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Modification and Relocation of Modification and Relocation of Container HandlingContainer Handling
CranesCranes
A presentation & case study by A presentation & case study by Portek International LtdPortek International Ltd
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Scope of our PresentationScope of our Presentation•• Introduction Introduction
( Who is Portek/Experience List/Key Customers )( Who is Portek/Experience List/Key Customers )
•• Crane ModificationCrane Modification(General introduction; FE simulation; Real world; Simulation (General introduction; FE simulation; Real world; Simulation vsvs design)design)
•• Crane/Crane/RTGsRTGs RelocationRelocation
(General introduction; FE simulation; Real word; Simulation (General introduction; FE simulation; Real word; Simulation vsvs design)design)
•• Accident RepairsAccident Repairs(Case Studies)(Case Studies)
•• Conclusions Conclusions
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The First Ship Crane1958 (Matson Navigation )
is capable of handling feeder vessels only
Crane vs. ShipToday’s Post-Panamax
Container Ship – 15/16 rows across
Today’s Container Crane must be capable of handling 22 rows wide vessels
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Brief Introduction of PORTEK
•Established in 1988.•Leading Provider of Equipment, Services, and Solutions to the Global Port Industry.
Company’s competencies shall include:
Technical Services - Design and Engineering Services
Crane Modification & Modernization
Crane Drive System Integration & Automation
Crane Mobilization & Relocation
Crane/Equipment Sale & Leasing
Knowledge of Crane Components
Crane Maintenance/Diagnostic Services
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Portek’s core business includes :
Crane & Equipment Sale & Leasing
Crane Mobilization & Relocation
Crane Modification – Span change
Crane Repair & Diagnostic Services
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Crane RelocationCrane Relocation
1988 to present – moved more than 200 cranes
Crane Modification Crane Modification –– geometry changesgeometry changes
1988 to present – modified more than 70 cranes
Crane Modernization Crane Modernization –– Drive retrofit/CMS/PLC etcDrive retrofit/CMS/PLC etc……
1993 to present – upgraded more than 150 cranes
Portek Experience ListPortek Experience List
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OUR CUSTOMERS ARE MAINLY PORT & TERMINAL OPERATORSOUR CUSTOMERS ARE MAINLY PORT & TERMINAL OPERATORSPSA Corporation Ltd ( Singapore ) & PSA Sical Terminals Ltd ( PSA Corporation Ltd ( Singapore ) & PSA Sical Terminals Ltd ( India )India )P. T. (P. T. (PerseroPersero)) PelabuhanPelabuhan Indonesia 1, 2 & 3 (Indonesia) Indonesia 1, 2 & 3 (Indonesia) Hutchison Ports in (H K, Myanmar, Panama, Mexico)Hutchison Ports in (H K, Myanmar, Panama, Mexico)PT. Jakarta International Container Terminal (Indonesia)PT. Jakarta International Container Terminal (Indonesia)Kelang Multi Terminals Sdn. Bhd. (Malaysia)Kelang Multi Terminals Sdn. Bhd. (Malaysia)P & O ports ( Botany Bay Sydney, Australia )P & O ports ( Botany Bay Sydney, Australia )Thai Laemchabang Terminal Ltd. (A2, Thailand)Thai Laemchabang Terminal Ltd. (A2, Thailand)Modern Terminals Ltd. (Hong Kong)Modern Terminals Ltd. (Hong Kong)Vietnam Intl Container Terminal (Vietnam)Vietnam Intl Container Terminal (Vietnam)PT Riau Andalan Pulp & Paper (Indonesia)PT Riau Andalan Pulp & Paper (Indonesia)Penang Port Sdn Bhd (Malaysia)Penang Port Sdn Bhd (Malaysia)PT. Terminal Petikimas Surabaya (Indonesia)PT. Terminal Petikimas Surabaya (Indonesia)
Key Customers Key Customers
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Crane Modification
Geometry changes
Performance changes
Operational changes
Retrofits
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Geometry changes
1. Increase outreach
2. Increase lift height
3. Rail gage change
4. Miscellaneous changes
Crane Modification
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Case 1 ==== Increase Outreach
Aims:
1. Extend boom 4.5 m
2. Strength & Fatigue
3. Design method
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FE Simulation
Solver: ANSYS/Mechanical
Elements: PlateBeamBarJoint
Models:1. Original boom 2. Extended boom without moving lug3. Extended boom by moving lug
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Loading conditions and load combinations (BS)
Operating Overload Fatigue Load name OP-1 OP-2 OL-1 OL-2 FL-1 FL-2
Dead load DL DL DL DL DL DL Trolley load TL TL TL TL TL TL Lifting system LS LS LS LS LS LS Lifted load LLE LLE LL’ LL’ - LL’’ Impact - IMP - - - - List LIST LIST LIST - - - Trim TRIM TRIM TRIM - - - Trolley lateral load - LATT - - - - Gantry lateral load LATG - - - - - Trolley skew load - SKT - - - - Operating wind load - WLO WLO - - - Earthquake load - - - EQ - -
For example: OP1 = DL+TL+LS+LLE+LIST+TRIM+LATG
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Simulation results Von-Mises stresses for all cases (Unit: MPa)
Loading Position
Load Case Model 1 Model 2 Model 3
OP-1 182 272 193 OP-2 203 304 214 OL-1 171 257 181 OL-2 156 236 165 FL-1 86 130 91
Severe Position
FL-2 135 204 143 OP-1 66
(106/79) 74
(104/74) 78
(128/86) OP-2 74
(116/92) 73
(113/84) 92
(136/107) OL-1 63
(102/77) 67
(100/72) 78
(121/91) OL-2 62
(106/78) 69
(105/75) 74
(127/92) FL-1 40
(60/40) 48
(58/37) 44
(73/49)
Normal Position
FL-2 51 (86/64)
59 (84/59)
76 (103/63)
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Simulation results & Comparison
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FE Analysis of lifting Lug at Mast Top
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Real World
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Simulation vs. Design
Extending the boom by moving the lug with the same length is a good scheme;
A certain reinforced component attached the lug is suggested.
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Case 2 ==== Height Increase
Aims:
1. Increase height 5.0 m
2. Strength & stability of jacking tower
3. Design method
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FE Simulation
Solver: LS_DYNA
Model: Inner tower & Jacking components
Key point: Multi-surface contact
Loads:1. Overall crane weight 2. Lateral wind
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Simulation results
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Simulation results
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Facing the Real World
Components to equipment
Jack up 1 m
Jack up 5 m&
Insert new leg
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Simulation vs. Design
The jacking procedure is safe despite contact stresses are high;
The stress on the pin is quite low;
Local modification of the jacking section is suggested.
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Crane Relocation
Principal Points of Consideration:
Ship motions and accelerations
Wind force
Ship & Crane stability
Crane strength
Lashing design
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Case 1 ==== Crane’s Relocation
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Case 1 ==== Crane’s Relocation
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Case 2 ==== RTGs’ Relocation
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Case 2 ==== RTGs’ Relocation
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Simulation vs. Design
To make sure that the relocation process is reliable:
1. Strength of Crane/RTGs is permissible;
2. No stability problem;
3. Deck has sufficient strength.
To suggest a more reasonable lashing scheme.
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1 unit Quay Crane moved from PSA to 1 unit Quay Crane moved from PSA to BantenBanten
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A Modified QC at A Modified QC at BantenBanten
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2 Quay Cranes & 2 RTG moved from PSA to VICT2 Quay Cranes & 2 RTG moved from PSA to VICT
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2 Quay Cranes in operation at VICT2 Quay Cranes in operation at VICT
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2 RTG Cranes in operation at VICT2 RTG Cranes in operation at VICT
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Relocation of 2 QCs in PSA from KT to BTRelocation of 2 QCs in PSA from KT to BT
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3 3 UnloadersUnloaders moved from Hong Kong to Indonesiamoved from Hong Kong to Indonesia
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2 QCs moved from Thailand to Indonesia2 QCs moved from Thailand to Indonesia
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Span Modification of cranes in IndonesiaSpan Modification of cranes in Indonesia
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Relocation of 7 QCs & 32 at MTLRelocation of 7 QCs & 32 at MTL
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Relocation of 2 QCs from PSA to DubaiRelocation of 2 QCs from PSA to Dubai
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Span Change of 9 RTGC in DubaiSpan Change of 9 RTGC in Dubai
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1 IHI QC moved from Taiwan to Tuticorin, India1 IHI QC moved from Taiwan to Tuticorin, India
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Span ChangeSpan Change
SkiddingSkidding
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Outreach ExtensionOutreach Extension
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Accident DamageAccident Damage
Survey &Survey &
RepairRepair
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Crane Collapsed in Surabaya due to Wind
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Hitachi container crane boom destroyed by vessel collision
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Manufacture & transport of new boom
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Installation of Installation of replacement replacement
boom boom designed by designed by
PortekPortek
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Another Incident of Boom Damaged
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Dismantling of Boom for Repair
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850T ship unloader crane & conveyor damaged by vessel collision
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850T ship unloader crane & conveyor damaged by vessel collision
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850T ship unloader crane after repair
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Panamax Quay crane damaged by vessel collision in Dunkirk
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Panamax Quay crane damaged by vessel collision
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Survey & Repair
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Survey & Repair
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Survey & Repair
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ConclusionsConclusions
• Modification and relocation of cranes are a part of the core businesses of PORTEK.
•A reasonable design & accurate simulation methods are required for a successful modification project .
• In the real world it is often complicated to do the works, so we believe that simplification is the key to carrying out the numerical simulations.
• Techniques can often be improved through research & time but experience to do the work is critical to ensure successful completion & customer satisfaction.
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Questions & Answers Questions & Answers