Extensions, upgrades and retrofits

Modernizations help terminals not only extend the lifetime of their assets but also improve efficiency and safety. Keeping your business moving with maximum efficiency and minimum downtime is ABB Port Service sole focus. Our global service offering includes value adding asset management services to optimize equipment performance, life-time and profitability. Whatever the system operation challenge is, we deliver an optimal solution.

Improvement and efficiency is vital to optimize performance and increase the lifespan with minimum downtime in a crane system. Let ABB asset management services move your business forward today.

Customer benefits
• Extended lifetime of the assets with low investment and fast ROI
• Turnkey projects with minimum impact on terminal's operations
• Improvement in productivity and efficiency of the equipment
• Higher level of safety
• Availability of spares and technical support
• Up-to-date IT systems with latest antivirus with option for remote diagnosis

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We handle the entire retrofit project

Whether basic essential improvements, upgrades or extensions are required, we handle every phase of the retrofit project - from design and engineering, to manufacturing new and/or reconditioning existing equipment, to installation, commissioning and the training of staff.

Typical modernizations

DC to AC drive conversion
DC to DC upgrade
AC to AC upgrade
Drive system - using DCS800 or ACS800 or ACS880
Upgrade third-party cranes by removing existing system and installing ABB equipment (or keeping third-party PLC)

Life cycle management for crane solutions

Crane drives and control systems

Environmental and energy savings solutions

Crane Information Management Systems Upgrade (CIMS)

Load cell replacement

Crane Drives and Control Systems (PLC) need to be updated at least once during the crane’s lifetime

The typical lifetime of a crane drive system is 10–20 years. After this, the availability of technical support and spare parts becomes more limited, and the drive system may become less reliable.
To achieve the full lifetime of the crane itself, the crane drive system needs to be updated at least once during its lifecycle.

ABB’s crane drives system update helps you achieve the full lifetime of your crane

ABB’s solutions save maintenance costs and increase productivity.
Upgrading gives access to the latest features and makes maintenance easier with faster delivery of spare parts and improved fault monitoring capabilities.

Modern crane drives with new electrical motors also improve the energy efficiency of the crane and simplify the crane operator’s work. This improves the whole terminal’s productivity.

ABB’s crane drives and control system updates include:

Replacing any existing DC drives with DCS880 drives or any existing AC drives with ACS880 drives. The existing electric motors can be reused in most cases.
The existing DC drives can be replaced with ACS880 drives. This requires new electric motors and also related motor cabling.
The existing crane control system by any provider can be replaced with AC800 or AC500 logics.
Solutions are available for most crane manufacturers and for most crane types in container, bulk and intermodal terminals, as well as in the shipyards.

ABB recommends upgrading/replacing the crane’s drive system at the same time with other modifications and replacements, since running projects simultaneously saves costs and shortens the total crane downtime.

Energy costs form a substantial amount of the crane’s lifetime costs

Improving the crane’s energy efficiency also improves its profitability.

Lower energy costs and more profitable operation with ABB solutions

ABB’s Environmental Friendly and Energy Saving Solutions for cranes help save energy for a cleaner environment and lower energy costs for more profitable operations.

ABB’s solutions for RTG cranes include:

Gpack: Two-speed Fuel Saver, which lowers the engine RPM during the crane’s idle period, saving energy and costs.

More sophisticated and comprehensive solutions for all cranes

Energy source and storage solutions.
Power quality solutions including Power Factor Correction (PFC) and Harmonic Filtering (HF).
Total electricity usage evaluation and optimization regarding quality and quantity like “kWh”, “kVARh”, “Peak Demand Charges” (PDC) and “Power Factor Penalties” (PFP).

Benefits of upgrading the ABB’s Crane Information Management System

Turnkey delivery, including engineering, mechanical and crane interface, latest software with licenses, components, installation and project specific deviations.
Software and hardware have been tested and approved.
Life cycle upgrades with different options:
- Hardware upgrade according to the computers’ life cycle and retaining existing functionality
- System upgrade including both hardware and software upgrades to the latest CMS functionality

Load cell system is a necessity for safe crane operation

The load cell system constantly monitors the crane to detect overload situations and helps to prevent breakage and serious accidents.
A broken load cell which ignores correct load indications or gives false ones is a major safety risk. Constant overload also reduces the lifetime of the crane.
Faulty or aged load cells can also create difficulties with maintenance, safety and quality concerns, and obsolescence of spare parts.

ABB provides a holistic solution for replacing faulty or aged load cells

ABB’s solution frees terminal operator’s maintenance personnel from time-consuming and possibly dangerous adjustment and calibration of existing load cell system.

Switch over contactor system

Crane gantry anti collision

STS-crane boom anti collision

ABB’s Switch over contactor system contains the removal of the mechanical latch of the original ABB switch over contactor (sizes from around 300A up to 1200A).
Typically with shared drives, e.g. Trolley / boom (engaged / disengaged & monitoring).
The mechanical latch contactor is often replaced by magnetic contactor and rewiring, studied case by case.

Collisions are a major safety risk for harbors

Collisions involving the crane gantry create a major risk for daily harbor operations and productivity, and personnel safety.

ABB’s Crane Gantry Anti Collision solutions improve the harbor’s safety and operations

With enhanced system diagnostics, ABB’s solutions prevent collisions on gantry cranes in gantry direction and on RTG’s on cross travel.
ABB’s solutions also improve the reliability of operations. Fewer unexpected failures also reduce possible crane downtime. This improves the efficiency of harbor operations.

Collisions are a major safety risk for harbors

Collisions involving the crane booms and ships create a major risk for daily harbor operations.

ABB’s STS-crane Boom Anti Collision solutions improve the harbor’s safety and operations

ABB’s solutions help advance the efficiency of harbor operations by improving reliability. This results in fewer unexpected failures, reducing possible crane downtime.
Preventing crane-to-ship and crane-to-crane collisions with enhanced system diagnostics.
ABB’s STS-crane Boom Anti Collision solutions are recommended by leading insurance company TT Club.

Related offering

24/7 remote technical support

Maintenance

Spares and consumables

Training

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