The use of Simulation & Emulation in Container Terminal ...€¦ · Container Terminal Development and Operation Presented by Ashebir Jacob . GLOBAL PROJECTS (unmatched experience)

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)


9

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


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


•Introduction to the container

terminal development & operation



23

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

26

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

29

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


•Introduction to the container

terminal development & operation



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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Documents

The use of Simulation & Emulation in Container Terminal ...€¦ · Container Terminal Development and Operation Presented by Ashebir Jacob . GLOBAL PROJECTS (unmatched experience)