Retrofit and modernization of STS crane at port terminal
Company
Concasa Cádiz is a key company in port operations, specializing in the management and handling of goods using STS cranes for loading and unloading containers.
One of its main container cranes (Crane 2) required a complete retrofit of its control and drive systems due to technological obsolescence, an increase in incidents, and maintenance difficulties.
The objective was to modernize the crane while maintaining the existing mechanical structure, improving the reliability, safety, and performance of critical movements, and ensuring the availability of spare parts and long-term support.
Challenge
Design and implement a comprehensive retrofit project for an STS crane, replacing obsolete PLCs and drives with state-of-the-art equipment, and reprogramming the main lifting, traveling, and slewing movements.
The solution had to ensure operational continuity, movement precision, functional safety, and compatibility with the port terminal's existing systems.
Problem
- Obsolescence of the control system
The PLCs installed were no longer supported, making maintenance difficult and increasing the risk of prolonged downtime. - Old drives with high failure rate
The drives had technical limitations and a higher probability of failure, affecting the crane's performance. - Operational risk in critical movements
The lack of updates compromised the reliability of the STS crane's lifting, orientation, and translation movements. - Difficulty for future improvements
The existing system did not allow for easy evolution of the crane or integration of new functionalities.
Solution
How we do it?
A complete retrofit of the STS crane control and drive system was carried out, replacing obsolete equipment with current technology and developing new programming adapted to Concasa's operational requirements.
- PLC replacement
Installation of new industrial PLCs with greater processing capacity, reliability, and long-term support. - Complete programming of new PLCs
Development of the control logic for all crane movements: lifting, orientation, and translation, ensuring precision, safety, and synchronization. - Renewal of drives
Replacement of old drives with new drives, optimized for port crane applications and heavy loads. - Optimization of critical movements
Fine tuning of ramps, accelerations, and decelerations to improve the crane's dynamic performance and reduce mechanical stress. - Integration with the existing port system
The retrofit was carried out ensuring compatibility with the terminal's electrical and control infrastructure, minimizing downtime.
Results
- Complete modernization of the STS crane control system
- Greater reliability and operational availability
- More precise and safer movements in lifting, orientation, and translation
- Reduction in breakdowns associated with technological obsolescence
- Ease of maintenance and availability of spare parts
- Platform prepared for future improvements and expansions