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S Y S T E M S : Quay crane technology

Providing effective back

up for terminal ‘muscle’
Container terminal productivity requires This function can be combined with a
function that determines the position of the
more than just the largest, most powerful vehicle that a container is to be placed on,
permitting vehicles positioned at an angle in
equipment, writes Fredrik Johanson the lane to be loaded without delay. The
angle discrepancy between the load and
vehicle is regulated to zero by the load
being skewed on the way from ship to
In everyday language, we define Automation, training, service and shore.
productivity as metrics and measures of support, spare parts, crane information The result of automatic skew control is an
output from production processes per unit management systems, preventive actual productivity increase, in that the
of input. maintenance and integration are examples crane can move more containers per hour
Depending on how a terminal’s of some of the areas in which crane but with equally large frequency converters
performance indexes are defined, productivity can be increased. and transformers as previously. Moreover,
productivity can refer to containers per A function used by some suppliers for the function assists operators by relieving
hour, moves per hour or cost per container, several years is anti-sway. The function them of a very difficult task.
for example. It is not all that difficult to entails the operator being assisted in With the help of a stack profiling system
measure containers or moves per hour, catching the sway and can thus focus on (SPS), the crane receives stack profiling
system suppliers can help a terminal to tasks other than controlling the sway of the data, which is updated on each cycle from
operate its dockside cranes faster. suspended load. This can be combined with the ship. The system can then calculate the
Cargo Systems consulting editor Brian electronic load control (ELC), with the lowest possible height of lift. This function
Robinson presents a legitimate argument operator using a touch screen to choose the not only reduces cycle times by the load not
that with “muscle” alone, a terminal can be position to which the container or empty being lifted higher than necessary, it also
operated faster to reduce cycle times and to spreader is to move. minimises energy consumption, thus
consequently increase productivity (CS, Dec Rather than using anti-sway, many crane reducing the impact on the climate.
08, p43). This typically provides shorter operators traditionally prefer to catch the Sticklers for detail may object to the
ramp times and higher speeds for hoist sway themselves, if for no other reason than argument that the energy used to lift the
operations, as well as optimal results in professional pride, and they are often highly load is regained during lowering, but it must
containers per unit of time. skilled at this. be kept in mind that losses in motors,
However, this approach requires higher Load pendulation in the other direction – cables, transformers and gearboxes are
installed electrical power, with subsequent the skew direction – is significantly more never regained; these losses are only used to
scaling up of motors, inverters, transformers complex for the operator to correct and it heat the planet.
and cables. becomes more difficult to stop, the longer If we now combine anti-sway, electronic
Furthermore, if the terminal does not the ropes. An automatic skew control is now load control, stack profiling systems and
have a sufficient number of vehicles to available that efficiently ensures that skew automatic skew control, we get something
receive the containers off-loaded from the pendulation is minimised, and consequently that ABB calls an automatic container
ships, crane hang times will become contributes to shortening cycle times. landing system (Aclas).
excessive, resulting in unnecessarily high
Look no hands!
idling and magnetising losses in motors and ABB has
transformers. The anticipated gains from the produced an
automatic
productivity increase would be entirely or container
partially negated by increased costs for both landing system
operations and investments. (Aclas) that
combines anti-
So what can the supplier of the electrical sway, electronic
system do to influence crane productivity? load control,
stack profiling
Selling larger components – which has an systems and
upside for the system supplier – is not a automatic skew
control
good long-term solution for society as a
whole, for the environment or for crane
users.

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cranes are rare; any problems that may arise

are usually caused by minor faults in
electrical systems. System suppliers can help
out by continually improving knowledge of
the systems through onsite training on the
cranes and at strategically selected training
centres, for example.
Upon delivery of new equipment or
modifications, participation in
commissioning must also be included as a
part of training so as to provide terminal
staff with the opportunity to familiarise
themselves with the new equipment.
A prerequisite is that all training is
conducted by knowledgeable personnel, who
are not only familiar with the latest advances
in technology, but also have knowledge of
older systems since, for example, many
crane users have some older cranes with
DC technology.
With the right personnel, properly trained
for the tasks at hand, any downtime can be
minimised and productivity maintained or
improved due to the personnel being
knowledgeable of the system.
Regardless of the skills, training and
system familiarity of the maintenance
department or whether maintenance is
correctly conducted, support from the
system supplier for an STS crane system
may be necessary. First of all, this requires
that such support exists, that it is
accessible, and not least, that it is
STS cranes must be constantly maintained while keeping terminal disruptions to a minimum competent.
As a crane user, one must demand that
In brief, Aclas entails the operator requires the landside transport of containers the system supplier fulfils these
monitoring only the process from the point to or from the quayside to keep up, but this requirements. Without this, crane availability
where the load leaves a safe height over the is a topic for several doctorial dissertations. can be negatively affected, and
ship to where it reaches a safe load height Naturally, the system onboard the crane consequently, productivity. The provision of
over the vehicle, with the correct skew angle must be the best possible and provide service and support are naturally a matter of
and with no pendulation whatsoever. The optimal availability, but even so, things can balance with all day, everyday service costly
operator can easily set the container on the go wrong. And when they do, knowledge of both for the crane user and system supplier.
vehicle and return to the ship for a new how faults are to be remedied must be If there is an installation base in the
cycle. readily accessible. geographic area, 24/7 support and service
For a conventional single hoist STS Personnel in maintenance and may be perceived as worth the investment
crane, the advantages of such automation engineering departments must possess solid by both parties since the costs can be
systems are obvious, but these become even knowledge of the system. An STS crane distributed over several installations. Once
more so if one studies a dual hoist STS cannot be quickly replaced like a robot on a again, this is not a one-size-fits-all matter;
crane where non-beneficial portions of the production line; it must be constantly each terminal must analyse the situation
cycle time can be expended for landing maintained. This requires skilled personnel based on its unique circumstances.
loads on vehicles. With the help of and management that understand the Reputable crane system suppliers provide
automation, which can determine the importance of time being allotted to support from crane-certified engineers with
positions of vehicles while the crane is maintenance, modifications or additions. documented experience in the industry and
moving from the ship, there are major gains Because operational priorities at a busy knowledge of the systems.
in time – and subsequently money – to be box terminal can naturally cause preventive The container handling industry is truly
made for large and modern STS cranes. maintenance to be postponed, each terminal global and crane users are often global
The system supplier can help crane must conduct an analysis of its particular operators with world-class demands on
operators to work much more intelligently situation – there is no one-size-fits-all service, support and spare parts supply.
and economically, and with lower energy solution – and based on the results of the These world-class demands must be met by
consumption, while shortening cycles. analysis, appropriately train its personnel. the system suppliers and often exceeded if
Increasing berth productivity, however, Actually, mechanical breakdowns on they are to remain in business.

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S Y S T E M S : Quay crane technology

management system (CIMS). A CIMS is market satisfies the demands placed on the
not intended to merely create long lists of system of an STS crane.
errors; it should also effectively guide the System suppliers prefer to undertake full
person troubleshooting to the right location responsibility for functionality due to their
in the hardware or software documentation. extensive experience in manufacturing
A CIMS is an important tool for reducing electrical equipment for crane applications,
crane downtime, and a simple and user- resulting in reliable systems with high
friendly CIMS, which is also powerful and availability. Such systems should be
intuitive, helps to increase the productivity modularly designed, easy to work with,
of STS cranes. electrician-friendly and have proper
Receiving all information on an onboard documentation that is prepared after
crane maintenance station (CMS) from a commissioning and then preferably entered
Using a crane maintenance station in an office or land station located in an office or vehicle is into a CMS for quick and efficient
vehicle is now more the rule than the exception
today more the rule than the exception. troubleshooting as necessary.
Artificial intelligence systems that learn from The integration concept also encompasses
Even if the systems are designed and built their experiences are surely the dream for responsibility for the correct dimensioning
with considerable demands on quality, spare the majority of crane engineers and of transformers, frequency converters and
parts may be needed. Between different maintenance technicians. motors based on data provided, but also that
terminals, as well as between operators, Three-dimensional views in the land the designs are based on the energy
there are various philosophies about how station over the docks and cranes are now conservation approach with, for example,
spare parts should be purchased and the routine and add additional information in energy-efficient motors, good engineering
type of support the system supplier should the form of even better overviews of the practices, optimally sized equipment,
provide. cranes. sectioning of floodlights – the list is long.
That an operator is global entails that Even if a system supplier is able to build Even in the integration of STS crane
rumours and information quickly spread systems that are technically advanced, easy systems, the system supplier influences the
around the world, and if a supplier has to maintain, inexpensive and that provide as productivity of STS cranes. cs
problems at one terminal on a continent, it high availability as possible, they
will not take long before knowledge of this nonetheless require maintenance. This
has spread to other terminals within the maintenance is, or should be, moving
group. Unfortunately, good news does not increasingly towards working with
travel as fast. Nonetheless, this helps system preventive maintenance rather than making
suppliers to stay on their toes and supply repairs when something fails.
spare parts in the shortest possible time. An airplane, or even a modern automobile
The life cycle philosophy also has an with indicator lights for service, is taken in for
effect on spare parts management, and not maintenance at specific intervals regardless of
least, on the costs for spare parts. whether anything is obviously in need of
Crane users must demand that their repair. A modern CMS supports this way of
system suppliers have a plan for the working and there must be counters, timers
products’ life cycles, for how obsolete and calendars to identify when certain service
systems and components are to be replaced tasks are to be conducted.
in the future, and to ensure that new The system generates histories, plans and
products are backward compatible with reports that effectively support personnel in
older products to a reasonable degree. A conducting maintenance at selected points
customer does not want to buy a system, in time. Proper maintenance results in fewer
only to be informed a few years later that unscheduled failures for any device, and
the investment is now obsolete and that the consequently higher productivity. A
price of spare parts has skyrocketed. correctly designed and configured CMS
Spare parts management, and service and gives STS cranes higher productivity.
support go hand-in-hand, and with good Moisture, vibrations, dust, electrostatic
support and efficient spare parts discharges (ESD), loose connections and Fredrik Johanson is general manager,
management at a level selected by the crane other difficulties in combination constitute a marketing and sales, for crane systems at
user, the system supplier has an tough environment for which to produce ABB, Sweden. He joined ASEA (ABB) in
unquestionably positive effect on the electrical systems, especially when they are 1984 as a Systems Design Engineer and
productivity of an STS crane. Moreover, to be inexpensive, easy to maintain, and at has held several positions in the company.
this effect applies regardless of whether the the same time, provide high availability. Johanson has a Bachelor of Science
crane is brand new or one that has been in To a certain extent, it is about choosing degree in energy engineering from
service for a few years. components that can withstand the Mälardalen University in Västerås, Sweden
Increasingly more technically advanced environment, especially outdoors, but it also and an MBA in project management from
cranes, perhaps with more automation, involves developing in-house components Linköping University of Technology in
require modern maintenance that can that are designed solely for crane Linköping, Sweden.
support a modern crane information applications when nothing else on the

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