Container Terminal Simulation Software Improves Operating Efficiency

Simulation provider TBA of the Netherlands has developed an emulation tool that allows terminal operators to experiment off line with changes in terminal layout, equipment and operating practices and changes to the main terminal operating system (TOS).

TBA has linked their container terminal simulation software tool with various products from TOS vendors (e.g. Navis, Cosmos, RBS) and it is now offering its emulation tool as licensed product.

Simulation is well known in the container terminal industry and is most commonly used to model throughput, layout and equipment scenarios at new and existing terminals. Simulation uses a model of a container terminal and its operating system to predict outputs such as productivity, maximum capacity and even profitability based on software that creates a replica of the operating environment. Emulation is the process of testing hypothetical events through an actual control system, in the industrial control sector it is often referred to as soft commissioning. The advantage of emulation is that it gives a better picture of how an actual control system will respond to an external event or change in operating requirements.

Terminal Simulation Software - CONTROLS

TBA's emulation programme is called CONTROLS (Container terminal optimised logistics solution). It allows terminal operators to experiment with changes in the operating environment using the actual software that is or will be controlling the terminal. More importantly, it enables terminal operators to assess the configuration and performance of the actual TOS itself, and allows training operators in a harmless off-line setting.

Two snapshots taken from the 3D CONTROLS visualization. This visualization can run parallel to the experiment, or even show last night's operation in retrospect.

CONTROLS is a model of all the components of the terminal including quay cranes, yard equipment and road/rail interface. The dynamics of each piece of equipment and their interaction with each other are closely modelled and visualized so required scenarios can be tested in an accurate way. CONTROLS communicates with the TOS in the same way the actual equipment at the terminal does, via on-line messaging. The actual TOS itself, however, must be an off-line version rather than the system actually in use, however using the actual operational data.

Integrating CONTROLS with the TOS means many of the control parameters such as pooling rules and yard planning algorithms can be maintained in the TOS, whereas other simulation tools must replicate these key factors. The actual terminal layout is specified in the emulation tool, but this can be input directly from the TOS if the configuration (.ini) files are disclosed.

Operational Software Scenarios

The scenario to be tested is run through the TOS and CONTROLS. It either can consist of a replay of past operations (using real data), or scenarios for future operations, created by TBA's Scenario Management tool (SCENEMA). This tool allow evaluating the terminal in the future, to make sure, the whole set-up is still sound.

Experimenting speed depends on the operational scenario, and the ability of the TOS to speed up but past experiences shows that speeds up to 10 times real time can be achieved. On average 5 times real-time should be expected. However, parallel experimentation is enabled, so multiple settings can be compared in parallel, leading to a quicker turn-around of what-if scenarios.

To test a scenario the user configures the initial yard, plans the operation and runs the experiment. An experiment will typically cover 8 to 24 hours of operation, but CONTROLS is capable of running as long as the TOS controls the operation. If the TOS is not able to run with out an operator for an extended period then one is required for an emulation experiment as well. The experiment will be available for rerun as many times as wanted, and with as many settings of the parameters as required. A result database ensures access of the results over longer periods of time.

Terminal Simulation Software Means Better Results

CONTROLS can run in animation mode enabling the user to follow the execution of specific moves in a scaled 2D or 3D animation. All equipment is 'clickable', giving the user access to its main properties at a point in time (location, speed etc.). During the run the user can create visual representations of the yard that can be manipulated to show specific items, such as all the containers from a particular vessel.

Using the TOS means all the reports normally generated will be available but these are typically broad measures such as QC productivity and truck turn-around and not the detailed statistics needed to assess performance. CONTROLS offers much wider data including: crane idle time, road truck service time, yard vehicle productivity (productive and non-productive moves), status of stacking equipment, detailed equipment performance (travel distances, speeds etc.) and yard filling and utilisation characteristics. The output is provided in text files that can be loaded into a database (any type) and analysed in TBA's reporting tools, which comes as all-in-one solution with the license.

Emulation with CONTROLS offers the benefits of simulation with improved insight into the TOS and how it affects terminal operations. As terminal operators look to increase stacking density and improve productivity through optimising real time equipment control and planning the TOS is obviously increasingly important. Emulation allows the operator to observe the short and long-term effects of different configurations of the TOS parameters. It also enables TOS operators to be trained in a virtual environment. Experience with CONTROLS has been gathered in various projects where new software was introduced, or where optimization of the TOS was required. Easily performance improvements of up to 10% could be measured. Besides, many bugs were found in the software, avoiding negative effects during live operations.

Example of a static coming out of CONTROLS. In this case the effect of more vehicles on the productivity of the yard handling RMGs.