the use of simulation & emulation in container terminal ...€¦ · container terminal...
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The use of Simulation & Emulation in Container Terminal Development and
Operation
Presented by Ashebir Jacob
GLOBAL PROJECTS (unmatched experience)
Services for Development of Automated Terminal Matrix (we provide a full service)
Services Moffatt & Nichol
Typical Simulation Consultant
Typical Infrastructure
Consultant
Typical Equipment
Vendor Master Planning Investment Advisory Basis of Design Simulation Interface Plan Equipment Specifications IT, Application Specifications Design (infrastructure) Procurement Process:
Equipment IT, Application
Program Management (infrastructure) Contract Management (equipment) Emulation Training Go-Live Support Optimization
The use of Simulation & Emulation in Container Terminal Development and Operation
(Agenda)
•Introduction to the container terminal
development & operation
•What is simulation?
•What is emulation?
5
Container Terminal Development & Operations
So, we port people only need to get our arms around a few little things……
CHANGE! Automation
Scrapping /
Cascading Capacity
Panamax vs Post
Panamax vs
Super Post
Panamax vs
Super-Duper Post
Panamax
Investment
Climate
Fuel Costs
Transit Time
vs Cost
Port
Productivity
Hinterland
Connectivity
VSA’s
Security
Seasonal
Peaking
IBC Handling
Technology
Appointment
Systems
IY Ground
Operations
The Chassis
Problem
Handling
Technology
ROI
Labor
Jurisdiction
& Costs
Vessel Size
The Internet IT Systems
Truck / Rail
Splits
Service
Consolidations
Infrastructure
Cost
Climate Change
Introduction to Container Terminal Development & Operations
•Floatation is, always and
forever, the best way to
move stuff on this planet
Introduction to Container Terminal Development & Operations (The Customer)
Introduction to Container Terminal Development & Operations
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Vessel - More than 13,000 ctr per call - Regular schedule with some variation - Demand for short port stay time
Train - “Call size” 600 or less - Tight and regular schedule
Truck “Call size” normally 1 to 2 ctr - Almost random appearance - Demand for short turn time
Container terminal - To handle - To store - To sort and consolidate
Critical Node In The Goods Movement Network
Introduction to Container Terminal Development & Operations Terminal productivity
• Top performers are at a BP of 163
• Customer is demanding a BP 250
• How to bridge the gap
• 50% BP improvement to meet the Voice of the Customer
Introduction to Container Terminal Development & Operations
11
E 3
The Business Case
Introduction to Container Terminal Development & Operations Define the Business Case
• At minimum the “Business Case” will include the following: – The business case will have required performance goals
Capacity – Annual throughput
Productivity – Vessel, gate, rail
Cost – CAPEX and OPEX
– In addition to the business case parameters, the “project” will occur in an environment that contains a unique set of opportunities and constraints
Land area and shape
Environmental requirements
Labor – cost, rules
Safety issues
A WELL-DEFINED BUSINESS CASE PROVIDES CLEAR PROJECT GOALS.
Planning and Layout – Tailoring to Fit the BC
• So, the planner is like a tailor
• He must try to fashion the terminal to fit the business case
perfectly
• One size does not fit all!
CAPACITY
• Annual throughput
PRODUCTIVITY
• Vessel
• Gate
• Rail
COST
• Facilities
• Equipment
• Labor
• Energy
Current Trends in Container Terminal Development (What is an “Automated” Terminal?)
Robotic Operation
Manned Main
Trolley
Automated
Secondary
Trolley
Automated
Horizontal
Transport
AGV’s
Container Yard
Automated
Container
Stacking,
Retrieval,
Shuffling
ASC’s
Semi-
Automated
Delivery to
Outside Truck
Vessel Outside Truck
Quay Crane
Path to Realization of Automated Terminals
DESIGN
Applications & IT HW Equipment Civil
IT Network
PROGRAMMING
MANUFACTURING FACTORY TESTING
CONSTRUCTION
LAB TESTING: EMULATION
Integration Testing
SITE TESTING
PROCESS FLOW TESTING
VOLUME TESTING
Automated Yard
Flavors CTA, Hamburg – nested Euromax, Rotterdam – 2 per block
Antwerp Gateway, Automated Truck Handling RWG, Rotterdam – End loading & Cantilever
Automated Yard
Busan Newport Jebel Ali
Virginia
Globally adopted
Lázaro Cárdenas
Automated Horizontal Transport
• First generation AGVs at ECT, Rotterdam
• Hybrid AGVs for a short time with us
• Fully electric
– Business case dependent on local energy prices.
• AGV - Coupled operation
• L-AGV - Semi Coupled operation
Conventional AGV (Toyota)
Full Electric lift AGV (GPT)
Automated Horizontal Transport
• Autoshuttle, first project
are there
• Casette AGV
– Not implemented yet
• Cassette Management adds
complexity
• Decoupled operation
Autoshuttle by Kalmar
Cassette AGV by TTS
Automated Vessel handling
Remotely Operated
Sway/Skew Control
Automatic Flight
Robotized 2nd trolley
Auto Lashing System
Crane OCR
ATH
Automated Vessel handling
Dual Trolley ZPMC/ABB STS at Euromax, Rotterdam
Remote Controlled STS at Qingdao
Remote Controlled/ Dual Trolley STS at APMT MVII
Automated Rail Handling
• Automated rail cranes are out
there
• Technically very similar to
ARMG in the yard
Automated RGC at APMT MVII, Rotterdam
Automated RGC at Warsteiner, Germany
Challenge
• How to avoid RGC is running over people working between the rail tracks
The use of Simulation & Emulation in Container Terminal Development and Operation
•Introduction to the container
terminal development & operation
•What is simulation?
•What is emulation?
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What is Simulation?
• An imitation of real world systems
• Include activities:
– Defining, designing, collecting, analyzing,
interpreting, and experimenting
• Based on behavior of parts,
With the purpose of obtaining insight in
the behavior of the whole system.
Why Simulation in Port Operation Optimization?
• The port logistics system is a complex discrete event dynamic
system, it involves all kinds of complex problems
• The most valid and efficient way of solving complex logistic system
is through system simulation.
• Through simulating terminals, decision makers can better
understand various statistics performance measures in the
transporting and storage processes, make informed decisions, and
achieve optimized results.
Berth CY Gate IY
Port Logistic Process Flow
Vessel
Main Benefits of Using Simulation for Terminal Planning • Better analysis of dynamic processes taking place in time and space
– Process analysis, conflict, traffic, congestion, exceptions, etc.
• Experiments involving individual process or complex combinations of
processes to verify productivities or compare alternatives
• Confidence in investment to stakeholders / investors
• Visualization of processes through animations
– Congestion, queuing, bottlenecks
– Presentation to non-technical stakeholders
• In summary: Higher Confidence, Lower Risk, Lower Cost, More Efficient
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What is FlexTerm?
• The first commercial off-the-shelf simulation package aimed at container terminal industry.
• FlexTerm is mainly used for the logistic system simulation modeling in ports and terminals.
• These models can be operated and observed as in the real word system or the conceptual system.
• Through the drag and drop 3D objects, FlexTerm can create any dynamic process simulation model in ports and terminals such as container terminal berth, container yard, terminal gate, rail yard etc.
Sample Simulation Results
Truck Queue Time Distribution
Truck Queue Length Distribution
Container Inventory
CH Equipment Utilization
Sample Simulation Visualization
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Garden City Terminal (GCT)
• Customer: GPA
• Description: Performed a series of simulation tasks
including cross-terminal road, rail system, E-RTG
simulation to support the terminal planning.
• Objectives: Specific to each task such as verifying the
intersection and road design, determining the best gate
locations, evaluating the impact of rail operation to
highway traffic, evaluating the congestions of various E-
RTG block configurations and compare the E-RTG
performances
Southern California International Gateway (SCIG)
• Customer: BNSF
• Description: Simulated the near-dock rail
facility that uses dual-cantilever RMG to
unload and load containers from trains to
trucks or buffer area, and vice versa.
• Objectives: To verify layout, evaluate
capacity, and determine equipment needs.
Middle Harbor Terminal (MHT)
• Customer: Port of Long Beach & LBCT
• Description: Performed a series
simulation tasks such as CY, QC, TA, IY,
Road simulation for the 3.3M TEU fully
automated container terminal.
• Objectives: To answer varies questions
raised for master planning and BOD,
such as optimal layout, optimal crane
configuration, right size of TA and
holding area, verify road design etc.
Automated Horizontal Transport Simulation
• Customer: Gaussin
• Description: Performed a series tasks to simulate and compare performance of AGV systems including LOLO- and LIFT-AGVs and different layout configurations.
• Objectives: To determine number of equipment to support desired operation, identify potential bottlenecks, provide suggestion on improvements.
Case Study - Terminal Simulation Objectives • To estimate CY equipment needs
under various target throughput levels
• To estimate CY equipment and gate truck activities for emission analysis
Approach • Collect inputs and verify • Develop a simulation model to
simulate CY, gate, and berth using a true-to-scale approach
• Run model, collect statistics, present, and get feedback
• Revise model to produce final result
Sample Model Screenshot
Sample Model Screenshot
The use of Simulation & Emulation in Container Terminal Development and Operation
•Introduction to the container
terminal development & operation
•What is simulation?
•What is emulation?
37
What is Emulation?
• In our industry, emulation means connecting to real-world control
software such as TOS and (emulated) equipment control system
– Usually a third-party software
• Purpose is to create a virtual world to test real world control systems
Why Emulation?
• TOS is:
– Important
– Expensive
– Risky
• Emulation provides a way to
reduce cost and risk.
Emulated Terminal
Real World
TOS
Benefits of Emulation
• Save TOS development and test time and cost – Functional Testing: TOS debugging and testing
• Give terminal operator higher confidence on the TOS product before and after purchase
– Performance Testing: Stress test, upgrading TOS, evaluating TOS products
• Allow operators to study various scenarios without impacting real world operation
– Optimization and Analysis: Fine tuning parameters, historical scenario replay and analysis
• Allow operators to train planners and staff in a controlled environment and evaluate their performances
– Operator Training: It’s a virtual world!
Case Study - Emulation
Some of FlexTerm’s Key Customers Are
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