

Over a 30-year period, the initiative will lower CO2 emissions by over 20 million tons, reduce

fuel consumption by nearly 2 billion gallons, and reduce highway congestion and maintenance.

The project has required ongoing coordination with the U.S. Army Corps of Engineers, the Ohio

Environmental Protection Agency, Ohio Department of Natural Resources, Ohio Department of

Transportation, Ohio Rail Development Commission, and the Wood County Engineer and

Economic Development Departments.

© 2011 AREMA ®

INTRODUCTION

The 540-acre Northwest Ohio Terminal (”NWOH Terminal” or “Terminal”) located near North

Baltimore, Ohio is the western anchor of The National Gateway and the cornerstone of CSX’s

intermodal network. The Terminal serves as a hub facility not only within CSX’s intermodal

network, but also efficiently connects transcontinental container moves between the intermodal

networks of major Western railroads and the CSX network. Being specifically designed for its

hub purpose, while also serving the local shipper community, the Terminal is the first of its kind

worldwide. The facility is expected to handle a throughput capacity of nearly 2 million containers

per year, including block swaps for trans-shipment. With its functionality, the Terminal not only

saves valuable interchange time for containers going to and from Western railroads, but also

helps to protect our environment by saving fuel and reducing emissions related to current

interchange operations in the Chicago metropolitan area.

The National Gateway is a public-private partnership which supports the movement of double-

stacked intermodal containers on rail cars by raising bridges, increasing tunnel clearances and

building new terminals along existing rail routes. The National Gateway will benefit CSX

customers by improving service reliability, reducing transit times and reducing highway

congestion. The NWOH Terminal, along with the National Gateway initiative also enhances the

environment by lowering CO2 emissions by over 20 million tons and reducing fuel consumption

by nearly 2 billion gallons over 30 years.

In order to achieve the ambitious objective of pioneering a dedicated hub trans-shipment

terminal in a short timeframe, CSX assembled the best team and supplier resources available.

The new intermodal terminal utilizes cutting edge technology with an efficient, environmentally

friendly design, which was engineered to consider innovation, safety, service performance and

operational reliability.

© 2011 AREMA ®

TERMINAL FEATURES

Throughout the terminal, unique features were designed to streamline operations and improve

efficiency while maintaining CSX’s commitment to environmental stewardship. Actual track

construction consisted of 32.5 miles of track and 74 #10 turnouts with hydraulic switches and

hot air switch heaters. The Terminal contains eighteen (18) classification yard tracks, eight (8)

3000’ process tracks, a five mile siding, a wye track, three (3) car repair tracks and two (2)

locomotive service tracks. Three million yards of earth were moved and over 500,000 tons of

stone were hauled in for utility installation, pavement base and ballast. The project includes

three buildings for terminal administration and operations which total 20,000 SF. Nearly 70 miles

of electrical conduit containing 1 million feet of electrical wire and 3 million feet of fiber optic

strands has been installed to link the various components of the terminal.

Equipment/Operational Features

Wide-Span Cranes

The NWOH Terminal features five

(5) total electric, state-of-the-art

wide-span cranes (WSC) supplied

by Hans Kuenz GmbH (Austria).

The WSC operate with zero

emissions and is designed to

regenerate 60% power back to the

terminal grid or back to the

provider. These WSC operate in a

designated 1,960’ working area over 8 process tracks, allowing a 400% increase in lift capacity

versus conventional terminals. The WSC are rail mounted on 3,000 feet long (175-pound) crane

rails and operate with significantly less noise decibel levels 48 dBA at 50’ as compared to

conventional diesel equipment 80 dBA at 50’. Stout foundations for the crane rail containing

Figure 1: Photo of Wide-Span Cranes at Night

© 2011 AREMA ®

8,300 cubic yards of concrete and

490 tons of reinforcing steel were

designed to ensure that the strict

operating tolerances of the high

caliber cranes will be met for the

design life, allowing them to

function consistently at peak

efficiency. In order to meet the

electric demands for these cranes,

a new electrical substation was constructed near the terminal, and backup power was extended

from a second source to provide the redundancy needed to ensure uninterrupted service at the

terminal.

Operations Planning

The NWOH Terminal operations planning was designed by Hamburg Port Consulting GmbH

(“HPC”). HPC’s services included a dynamic analysis of terminal design by means of simulation

of terminal operations, along with process definitions and descriptions specifically elaborated to

meet the needs of the NWOH Terminal. In addition, HPC performed static operations and crane

performance planning that would best fit and accommodate CSX’s intermodal network needs.

These analyses led to the creation of a new Terminal Operating System (TOS) implementation

and use of wide-span cranes and ultimately the final layout for the NWOH Terminal. HPC’s

study recommended the implementation of five (5) WSC to meet the opening day lift demand

estimated to be 576,000 containers, and allow for volume growth to 2020.

Logistics Planning

Computer modeling was performed by Innovative Scheduling, Inc., a leader in optimization-

based software solutions for planning and scheduling of logistics, in order to confirm operational

Figure 2: Photo of Wide-Span Cranes

© 2011 AREMA ®

switching efficiency and capacity

for 30 trains on opening day. This

modeling considered switching

moves to and from

process/support tracks, arrival and

departure of train schedules, train

lengths, train capacity and track

configuration, which led CSX to

the new “center ladder design” in the support yard. This design has offset track centers (first

design of its kind for CSX), which allows access to any of the tracks for switching operations, or

arrival/departure of trains.

Terminal Operating System

Controlled from the 5,447 SF Administration Building, the main Terminal Operating System as

developed by Tideworks Technology specifically for the NWOH Terminal is “Intermodal Pro”

(iPRO). iPRO visualizes the Terminal as a whole and supports every operational process in the

Terminal. iPRO utilizes a “Digital Bridge” which serves as a management dashboard with traffic-

light functionality. Information is shared between all systems through the wireless network.

CSX’s wireless network allows iPRO to communicate instantaneously with Mi-Star, which will be

described further in this document, and other systems by exchanging Differential Global

Positioning System (DGPS) information and events, move requests and confirmations, railcar

positions, crane alerts and events as well as blue flag status. The iPRO system enables the

technologically advanced NWOH Terminal to operate at peak performance while being

exceptionally safe.

To provide an Automated Yard Management and Real Time Locating System (“RTLS”), Mi-

Jack’s Mi-Star system utilizes the combined hardware and software applications of AccuStack™

Figure 3: Photo of Center Ladder

© 2011 AREMA ®

and AccuView™. These programs not only assist in efficient inventory management, they also

generate multiple types of warning and safety zones. The Mi-Star system uses DGPS to provide

precision tracking of equipment and vehicles within the Terminal. Mi-Star relays the RTLS

information to iPRO and the Crane Management System (“CMS”) to calculate safe execution of

crane move requests. Each crane work order generated in the TOS is again calculated by Mi-

Star for the safest way of execution before the crane will respond. Mi-Star also generates safety

zones around each wide-span crane. The safety zones are created by relaying the location of

each terminal vehicle relative to the position of the crane and preventing safety conflicts

between multiple pieces of equipment. Should a conflict occur by a vehicle entering the safety

zone, the system will activate an alarm inside the breaching vehicle. The Mi-Star AccuView™

system provides the operator the ability to graphically generate inventory stacking grids, gantry

crane shuttle carrier lanes, rail loading tracks, live lift lanes and parking spots. This system

increases operational efficiency, while maintaining safety as the top priority.

Car Tracking System

Further innovative features of the NWOH Terminal

are the rail OCR (Optical Character Recognition)

portals designed by APS Technology Group, which

automatically identify container laden railcars as

they enter and exit one of the four lead tracks at

the facility perimeter. As railcars pass through the

portal, a virtual train inventory of all railcars and

their equipment is electronically constructed in real

time. Information is collected and combined to produce fully automated container-to-railcar

association and thereby eliminates the need to manually perform train inventories in the yard.

Figure 4: OCR Portals at Lead Tracks

© 2011 AREMA ®

Additionally, based on a confidence level of the OCR reading or possible safety or loading

exceptions in EDI inventory, X-Clerk, an integrated exception management system from APS

Technology Group, resolves system data errors from unplanned or unrecognized “ghost”

equipment (either railcars or containers). X-Clerk detects these exceptions and routes the

information, along with associated portal images, to a service representative who can remotely

correct the car naming, classification or equipment ID data without entering the yard. The

“ghost” equipment then synchronizes with RailComm and iPRO to ensure personnel do not

have to enter the yard in order to correct the recently updated inventory, providing another layer

of safety for personnel and continued on-time performance and delivery.

The Railcar Tracking System (RTS) combines the APS OCR Portal data along with RailComm

wheel sensors and switch position indicators. Wheel sensors, part of the RailComm yard

automation platform, are located at each turnout throughout the Terminal to track train

movements. As cars are switched within the Terminal, the RTS is continuously updated with

data from the RailComm sensors.

The SureSpot™ Car Locating System from APS Technology Group uses crane mounted

machine vision cameras to precisely locate the railcars on the processing tracks. The cameras

Figure 5: OCR and Process Automation Systems Schematic

© 2011 AREMA ®

are located face down on the WSC towards the processing tracks for exact positioning

information of the railcars. The RTS receives crane position data directly from the Crane

Management System to provide full visibility to iPRO and enable the automated movement of

the WSC in preparation for their next work instruction.

Figure 6: APS SureSpot™ Rail Tracking System

Automatic Gate System

The Automated Gate System (AGS) processes inbound and outbound truck cargo more

efficiently than traditional gate systems by reducing transaction time, truck idling time and

exhaust emissions. The GateVision System

from Tideworks Technology utilizes APS

Technology Group’s OCR cameras,

inspection portals and License Plate

Recognition (LPR) systems deployed on

Tideworks pedestals to automatically identify

trucks and containers as they enter and exit

the facility.

Figure 7: APS OCR Truck Portal

© 2011 AREMA ®

Shuttle Carriers

In order to transfer containers between cranes more efficiently, CSX has implemented the use

of diesel electric shuttle carriers. The shuttle carriers are known as ‘One-Over-One’ shuttle

carriers because they traverse containers on the ground while a container is loaded inside the

shuttle carrier. The shuttle carriers are able to effectively handle every type of container from 20’

international to 53’ domestic containers. The shuttle carriers have a fixed cabin with rotatable

seats which allow the operator a direct line of sight to the front of, or the container-side of the

shuttle carrier, enabling the

operator to safely maneuver

throughout the Terminal. All

shuttle carriers are equipped with

a DGPS unit on board which

communicates with the Mi-Star

system. This gives the shuttle

carrier operator an exceptional

level of safety.

Locomotive and Railcar Maintenance Facility

To maintain train schedules and performance reliability, locomotive servicing, including fueling,

lube oil and sanding and railcar maintenance are performed onsite. Two (2) 250,000 gallon fuel

tanks, an 8,000 gallon lube oil tank and a 40 ton sand silo, each with its own environmental

safeguards have been constructed onsite to support the mobile and locomotive servicing

capabilities.

Figure 8: Shuttle Carrier

© 2011 AREMA ®

Safety Features

Shove Protection System

The RailComm Shove Track Indication System, which protects train movement on the center

Figure 9: RailComm Shove Track Indication System

ladder, provides remote indication of shove track status, allowing train operators to know when

their train has reached the limits of the shove zone. The shove track system for the NWOH

Terminal consists of a Detection subsystem and an Indication subsystem. The Detection

subsystem is responsible for monitoring track occupancy in the area at the end of the shove

track. Two detection zones are located at the end of each shove track. One detection zone is

designated as the approach or slow zone and the other as the stop zone. The approach zone is

located immediately prior to the stop zone. Each zone is associated with a lighted aspect which

indicates the position of the train to the operator. When neither detection zone is occupied, the

Indication subsystem displays a green aspect for the corresponding track indicating that it is

clear to shove cars into this track. As the approach circuit becomes occupied, the Indication

subsystem displays a yellow aspect, indicating that the cars are nearing the stop zone. When

the stop zone becomes occupied, the Indication subsystem shows a red aspect indicating that

the cars have reached the end of the shove track. In the event of loss of communication

© 2011 AREMA ®

between the Indication subsystem and the Detection subsystem, all indications are turned off.

This is treated like a red signal and all shove action must stop until communication is re-

established or the shove move is manually monitored.

Remote Control Switching

The classification and working tracks are

switched by remote control engines. Two

operators, one on each end of the Terminal,

perform and monitor switching movements

from the ground, or the Remote Control

Operations Building, through a system of

cameras, including infrared cameras for

nighttime use.

All 74 turnouts in the Terminal are power GE

Hydra Switches controlled by the RailComm

DOC system over CSX’s wireless network. The use of remote control switching operations

along with the power GE Hydra Switches provides the most efficient and safest means for

switching operations.

WSC Simulator

To safely teach the operation

and control of a wide-span

crane, while exposing the

operator to the highly complex

working environment of an

intermodal terminal, a simulator

Figure 4: Remote Control Locomotive

Figure 11: Global Sim WSC Simulator © 2011 AREMA ®

designed by Global Sim is stationed onsite. Operators are guided through high fidelity

simulations within a virtual terminal. The motion and controls of the simulator focus on building

the requisite motor skills while the realistic sounds build tonal memories for auditory queues.

The scenarios created and saved in the simulations repository help build the reasoning,

judgment and analytical skills a wide-span crane operator needs to interact with shuttle carriers,

grunts and ground personnel. In addition to skills training, this versatile multi-use tool can be

used for remediation, planning, post-mishap re-creation and operational procedure design.

Security Features

In addition to the many safeguards included on the equipment within the facility, the NWOH

Terminal was designed with added safety features to further protect yard personnel and the

cargo within the Terminal. The entire facility is lighted with energy efficient high-pressure

sodium bulbs affixed on thirty 100’ high mast light towers and thirty-four 40’ high poles. A

closed-circuit camera system covers the entire terminal, providing continuous monitoring 24

hours a day, 365 days per year, with looped recording cycles for easy investigation access. The

cameras have full pan-tilt-zoom capabilities for real-time exploratory capability. A substantial

earthen mound and over 7 miles of perimeter fencing secure the perimeter of the Terminal.

Access controlled gates and building entries are monitored by ADT Security. These systems

ensure a safe and controlled environment at the NWOH Terminal.

Environmental Features

The NWOH Terminal has several

“green” features such as:

NARSTCO steel ties, recycled

plastic composite crossings, and a

Standard LEED certified crew

Figure 12: LEED Certified Crew Building

© 2011 AREMA ®

building with the first Intermodal Health and Wellness Center available to all employees. The 40

acres of driving and parking surface of the facility was constructed with roller-compacted

concrete. This surface generates significantly less atmospheric heat as opposed to an asphalt

design and has a much greater lifespan with significant cost savings.

Stormwater Control

Stormwater design includes self-

sustaining stormwater controls the

provide runoff and water quality

control for the site. Retention

basins located in critical portions

of the property were designed

with upstream forebays and

oil/water separators to provide

additional levels of environmental

controls for the facility. Figure 13: Stormwater Controls

Figure 14: Stormwater Controls

© 2011 AREMA ®

Standard LEED Certified Crew Building

The Crew Building at the NWOH Terminal (see Fig. 12) was selected as a prototype for building

designs on future CSX intermodal terminals, incorporating green technologies such as

upgraded HVAC, energy efficient lights and natural stormwater control around the perimeter of

the building to obtain the US Green Building Council’s Standard LEED certification. Within the

Crew Building, employees will find a

1,356 SF Health and Wellness Center,

stocked with a variety of exercise

equipment to promote physical activity

and improve the general wellbeing of

the many employees and crew

members passing through the NWOH

Terminal.

Figure 15: Stormwater Controls

Figure 16: Health & Wellness Center

© 2011 AREMA ®

CONCLUSION

The integration of all rail, crane and equipment processes through terminal modeling,

operational planning and system implementation make the Northwest Ohio Intermodal Terminal

the country’s most environmentally friendly and technologically-advanced intermodal terminal.

The Terminal is the next generation of intermodal terminals incorporating multiple innovative

systems, enhancing and improving service performance and operational reliability, while

prioritizing safety. CSX’s proven vision and dedication to the advancement and success of the

railroad industry is evidenced in the completed construction of this facility.

Figure 17: NWOH Terminal

© 2011 AREMA ®

2011 ANNUAL CONFERENCESeptember 18-21, 2011 | Minneapolis, MN

RICHARD HISRICH AND CHRIS DURDENCSX INTERMODAL TERMINALS, INC.



HIGHWAY CONGESTION

CSX Territory

Source: USDOT FHWA Freight Analysis Framework

Today 2020


REQUIRED INVESTMENT IN TRANSPORTATION BY 2035

FreightRail

Highways

Source: Rail – 2007 AAR/Cambridge Study; Highway – 2007 DOT Surface Transportation Study

PassengerRail

$ 135 Billion $ 198 Billion

$ 5 Trillion


NATIONAL GATEWAY

Memphis

St Louis Norfolk

Wilmington

Baltimore

Chicago

New Orleans

Pittsburgh

NW Ohio

PROJECT OVERVIEW$860 million in investments 61 double stack clearance projectsConstruction of 6 intermodal terminals

STRATEGIC VALUEIncreases intermodal capability in key population centersProvides double stack capacity from East Coast Ports to Midwest


HUB FACILITY

Terminal allows Chicago run-through serviceHub strategy will significantly improve routing efficiencyNew service offerings available due to “hub density”


CONNECTION TO MAJOR MARKETS

Gulf Coast

SouthernCalifornia

NorthernCalifornia

Pacific Northwest

Florida

Northeast

Midwest

Atlanta –Research Triangle

Existing flowsNG opportunities

National Gateway projects

NWO


IDEAL LOCATION

The Henry Township location is ideal in terms of access to rail routes and proximity to the Interstate.

South to Cincinnati

North to Detroit

Access toI-75

Facility Location

970 Miles from N. Platte, NE

South to Columbus


TERMINAL FEATURES

Electric Wide Span CranesRailcar Tracking SystemAutomated Gate SystemRemote Controlled YardShove Protection SystemSteel Yard Ties

Composite CrossingsHydraulic SwitchesLEED Certified Crew BuildingCCTV Camera SystemRoller Compacted Concrete



WIDE SPAN CRANESElectric - zero emission5 cranes operating over 8 process tracksCustom designed and fabricated by Hans Kuenz GmbH

OperationPollutant (grams/lift)

HC CO NOx PMWSC 1.8 8.3 23.9 2.1

Reduction vs.

conventional 84% 83% 84% 82%

HC=Hydrocarbons , CO=Carbon Monoxide, Nox=Oxides of Nitrogen, PM=Particulate Matter,

454g/lb., 2000 lbs/ton


SHUTTLE CARRIERS4 shuttle carriers are used for efficient horizontal transport of containers between crane work zones1 over 1 capability allows a shuttle carrier to pass over grounded containersSpeed, ease of container handling, and independently optimized work orders allow one shuttle to safely do the work of multiple UTRs


GRUNTS

The right truck for the right jobOperates between processing tracksImproves safety, speed and efficiency of ramp workers


SIMULATOR

GlobalSim developed a simulator that closely recreates the WSCenvironmentSimulator is part of the standard training for all crane operators prior to their operation of a WSCWill allow for long term employee skill set development and refinement



CENTER CROSSOVER LADDER

Offset track centersAllows access to any of the tracksAccommodates multiple train arrival/departures


RAILCAR TRACKING SYSTEMRailcomm yard automation platform

Wheel sensors and switch position indicatorsLocated at each turnout throughout the Terminal


APS OCR rail portalsPortals located on each of four lead tracksAutomatic identification of railcars and containersFully automated container-to-railcar association

RAILCAR TRACKING SYSTEM


CAR LOCATING SYSTEM

APS SureSpot systemCrane mounted camerasPrecisely locates railcars for automated movement of the WSC


AUTOMATED GATE SYSTEMProcesses inbound and outbound truck cargoReduces transaction timeDecreases idling and exhaust emissionsUtilizes APS OCR camerasRecognizes license plates


TERMINAL OPERATING SYSTEM

New system developed by Tideworks for NW Ohio TerminalUtilizes a digital bridge to manage all systems



REMOTE CONTROL LOCOMOTIVE

Switch classification and working tracksYard controlled by two operatorsAll movements are monitored from the ground


REMOTE CONTROL SWITCHING

Locomotive movements overseen by single operatorAll movements are monitored from the ground or Remote Control Operations BuildingInfrared cameras for nighttime visibility


MiSTAR and WLAN Real Time Locating System

Efficient inventory managementMultiple levels of warning and safety zonesUtilizes the DGPS to track equipment and vehicles


SHOVE PROTECTION SYSTEM

Shove Track Detection ZonesShove Track Indicators

Shove Track Detection ZonesShove Track Indicators



RECYCLABLE STEEL TIES

Steel ties supplied by NARSTCOReduced maintenance costsIncreased construction efficiency


COMPOSITE CROSSINGS

Supplied by LT ResourcesEngineered 100% Recycled PlasticsSkid-Resistant Surface


STORMWATER MANAGEMENT


LEED CERTIFIED CREW BUILDING

35% reduction of water useOptimized Energy Performance (use of Green Power)Recycled content and regional materials utilizedInnovated design including non-roof heat island



HEALTH AND WELLNESS CENTER

First Intermodal Health & Wellness Center1,356 Square Foot FacilityUtilized by CSX Employees and Train Crews


TERMINAL SECURITY

High mast and pole mounted lighting utilized throughout siteClosed circuit camera system providing continuous monitoringPerimeter fencing and access controlled gates and building entries


ROLLER COMPACTED CONCRETE

Fast and economical constructionHeavy load capacityDurable and low maintenanceLight surface reduces lighting requirements and heat island effect


QUESTIONS?VIDEO TO FOLLOW!


Thank you!

Documents

AREMA 2011 Manuscript Submission Northwest … · AREMA 2011 Manuscript Submission Northwest Ohio Trans-Shipment Terminal CSX Intermodal Terminals, Inc. June 15, 2011 Principal Author: