Ross Clarke

Technologies Supporting
Improvements in
Container Terminal Safety
A Global Operators Perspective
NMSA Annual Meeting
June 27th 2013
Ross Clarke
Head of Design & Innovation
• Introduction to APM Terminals
• Approach to Terminal & Process Design
• Experiences with Personnel Proximity
Warning Systems
• Load Collision Prevention for RTG’s and
STS Cranes
• Remote STS crane operations
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APM Terminals is one of four primary business units
of the A.P. Moller–Maersk Group
A.P. Moller-Maersk Group
The Hague, Netherlands
Copenhagen, Denmark
• 2012 Revenue: $59b USD
(Shipping, Energy, Ports)
• 117,000 employees in over 130
countries.
APM Terminals
The Hague, Netherlands
• 2012 Revenue: $4.8b USD
• 2012 container volume: 35.4m
TEUs (Container Volumes weighted by
equity share)
• 25,000 employees, 68 countries
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History: 55 years of innovation, growth and progress
1958
First dedicated A.P. Moller terminal facility opens, in the Port of New York.
1970s
Containerization begins to change patterns of global trade and growth; the company
opens its first dedicated container terminal at Berth 51, Port Newark, NJ USA.
1980s
Ongoing evolution of containerization and economic efficiencies of international trading
patterns lead to the rapid establishment of global port load centers and transhipment
networks, requiring highly coordinated and specialized container terminal operations and
equipment as vessels grow in size and capacity.
1999
Maersk Line acquisition of US-based Sea-Land Services enlarges scope of terminal
operations globally.
2001
APM Terminals is established as a separate container terminal operating company within
Maersk Line.
2004
APM Terminals becomes an independent corporate entity, with HQ in The Hague, Netherlands.
2006
Named “Port Operator of the Year” by Containerisation International Magazine.
2007
Revenue of $2.5 billion, $111 million profit; APM Terminals reports earnings separately.
2008
Only true Global Terminal Network in port industry; Focus on emerging market investment.
2009
Named "Port Operator of the Year" by Lloyd's List.; Revenue of $3 billion
2010
Inland services unit transferred to the APM Terminals; combined revenue of $4.2 billion
2011
APM Terminals named winner of Lloyd’s List Global Safety Award
APM Terminals: The world’s only geographically balanced
Global Terminal Network
Port and container terminal development, management and
operation, and associated inland services capabilities.
25,000 employees in:
68 countries
5 continents
2012 Revenues of
$4.8b USD
Customer base:
60
shipping lines
and leading importers
and exporters
62 operating ports
and terminals:
40 countries
7 new projects;
15 expansion
and upgrade
programs
Annual container
throughput:
35.4m TEUs
(by equity-weighted
volume)
68 inland services
companies in:
171 locations
48 countries
Global market
share of container
throughput:
5.7%
in 2012
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Protecting our people and the environment:
Safety and sustainability progress and goals in 2012
APM Terminals was named winner of the 2012
Signal Mutual Gerald H. Halpin Safety Excellence Award
Lost-Time Injury
Frequency Rate:
37%
To 2.42 per million man
hours worked for 2012
from 2011 (including inland
Reported injuries:
484
Continued decline for
combined marine and
inland services
services)
Global
Transformation
Project:
8%
Increase in crane lifts
per hour across the
portfolio in 2012.
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CO2 output per TEU:
4%
25% reduction from
base year 2010 is
the goal for 2020
MAGNUM advanced
management training:
Participation
70% of the 2012 MAGNUM
class came from
operations in emerging
market countries.
Workforce diversity
72%
of employees find APM
Terminals’ leadership to
be genuinely committed
to attracting, training
and retaining a diverse
workforce.
Our port facilities: A balanced global network
serving all major markets
Current Projects
Gothenburg
MV2
Vado
Poti
Algeciras
Izmir
Qingdao
Aqaba
Ningbo
Pipavav
Lazaro Cardenas
Moin
Salalah
Monrovia
Apapa
Pointe-Noire
Luanda
Callao
Santos
Itajai
Buenos Aires
Projects under
implementation
New Terminal Project
Terminal Expansion/Upgrade
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Tanjung
Pelepas
Our Priorities
Safety
Innovation
Productivity
Cost
Competitiveness
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Automated Handling Reduces Man / Machine
Interaction Risk
Personnel exposure to risk of accident
with heavy machines greatly reduced.
ASC operations greatly reduce traffic
collision risks.
Trucker safety during receival and
delivery greatly ops improved.
But, new risks need to be identified and
addressed such as; access to reefer racks,
procedures for working near ASC rails, and
for servicing broken down AGV’s.
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Personnel Proximity Detection & Warning
Objective : To provide a means of alerting mobile equipment
operators to the presence of people who are in close proximity to
the machine, thus improve the safety of personnel working in the
vicinity of mobile equipment.
• Method of alerting vehicle/machine operators to other vehicles
and personnel in their vicinity
• Provides an additional layer of protection, but cannot be a
substitute for good training and S.O.P’s.
Personnel Detection
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z%
SOP
y%
Driver Training
x%
Total %
Risk
Reduction
MineSite – Magnetic Field Technology
Around corner detection ability
typically:
•At 60m –Detects 20m around
corner.
•At 30m –detects 40m around
corner.
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Callao, Peru
Largest port on West Coast of South
America.
APM Terminals began operations
July 2011.
A multi-purpose terminal handling
both containerized cargo and general
cargo such as metals, grains,
fertilizers and chemicals, coal,
vegetable and fish oils and
machinery.
Extensive modernization plans will
transform APM Terminals Callao into
a benchmark for South American port
operations. The first two phases of
construction are expected to be
completed by 2015.
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ZoneSafe – RFID Technology
Implemented at APM Terminals Callao
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•
•
•
•
•
•
•
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Installed on 22 reach stackers in February
2013.
Needs to be modified so that system is
disabled when machine is stationary, to
eliminate pointless alarms.
Modifying system so that detection is only in
direction of travel being considered.
Technical operation is very satisfactory.
Detection ranges are accurate and
consistent.
Range of forward facing detection needs to
be reduced slightly to ensure truck drivers in
cab do not trigger an alarm.
Approx 1,000 tags will be issued to local
trucking companies, who make up approx
90% of all truck visits.
1,000 truck drivers have received 15 minute
training about the system.
Tags will be required pass through gates to
gain access to operational areas. Also serves
as a tag test opportunity.
ZoneSafe and AME Detection Zones can be Tuned
Detection range and shape of field can be accurately tuned.
An ability to vary detection range according to speed may also be
beneficial.
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RFID Tag Based Systems - Considerations
• A personnel proximity detection and warning system should only be
implemented after all non-essential personnel have first been
removed from operational areas.
• Up to date operational SOP’s and risk assessments need to be in
place prior to considering implementation of a PDS.
• Rigorous access controls need to be in place to ensure that people
in operational areas are wearing RFID tags.
• A process for issue, control and return of tags needs to be
implemented.
• Risk that equipment operators may become reliant on the warning
• System and tags will require regular checking and maintenance to
ensure correct operation.
• Alarms need to be infrequent events to avoid complacency.
Avonwood and AME record all alarms in a database to enable later
analysis.
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We Need To Eliminate This…
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RTG Stack Profiling for Load Collision Prevention
Stack profiling uses 3D laser scanners to build up a map of where
the containers are on a ship, or in a stack. Because the crane
“knows” where the containers are, damage due to accidental
impacts, or heavy landings can be virtually eliminated.
Knowing the shape of the container stack enables the “flight path” of
the container to be automated and optimized – reducing cycle time.
Now standard on all new RTG’s for APMT. Options for retro-fit to
existing machines under investigation
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We Need to Eliminate These Types of Accidents…
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Load Collision Prevention Systems for STS Cranes
• Soft landing systems being trialed
at APMT Elizabeth, NY, and
APMT Mobile, AL.
• System operation and operator
feedback are both positive.
• Requirement for load collision
prevention on all new cranes is
under consideration.
• Retro-fitting of load collision
prevention for existing STS cranes
under consideration.
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Remotely Operated STS Cranes
From this…
To this…
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Maasvlakte 2 – Remotely Operated STS Cranes
• Remote STS operations provide significantly improved working environment for
operators.
• Operator change overs will be more efficient than with conventional cranes.
• Soft Landing, and load collision prevention systems are an integral part of the
remote operating system.
• MV2 and ABB working with TNO1 to design ergonomically correct operator
stations and work environment.
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1. TNO is a Dutch organization with extensive experience in remote
operations of canal locks and bridges in The Netherlands.
Personnel detection – possible future application?
A possible further development of personnel proximity warning systems is to
use this technology to provide a warning when are working too close to STS
crane ops.
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