container terminal planning & operations · •high power consumption –1280 w x $0.146/kwh =...
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Container Terminal Planning & Operations
American Association of Port Authorities
Marine Terminal Management Training Program
Long Beach, California
June 9-13, 2013
Thomas Ward, PE/SE, D.PE
Chief Engineer
Ports America
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Latest Trends – This and That
• Marine terminal lighting technology
– Light emitting plasma and other new technology
• Ships and cranes
– 8-high on deck and its implications
• New terminals in old boundaries
– Automating the original terminals
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Terminal Lighting Technology
• Virtually all terminal lighting is done with high-pressure sodium (HPS) fixtures mounted on high-mast light towers
• These are typically “1000 W” fixtures
• Poles range from 80’ to 150’ in height
• Pole spacing is usually on the order of 3.0 to 3.5 times the pole height, typically 250’ to 400’
• Poles have rosettes of 8 to 12 fixtures per pole
• Maintenance is done by longshore mechanics
• Each pole and foundation costs ~$300,000
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Regulatory and Safety Environment
• Lighting of the working areas of marine terminals is governed by 29 CFR 1917.123 (OSHA/NMSA)
• This requires: – 5 foot-candles “minimum average” in marine terminal
working areas
– 1 fc minimum
• Engineers limit Maximum / Average to 3:1 or less
• The regulation is silent as to how this is to be measured or established
• Traditionally, this has been done with lighting models prepared by the light fixture vendors
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Limitations of HPS
• High power consumption
– 1280 w x $0.146/kWh = ~$818/fixture/year (California)
• Short replacement cycle
– 10,000 hours to ballast and fixture replacement (2 yr)
• High light pollution
– Fixture design relies on glowing housing to spread the light, which causes substantial sky glow
• Poor light quality
– Light is in the pink-yellow part of the spectrum, not optimized for human night vision
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Outer Harbor Marine Terminal, Oakland
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175 gross acres of marine terminal
107 high-mast light poles, 8 to 12 luminaires each
1,000 luminaires total
About 1 MW in total power consumption by lights
Massive light pollution from this and other facilities
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Light Emitting Plasma
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LEP Test Installation at OHMT
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LEPs vs. HPS at OHMT
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At Luminaire Height
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!
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LEP Numeric Results vs. OSHA Requirements
• OSHA Minimum Average: ≥ 5 fc required, 5.1 achieved
• OSHA Minimum: ≥1 fc required, 1.3 achieved
• Uniformity: ≤3:1 required, 2.1 achieved
• With new LEP lamps, OSHA requirements are met
• Color is substantially improved
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Summary
• LEP effectiveness established
• Payback for new: 1.5 years
• Payback for replacement: 3.2 years
• Substantially improved visibility
• Substantially improved uniformity, spread
• Substantially reduced light pollution
• Substantially improved control
• Substantially reduced maintenance
• Energy consumption reduced >50%
• All on the current light pole system
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Alternatives to LEP and HPS
Light-Emitting Diode
• Each emitter is small, 100s of emitters per fixture
• Very pointable
• Very sensitive to heat, so large heat sinks required
• Result is a heavy head, about 95 lbs, to achieve current lumens/fixture
• Capital cost the same as LEP
• Energy savings a bit more than LEP
Metal Halide
• Each emitter is large, and can produce a lot of light
• Mirrors can direct as needed
• Not a lot of energy savings
• Not a lot of capital savings
• A good option if you are stuck with very long pole spacing and need more light
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Ships and Cranes
• Shipping lines have long predicted ships of 20 to 24 container stacks across on deck
– Beam up to 200 ft or 61 m
• No one really predicted that ships would get a lot taller, up to 8-high on deck
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The New Monsters
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A Bit of Perspective
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Dock Gantry Cranes – Target Envelope
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Outer Harbor Crane Array
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Outer Harbor X434/X435, Mean Tide, 3o list
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Potential Crane Modifications
• To be fully capable:
– Raise X438/X439 by 34’, extend by 24’
– Raise X434/X435 by 32’, extend by 17’
• Issues:
– Mechanical capabilities - ropes, drums, drives
– Productivity - drives, motors, speeds, duty cycles
– Frame structural strength - boom, frame seismic
– Wharf structural strength - rail girders
– Wharf tie-downs and stowage pins
– Power supply and demand – terminal and wharf
– Cranes may need to be shuffled
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Choices
• There are only three possible responses to bigger ships
• 1. Do nothing
– Keep going with what you have
– Forego new freight and revenue from big ships
• 2. Modify existing cranes, if possible
– Raise and extend
– $1.0M to $2.0M per crane, 30 to 60 days of downtime
• 3. Build new cranes
– $11.0M to $12.5M per crane, depending on location
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New Terminals in Old Boundaries
• We are being asked to consider the application of new automation technologies in old terminals
• Automation likes nice, rectangular shapes
• Most automation to date has been deployed on new sites, which can be made rectangular
• Existing sites are what they are – changing shapes is difficult
• We must work with what we have, and adapt technologies to suit
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Greenfield Rectangles are:
• Flexible
• Efficient
• Productive
• Capacious
• Easy to lay out
• Easy to design
• Easy to build
• Lack pesky constraints
• …and exceedingly rare
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Not Everything is a Greenfield Rectangle
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A Case in Point: West Basin Container Terminal
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Existing Wharves
New Wharves
Refinery
River
Rail Yard
South Yard
North Yard Bridge
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Challenges
• No rectangles, anywhere
• Port is rebuilding the wharves to ease navigation and increase crane gauge from 50’ to 100’
• Uncertain future access to refinery area
• Split terminal
• And a desire to convert this to a high-performance automated facility for very large container ships
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Imposing Rectangular Thinking
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Assume Kinder Morgan Site
Extremely Long ASC Blocks
No Way to Get There from Here
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Perpendicular to Berth 122?
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Perpendicular to KM Boundary?
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Parallel to Both Berths?
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Rebalanced with KM?
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What’s a Planner to Do?
• There is no obvious “best” solution that perfectly balances:
– Capacity
– Productivity
– Efficiency
– Phaseability
– Flexibility to use or not use Kinder Morgan
– Accessibility from North Yard to rail yard
• Something unorthodox is required…
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An Unorthodox Solution
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8w 5h ASCs
AGVs
Manual Trucks
CRMG Rail Yard
Zipper Grid
Phased Capacity
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Zipper Grid
• Zipper Grid concept allows yard/truck interface in a very compact space
• Overhead bridge crane, very similar to an ASC trolley, shuffles boxes across the wall: 1 OHBC per six pairs of slots
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But will it work?
• Detailed simulation analysis
– Equipment counts, Productivity
– Inter-yard transfer performance
– Congestion relief
– Resource allocation paradigms
• Detailed phased financial model
– Equipment
– Manning
– Management Labor
– Capital and Operating Costs, Revenue Phasing
• …Yes!
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Current Layout, 2.2M TEUs
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Rail Yard, Berth 126 Yard, to 2.6M TEUs
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Dredge, Fill, Berth 122, to 2.9M TEUs
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Future Expansion into KM
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Future Buildout, 3.3M TEUs
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From Past to Future through Present
• Many “Terminals of the Future” will be built atop “Terminals of the Present”
• We must adapt to big ships using big, fast, efficient cranes backed by dense, fast, efficient yards
• We will use our existing terminal resources
• We will reconfigure yards while operating
• We will run “two terminals in one”
• We will have parallel resources (TOS, etc.)
• We will flex manned and automated models
• We will cope with construction
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