Extending the life of quay cranes at ECT

Hutchison Ports ECT Rotterdam (ECT) faces increasing technical problems with its quay cranes due to years of intensive use. This has led to frequent maintenance and welding repairs. Despite the work carried out to repair the cranes, additional inspections are necessary, requiring a structural solution. By continuously monitoring ECT’s quay cranes, we extend their lifespan. 

Iv started monitoring the quay cranes in Rotterdam. What does this monitoring entail? First, we review the cranes’ technical documentation. Then, we model the crane structure, analyse the so-called container handling movements, define an equivalent fatigue load, and perform a life cycle assessment according to the EN 13001 standard. Based on these insights, critical points can be identified. Iv then equips these critical points with sensors for continuous monitoring. If the data collected raises concerns, Iv provides immediate advice.

The monitoring method used is unique and largely unknown to crane operators. Correct implementation requires specialist knowledge of the structure and fatigue. We place sensors in precisely the right places on the quay cranes to obtain the necessary information. Although Iv is experienced in life calculations, combining this with sensor placement requires precision and care. Mistakes in placement can have major consequences, which is why we apply internal verification checks to ensure the correct installation of sensors.

Previously, the quay cranes were inspected twice a year. This was a very time-consuming and costly exercise. Iv’s new monitoring approach provides constant and up-to-date monitoring of the crane’s condition. Physical inspections, such as TOFD measurements, are no longer necessary as they provide only a snapshot of the crane’s condition. With the new approach, sensors collect data continuously, allowing us to identify and address problems early, saving time and costs and thus extending the life of the quay cranes.