Design of Terminal Lay Out and Handling Systems

Container terminals operators have to adjust their terminals to future container development.

This can be a new terminal, a terminal extension, or improving the terminal so that it can handle more volume. In all three cases, the handling system (yard and transportation equipment), the terminal control system (TOS) or the equipment specifications need to be (re)considered. Today's key issues concerning terminal (re)design are:

• What is the required quay length, stacking size, and number of quay cranes to facilitate future container growth and modal split distribution?
• What is the best horizontal transport systems and yard handling system to meet today's and tomorrow's performance requirements, handle future vessels, and still operate in a competitive cost-efficient manner?
• How to handle the increased complexity of large scale operations at high density; what software systems are available on which algorithms are necessary to manage these operations?
• What are the long-term investment costs and operational costs if the terminal is changing from the current terminal handling system to a high-capacity handling system?

TBA project approach

The approach of TBA Nederland is to:

• Analyse, acquiring a detailed understanding of the operational conditions and processes.
• Quantify the effect of different handling systems, improvement measures and other solutions.
• Decide, providing clear insight for the customer what the consequences of different courses of action are.

A sound terminal design is always unique considering local circumstances, cargo flow, peak handling requirements, and operating legacy. On top, the designs must meet the requirements in operational and investment costs.

Our project approach can be characterised by iteration and interaction with the customer, designing in close co-operation a design that fulfils the objectives, and is a result of joint work. It is typically based on best practices from previous projects, whenever applicable.

One of the high density terminals designed by TBA being constructed (Norfolk, Virginia)

The project result

Using the technical know-how and experiences of previous projects we can offer the complete terminal design with good communication with the customer with optimal results:

• Number of quay cranes in relation to vessel service times.
• Future quay transport and stack handling capacity and number of ground slots.
• Equipment numbers for quay transport, stacking, landside handling for different terminal systems and different growth scenarios.
• Terminal handling system performances in service levels, occupancies, investment costs and operational costs.
• Layout for the terminal, including all main functions.
• Custom-made terminal operating system functionalities.
• Custom-made terminal equipment specifications.

TBA focuses in its design on the logistics, whereas others (should) take care of the civil engineering, electrical engineering, and so on.

TBA developed detailed simulation models, for all major terminal handling systems available (including automated systems) to assist this approach.

Advanced high density solutions for any type and size of terminal

TRAFALQUAR strategic model

TBA uses the TRAFALQUAR to assess the strategic key terminal performances. In the model a year of vessel arrivals, landside arrivals, berth assignment and quay crane assignment is simulated to assess berth, quay crane and stack occupancy. The model uses container volume prognoses, berth schedules, and all variations as input. The model can cope with the effect of locks and tidal influences. It results in an analysis of:

• Vessel service times.
• Required quay length and number of cranes.
• Required berth productivities.
• Required terminal transport capacity.
• Required stack size and stack handling capacity.

Based on Trafalquar the boundaries for further detailed design are set. So far, Trafalqaur has been applied successfully in about 60 studies world-wide. Several large terminal operators use Trafalquar in-house to support their business development.

TIMESquare design and handling system assessment model

TBA has developed the TIMESquare models for all major container handling systems. These models are used for the design and performance assessment studies for new and container terminals extensions, but also for improvement measures.

Example of TIMESquare simulation model of a terminal already in operation (Antwerp gateway)

Using the technical know-how and experiences of previous projects the following results are obtained:

• The specifications and number of (stacking & transportation) equipment for each considered system,
• The performance levels, and service levels.
• Future capacities and possibilities for further growth
• Design and evaluation of control strategies
• The impact of high density operations, operations including technological improvements such as tandem 40, dual cycling, pooling, etc.

TIMESquare exists for straddle carrier operations, RTG / terminal trucks operations, RMG operations in various configurations, forklift terminals, intermodal terminals, and fully automated terminals. The accuracy of the TIMESquare models compared to real-life operations is 5%. When necessary, the tool allows for replaying real operational data for longer periods of time (i.e. 6 weeks).

Real and virtual operations: with TBA's Timesquare simulation tool not far apart: achieving accuracy of 5%.

Cost analysis of container systems

TBA developed the Cost Analysis of container Systems Help tool (CASH) for the cost analysis and comparison of terminal operations. The model computes the investments, operational costs, revenues, and cash flow over a 20-30 year period. In the tool the following components are included:

• Development in the number of cranes and pieces of equipment during 20-30 years.
• Investment costs in infrastructure and equipment including pavement, rail tracks, IT-infrastructure and equipment improvement during its lifetime
• Operational costs of operations including energy consumption, maintenance costs
• Number of labour hours on a yearly basis separated for terminal operations (incl. Housekeeping), maintenance, and terminal control

Based on typical financial indicators such as the cost per move, the Net Present Value, and the payback period a financial assessment of various alternative systems can be made.

Resume

TBA has a long track record of 10 years design and analysis of container terminal operators. Working with the largest operators word-wide, the TBA team is familiar with state-of-the-art technology, the various software systems available on the market, and best practices for terminal operations. TBA has the largest team world-wide dedicated to designing terminal logistics and optimizing operations.