Designing semiDesigning semi--automated terminalsautomated terminalsUsing dynamic modelling tools Using dynamic modelling tools
Dr. Dr. irir. Yvo Saanen. Yvo Saanen
(c) TBA 2007 / Semi(c) TBA 2007 / Semi--automated terminals / AAPA 2007automated terminals / AAPA 2007
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1.1. Automated terminal amid their main competitorsAutomated terminal amid their main competitors
2.2. Design approach (semiDesign approach (semi--) automated terminal) automated terminal
3.3. Emulation as tool to ensure software qualityEmulation as tool to ensure software quality
4.4. Concluding remarksConcluding remarks
Contents of presentationContents of presentation
Automated terminals amid their main competitorsAutomated terminals amid their main competitors
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(c) TBA 2007 / Semi(c) TBA 2007 / Semi--automated terminals / AAPA 2007automated terminals / AAPA 2007
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The most efficient (semiThe most efficient (semi--) automated concept nowadays) automated concept nowadays4. RMG + AGV4. RMG + AGV
§ Density: 1500 TEU / ha§ Terminal capacity: 2000 TEU / m quay§ Operational cost reference number: 1§ Investment cost reference number: 5
(c) TBA 2007 / Semi(c) TBA 2007 / Semi--automated terminals / AAPA 2007automated terminals / AAPA 2007
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Why automate?Why automate?
Designing a semiDesigning a semi--automated container terminalautomated container terminal
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Simulation approach for robust design of an automated terminalSimulation approach for robust design of an automated terminal
§§ S.M.A.R.T. definition of goals and KPIS.M.A.R.T. definition of goals and KPI‘‘ss• Realistic operational scenarios• Performance targets• Operational costs / investment
§§ Static terminal design:Static terminal design:• Berth capacity• Storage capacity
§§ SimulationSimulation of of quayquay operationsoperations
„„setting the scenariossetting the scenarios““
§§ Initial drawings of alternativesInitial drawings of alternatives
§§ SimulationSimulation (alternative) terminal operations(alternative) terminal operations
„„productivity assessmentproductivity assessment““• Equipment selection• Dimensioning of „handling system“• Defining the logistical concept• Defining business logic
§§ Simulation of terminal during 6 weeksSimulation of terminal during 6 weeks
§§ TerminalTerminal costcost calculationcalculation ((investmentinvestment and and
operational)operational)
§§ Implementation planImplementation plan
Inputdata
Area constraintsGoals & requirements
Static terminaldimensioning
Preliminaryterminal design
Quay wallsimulation
Final principalterminal design
Handling systemdesign
Cost calculation
Simulationtools
Cost model
Productivity calc.and assessmentRisk assessment
Satisfied?
No
Yes
Project continuation
Handling systemsimulation
Inputdata
Area constraintsGoals & requirements
Static terminaldimensioning
Preliminaryterminal design
Quay wallsimulation
Final principalterminal design
Handling systemdesign
Cost calculation
Simulationtools
Cost model
Productivity calc.and assessmentRisk assessment
Satisfied?
No
Yes
Project continuation
Handling systemsimulation
(c) TBA 2007 / Semi(c) TBA 2007 / Semi--automated terminals / AAPA 2007automated terminals / AAPA 2007
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Simulation cycle (in each phase)Simulation cycle (in each phase)
model“as is”
models“to be”
currentsituation
newsituation
search forsolutions
pre-evaluation
diagnoseproblemvalidation
problem identificationand specification
choice andimplementation
post-evaluation
evaluation
model“as is”
models“to be”
currentsituation
newsituation
search forsolutions
pre-evaluation
diagnoseproblemvalidation
problem identificationand specification
choice andimplementation
post-evaluation
evaluation
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The key: balanced design of the yardThe key: balanced design of the yard
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Right balance / right designRight balance / right design
§§ Target productivity waterside Target productivity waterside –– capable of handling future demands?capable of handling future demands?• Peak loads (twin lift, tandem 40, dual cycling, reefer handling, MTs)• How many QCs on one vessel?
§§ Peak at the landside, gate + rail?Peak at the landside, gate + rail?
§§ Typical peak scenario: how many out of all QCs are actually in oTypical peak scenario: how many out of all QCs are actually in operation?peration?
§§ How many stacking cranes to meet this demand, in relation to theHow many stacking cranes to meet this demand, in relation to their specifications:ir specifications:• Length of stack module• Gantry speed & acceleration• Hoist speed and acceleration• Design of the waterside interchange zone (“buffering”)• Rolling percentage (effective rehandling)• Landside operation (remote operation)• Safety rules (e.g. access to interchange zones)
§§ Which automated transportation system is the most cost efficientWhich automated transportation system is the most cost efficient??
§§ How much waterside equipment to meet demands?How much waterside equipment to meet demands?• Interaction between yard equipment and transportation equipment• Sequence during vessel loading• Etc.
(c) TBA 2007 / Semi(c) TBA 2007 / Semi--automated terminals / AAPA 2007automated terminals / AAPA 2007
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Right design / which stack handling system?Right design / which stack handling system?
§§ The Twin RMG:The Twin RMG:
• 2 similar RMGs on one track
• Ability to mutually support
§§ The crossThe cross--over twin RMG:over twin RMG:
• One large, one smaller RMG on 2 tracks
• Ability to pass, and work on either side
§§ The crossThe cross--over tri RMG:over tri RMG:
• One large, two smaller RMG on 2 tracks
• One small RMG for either side
• Ability to pass, and work on either side
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Right design / which transportation system?Right design / which transportation system?
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Various combinations of yard and transportation equipmentVarious combinations of yard and transportation equipment(example)(example)
Iso performance / cost graphsquay length = 400m, 4 quay cranes, pooled vehicles
6
7
8
9
10
11
12
13
14
4 5 6 7 8 9 10 11 12 13 14 15 16# Transport vehicles (ShCs)
# St
acki
ng c
rane
s
Berth productivity 100 moves/hour Berth productivity 110 moves/hourBerth productivity 120 moves/hour Berth productivity 130 moves/hour
32
34
37
39
42
47
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Various terminal designs Various terminal designs depending on local circumstancedepending on local circumstance
§§ Terminal 1:Terminal 1:
§§ 2.0 M TEU2.0 M TEU
§§ 5% transhipment5% transhipment
§§ Dwell time: 9 daysDwell time: 9 days
§§ Peak productivity (WS/LS): 550/400Peak productivity (WS/LS): 550/400
§§ Configuration: 30 modules, 60 TEU long, 8 wideConfiguration: 30 modules, 60 TEU long, 8 wide
§§ Terminal 2:Terminal 2:
§§ 3.5 M TEU3.5 M TEU
§§ 50% transhipment50% transhipment
§§ Dwell time: 5 daysDwell time: 5 days
§§ Peak productivity (WS/LS): 720/400Peak productivity (WS/LS): 720/400
§§ Configuration: 52 modules, 45 TEU long, 10 wideConfiguration: 52 modules, 45 TEU long, 10 wide
§§ Terminal 3:Terminal 3:
§§ 4.5 M TEU4.5 M TEU
§§ 45% transhipment45% transhipment
§§ Dwell time: 4.5 daysDwell time: 4.5 days
§§ Peak productivity (WS/LS): 840/450Peak productivity (WS/LS): 840/450
§§ Configuration: 48 modules, 36 TEU long, 10 wideConfiguration: 48 modules, 36 TEU long, 10 wide
§§ Terminal 4:Terminal 4:
§§ 1.8 M TEU1.8 M TEU
§§ 5% transhipment5% transhipment
§§ Dwell time: 4 daysDwell time: 4 days
§§ Peak productivity (WS/LS): 375/300Peak productivity (WS/LS): 375/300
§§ Configuration: 24 modules, 26/52 TEU long, Configuration: 24 modules, 26/52 TEU long,
11/8 wide11/8 wide
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ASC specificationASC specification
Effect of the stacklength2-8 Corridor - Vgantry = 4,0 m/s - Agantry = 0,3 m/s2 - Vtrolley = 1,0 m/s - Atrolley = 0,3 m/s2 - Vhoist
= 1,0 m/s - Ahoist = 0,33 m/s2 - Scenario 3
19.8 19.418.6 18.5 17.9
17.3
15.2 14.6 14.1 13.9 13.4 13.2
0
5
10
15
20
25
30 35 40 45 50 55 60Stack length [TEU]
AC
S pr
oduc
tivity
[mph
]
Waterside crane
Landside crane
Effect of gantry speedAgantry = 0.3 m/s2 - Vtrolley = 1,0 m/s - Atrolley = 0,3 m/s2 - Vhoist = 1,0 m/s - Ahoist = 0,33 m/s2
21.4 22.0 22.0 21.9
14.8 15.5 15.8 15.8 15.9
21.7
0
5
10
15
20
25
30
3.0 3.5 4.0 4.5 5.0
Gantry speed (m/s)
AC
S pr
oduc
tivity
[mph
]
Waterside craneLandside crane
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Design of the reefer solutionDesign of the reefer solution
§§ Reefer solution:Reefer solution:
• Dependent on reefer share
• Dependent on # reefer mechanics
• Dependent on reefer solution (location in
the stack module, access, ASC restrictions)
Antwerp Gateway Project - Net quay crane productivitySmall terminal - 8 stack modules - 90 LS moves - 4 QCs - 3 SC per QC
35.433.2
27.4
35.3
31.8
24.7
0
5
10
15
20
25
30
35
40
45
50
0% 10% 20% 0% 10% 20%
1:4 rf mod - 20 cntrs/bay - 2 rf mechs 1:4 rf mod - 20 cntrs/bay - 1 rf mechsPercentage reefers of total containers
Net
QC
pro
duct
ivity
(bx/
h)Antwerp Gateway Project - Net quay crane productivity
Small terminal - 8 stack modules - 90 LS moves - 4 QCs - 3 SC per QC
35.434.2
29.7
35.8
32.6
26.3
0
5
10
15
20
25
30
35
40
45
50
0% 10% 20% 0% 10% 20%
1:3 rf mod - 20 cntrs/bay - 2 rf mechs 1:3 rf mod - 20 cntrs/bay - 1 rf mechsPercentage reefers of total containers
Net
QC
pro
duct
ivity
(bx/
h)
Antwerp Gateway Project - Net quay crane productivitySmall terminal - 8 stack modules - 90 LS moves - 4 QCs - 3 SC per QC
35.5 34.833.5
35.6
33.4
27.8
0
5
10
15
20
25
30
35
40
45
50
0% 10% 20% 0% 10% 20%
1:2 rf mod - 20 cntrs/bay - 2 rf mechs 1:2 rf mod - 20 cntrs/bay - 1 rf mechsPercentage reefers of total containers
Net
QC
pro
duct
ivity
(bx/
h)
1 out of 4 blocks with reefers 1 out of 3 blocks with reefers
1 out of 2 blocks with reefers
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Traffic analysisTraffic analysis
X 650 850 1050 1250 145040
56
72
88
104
120
x coordinates
DP World - London Gateway - Traffic density22 QCs - 88 lift AGVs - correct berthing
Right side of terminal - average number of vehicles per hour
0-15 15-30 30-45 45-60 60-75 75-90 90-105 105-120 120-135 135-150 150-165
165-180 180-195 195-210 210-225 225-240 240-255 255-270 270-285 285-300 300-315 315-330
4 QC vessel6 QC vessel
stack 1stack 29
Traffic density
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Performance under breakPerformance under break--down circumstancesdown circumstances(example)(example)
Truck service time module A257
-3600
0
3600
7200
10800
0 3600 7200 10800 14400 18000 21600 25200
Time of arrival at gate (s)
Tim
e (s
)
Waiting time for transfer point Terminal time Breakdown Breakdown resolved
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Typical deliverables of a design studyTypical deliverables of a design study
§§ Berth simulation:Berth simulation:• Berth occupancy• Quay crane utilization• Vessel service times• Yard occupation throughout the year• Handling peaks waterside & landside
§§ Handling system simulation:Handling system simulation:• Required numbers of yard cranes & shuttle
carriers• Optimized yard design• Reefer solution• Design of interchange zones• Effect of breakdown and mitigation
strategies• Algorithms for dispatching, scheduling and
grounding
§§ Other:Other:• Solution (conceptually) for scheduling /
dispatching ASCs• Solution (conceptually) for scheduling /
dispatching ShCs
QC productivity - Vehicle Comparison [6 QCs @ 45 ccph, 25 TwinRMG modules, 350 landside bx/h]
0
5
10
15
20
25
30
35
40
45
50
9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54
Total number of vehicles available
Prod
uctiv
ity (b
x/hr
)AGVShCAGV_LiftALVC-AGV
RMG: Productive moves all cranes
22.6
25.4
28.0
23.9
26.2
23.9
27.1
29.9
32.8
34.8
36.1 36.2
30.7
35.034.6
33.3
33.533.1
31.8
30.728.2
20
25
30
35
40
0 3 6 9 12 15 18Number of container moves landside
Prod
uctiv
e m
oves
per
hou
r all
cran
es
Twin
Dual (Large LS+WS)
Tri (Large LS+WS)
100% 85% 70% 55% 40% 25% Transhipment ratio
(c) TBA 2007 / Semi(c) TBA 2007 / Semi--automated terminals / AAPA 2007automated terminals / AAPA 2007
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Typical deliverables of a design studyTypical deliverables of a design study
Emulation as a way to ensure software quality and performanceEmulation as a way to ensure software quality and performance
or
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Link software to a virtual terminal (CONTROLS)Link software to a virtual terminal (CONTROLS)
TOS (control system)TOS (control system)TOS (control system) TOS (control system)TOS (control system)TOS (control system)
Real terminalReal terminal Virtual terminalVirtual terminal
(c) TBA 2007 / Semi(c) TBA 2007 / Semi--automated terminals / AAPA 2007automated terminals / AAPA 2007
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Key properties of Key properties of dynamic modelsdynamic models
1.1. DynamicsDynamics
2.2. Safe and inexpensive trial and error environmentSafe and inexpensive trial and error environment
3.3. Analysis of nonAnalysis of non--repetitive eventsrepetitive events
4.4. See processSee process
5.5. Quantify and prioritizeQuantify and prioritize
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ÉÉ TrainTrain ““control roomcontrol room”” operators:operators:
• Operate a virtual terminal
• No “learning” impact to operation
• Get immediate feedback
• Practice on irregular operations
3T3T--Concept: Concept: TTesting, esting, TTuning and uning and TTrainingraining
ÅÅ TestTest new software:new software:
• Reducing risk
• More focus on performance
• Knowing problems earlier in process
• Insight for non software experts
ÇÇ TuneTune your operation:your operation:
• Anticipation on problems
• Validation of planning
• Replay of operation
• Running future growth scenarios
Key references:Key references:
§§ Pusan Newport (Zodiac)Pusan Newport (Zodiac)
§§ MSC Home (SPACE/TRAFIC)MSC Home (SPACE/TRAFIC)
§§ APMT Virginia (SPARCS)APMT Virginia (SPARCS)
§§ EurokaiEurokai Hamburg (TOPHamburg (TOP--X)X)
§§ APMT Rotterdam (SPACE/TRAFIC)APMT Rotterdam (SPACE/TRAFIC)
§§ Euromax (SPARCS / TEAMS)Euromax (SPARCS / TEAMS)
§§ APMT Aarhus (SPARCS)APMT Aarhus (SPARCS)
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Example: testing the TOSExample: testing the TOS
Concluding remarksConcluding remarks
or
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ConclusionsConclusions
§§ With the right approach, and the proper tools, automated terminaWith the right approach, and the proper tools, automated terminals can be ls can be
designed and implemented:designed and implemented:
• Without major risk
• Within time
• Within budget
• Delivering the targeted productivity
§§ The design will very from site to site, as many conditions deterThe design will very from site to site, as many conditions determine the mine the ““optimaloptimal””
designdesign
§§ Automated terminals Automated terminals –– more than any other type of terminal more than any other type of terminal –– require proper require proper
planning, with a long term vision on service levels and handlingplanning, with a long term vision on service levels and handling capabilitiescapabilities
(c) TBA 2007 / Semi(c) TBA 2007 / Semi--automated terminals / AAPA 2007automated terminals / AAPA 2007
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Contact detailsContact details
TBA B.V.TBA B.V.
Dr. Yvo Saanen Dr. Yvo Saanen –– Managing DirectorManaging Director
VulcanuswegVulcanusweg 259259
2624 AV DELFT2624 AV DELFT
The NetherlandsThe Netherlands
Tel.Tel. +31 15 3805775+31 15 3805775
Fax.Fax. +31 15 3805763+31 15 3805763
WebWeb www.tba.nlwww.tba.nl
EE--mailmail [email protected]@tba.nl