Rubber Tyre Gantry Crane

Rubber Tyre Gantry Crane

Crane Automation for Container Freight Station (CFS)

CONTAINER FREIGHT STATION

The Challenge

Situated in JNPT port, Navi Mumbai (Maharashtra), the customer boasts a long-standing presence as one of the oldest Container Freight Stations (CFS). They approached Velox with a unique challenge: the need to retrofit the entire electrical, automation, and control systems of an outdated Hitachi RTG Crane model.

Executing crane jobs necessitates proficiency in both drives and PLC systems, as critical logic operations are indispensable for ensuring safety and synchronizing diverse crane movements. 

Moreover, cranes typically have an E room to accommodate all system components. Constructing such E rooms demands a high level of skill and expertise. Furthermore, retrofitting cranes often involves the conversion of high-rating DC motors to AC motors, enhancing operational efficiency and performance.

The Solution

In crane automation, the domain is typically dominated by industry giants like Siemens and ABB. This sector demands a distinct level of expertise, given the high power ratings involved. 

Velox Automation's remarkable prowess and expertise allowed us to emerge victorious in a fiercely competitive landscape, securing the project amidst major players like ABB. Velox Automation showcased its unwavering commitment to excellence as one of the rare system integrators equipped to tackle intricate projects internally.

Project Handling
 
  • Velox successfully undertook a comprehensive turnkey retrofitting project encompassing mechanical, electrical, and automation systems.
  • Shutdown project necessitated meticulous planning and execution within a constrained time frame to ensure successful completion of all tasks.
  • DC motors were replaced with AC motors, bringing about enhanced performance and efficiency.
  • Siemens made AC motors of S4 duty cycle were selected.
  • Velox employed the latest Siemens AC drives, specifically the Sinamics S120, with Simocrane software, to control all system motions.
  • Siemens S7 300 PLC system was paired with a cutting-edge touch screen HMI for enhanced control and monitoring.
  • Velox built a complete E room and supplied the operator cable joystick and chair system.
  • The process involved dismantling the old systems and installing new ones. All necessary mechanical modifications for the installation of the new system were expertly carried out.

Why Velox Solutions Makes Sense

Velox exhibited remarkable efficiency by successfully executing the project within a tight shutdown schedule. The customer expressed high appreciation for the exceptional quality of work delivered by our dedicated team.

For the Client
 
  • The entire project was successfully completed well within the allocated shutdown time frame, allowing the customer the advantage of restarting operations a full day ahead of schedule.
  • Old system was replaced with the latest technology, resulting in improved efficiency and reduced operation costs.
  • Implementation of regenerative drives in the new system resulted in significant power savings, showcasing the remarkable energy efficiency achieved after installation.
  • Client realized the cost savings by entrusting the execution of the order to Velox.
For the Environment
 
  • Automation systems ensure precise and controlled crane movements, minimizing errors, improving safety, and reducing material waste.
  • Advanced technology features improve energy efficiency by optimizing power consumption and reducing wastage during crane operations.
  • Automation systems help reduce fuel consumption and associated greenhouse gas emissions.

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