Twin 40 Dockside Cranes and Associated Terminal Operations AAPA Facilities Engineering Seminar - 2007 Arun K. Bhimani, S.E. President Liftech Consultants Inc. www.liftech.net Introduce yourself, Liftech … Dave Rudolf, VIT Robert Johansen, P.E. Planning Director DMJM HARRIS – AECOM

Presentation Outline Twin 40 Dockside Cranes – Arun Bhimani Terminal Operations – Bob Johansen Summary Comments – Q & A

Outline - Twin 40 Dockside Cranes General Information Head Blocks and Coupling Head Block Stowage Operational Issues Design Considerations

General Information We’ll start with Crane Procurement …

Typical Dimensions Rail Gauge 100 ft typical, some 115 ft Outreach 200 – 225 ft Backreach 50 – 75 ft Lift Height 136 ft Overall Width 88.5 ft

Lift Capacity – Under Spreader Up to 40 t Up to 60 t Up to 40 t 30 t 30 t 30 t 80 t Total 80 t Total 120 t Total Metric Tons

Speeds Main Hoist 60 t Single Lift 245 - 295 fpm 80 t Tandem Lift 245 - 310 fpm Empty 500 fpm Trolley 800 fpm

Crane Weights – Metric Tons Single Hoist DHT40 Increase 61 t 80 t Dead Load 1455 t 1860 t Trolley 27 t 50 t HB + Spreader 18 t 40 t Total 1500 t 1950 t 30% Rope Towed Trolley Crane in Typhoon Area

Operating Wheel Loads – Seaside Type Single Hoist DHT40 Increase 80 t Service 42 k/ft 56 k/ft 33.3% Factored 60 k/ft 81 k/ft 37.5% (ASCE) - Rope Towed Trolley Crane in Hurricane Area - 8 Wheels per Corner

Single Hoist Dual Hoist Bromma

Single Hoist Twin 40 Advantages Use with single hoist cranes Multiple spreader suppliers Disadvantages Remove twin 20 spreader Spread sheaves on trolley Add twin 40 spreaders Store on ground when through Initial tandem 40 operation with existing STS cranes promoted by the spreader manufacturers Source: Bromma Presentation

Dual Hoist Twin 40 (DHT40) - Shanghai

Number of DHT40 Cranes – ZPMC PRC Other* Total Delivered 37 10 47 On Order 31 49 80 Capacity 80 t 90% 100 – 120 t 10% * Primarily Dubai, Singapore

DHT40 Machinery Two Main Hoists One Extended Trolley Complex Dual Head Blocks Special Operator Controls WS Hoist LS Hoist Suggest add to Mechanical

Extended Trolley Waterside Sheaves Two HB Power Cable Reels Landside Sheaves

DHT 40 Head Blocks The crane manufacturer taking back the DHT40 with purpose designed cranes

Operator’s Controls Left Console 8 Foot Switches Right Console

DHT Head Blocks Landside Waterside We’ll start with Crane Procurement … Waterside

Waterside Headblock Separating Cylinder Pitch Cylinder Yaw Cylinder

Landside Headblock Ball clamp extended Ball clamp retracted

Headblock Relative Motion Translation Vertical offset Separation and Relative Skew Control 500 mm

DHT40 Challenges

DHT40 Challenges

DHT40 Challenges

DHT40 Challenges

DHT40 Challenges

DHT40 Challenges

Head Block Stowage We’ll start with Crane Procurement …

DHT40 – Headblock Stowage For single hoist operation, unused headblock and spreader “two blocked” to trolley Converting from single hoist to dual hoist without outside assistance

DHT40 Challenges

DHT40 Challenges

DHT40 Challenges

DHT40 Challenges

DHT Operations We’ll start with Crane Procurement …

Ship Side Landside Typical Tandem 40 operation

Ideal Ship Stow

Ideal Land Side Operations Bomb carts in position Extra bomb carts in line behind Evenly stacked deck containers Same height containers

Not an Ideal World Efficient headblock uncoupling and re-coupling is required

Bomb cart landing

Simultaneous Entry Staggered Entry

Spreaders repositioned while handling two containers of differing size Head Block Coupling Spreaders close together and level while handling two containers of the same size and working within cell guides Spreaders spread apart and not level while handling two containers of differing size and spotting containers onto yard chassis Hydraulic cylinder used to accommodate container geometry and space the spreaders Spreaders repositioned while handling two containers of differing size

Productivity Potential DHT40 is expected to be at least 50% more productive than a single lift crane. Crane Type FEU Potential Single-Lift 25 – 30 Dual-Hoist 35 – 45 FEU – Forty-foot Equivalent Container Moves per Hour; Single Cycle

Productivity Challenge Efficient Head Block Coupling Operator’s controls Operator training Terminal infrastructure

Design Considerations We’ll start with Crane Procurement …

Fatigue Design Criteria – Single Hoist Lift Capacity 61 t Fatigue Load 38 t

Fatigue Design Criteria – DHT40 Lift Capacity 60 t – Landside 40 t – Seaside Fatigue Load 38 t – 4 x 106 Cycles; Landside or 50 t – 2 x106 Cycles; Total

Fatigue Spectrum Single Cycles Waterside Double Cycles

Snag Load Head block and empty spreader traveling at high speed striking the cell guide

Summary – DHT Cranes Predominantly 80 t Capacity Landside 60 t, Seaside 40 t Premium Over Single Hoist Weight 30% Wheel Loads 30% – 40% Potential Productivity Increase 50%

What is Next? Triple 40 We’ll start with Crane Procurement …

Triple 40 100 t Total

Triple 40

Terminal Operations Circa 1960

Summary Twin 40 Cranes are Here Primarily Used for Trans-shipment Hubs Twin 40 Content Average 20% Increase over Single Hoist Crane Weight – 30% Wheel Loads – 35%

Is the DHT40 Crane For You? Summary DHT40 Crane Design still Evolving Productivity Potential 50% Operator Training Infrastructure Planning Is the DHT40 Crane For You?

Your Comments We’ll start with Crane Procurement …

Acknowledgements Engineering and Operations Personnel Hutchison Port Holdings Yantian Int’l Container Terminals Modern Terminals Limited Dachan Bay Container Terminals ZPMC McKay International Engineers

www.liftech.net Thank You This presentation is available for download on our website: www.liftech.net

Liftech Consultants Inc. file data: N:\Papers & Presentations\!Working\2007_AAPA_T40/AB tandem.ppt Copyright 2007 by Liftech Consultants Inc. All rights reserved. This material may not be duplicated without the written consent of Liftech Consultants Inc., except in the form of excerpts or quotations for the purposes of review. The information included in this presentation may not be altered, copied, or used for any other project without written authorization from Liftech Consultants Inc. Anyone making use of the information assumes all liability arising from such use. Quality Assurance Review: Author: Arun Bhimani Editor: Teresa Ferguson Principal: Arun Bhimani