– Preventing Collisions between Shiploaders and other equipment.

Daniel Beale, This e-mail address is being protected from spambots. You need JavaScript enabled to view it

PROBLEM:

When ship loaders collide with ship access ladders not only does this pose major safety risks, but also it potentially costs millions of dollars in unscheduled outages and damages. This scenario has been experienced at a number of Coal and other material loading facilities around Australia with each resulting in expensive equipment repairs and lost productivity.  In the Coal industry it can typically costs in excess of $500,000 for each hour coal fails to be loaded, so collision costs can easily slide into the millions when “down-time” is also factored into the equation. Such incidents also present unacceptable safety risks for operators. Usually an operator would be focused on their immediate task, for example, loading coal, so they are not necessarily aware of a potentially fatal ladder collision.

SOLUTION:

Drawing on technology used in computer games and flight simulation technology, GROUP used a Vector maths model that was added into the existing Programmable Logic Controller (PLC) to alarm and inhibit movement of the many ship loader parts and access ladders. GROUP used a 3D laser machine to survey the site to ensure all drawings were 100 per cent accurate before they were entered into an AutoCAD Inventer 3D program. Using sensors and mathematical equations, the system allowed equipment to reach within metres without safety issues, but after that point, warnings were issued and vehicle movement was restricted to only allow movement away from potential collisions. A Dual Redundant System that constantly checked and compared information was also installed to guard against mechanical failure. When new vehicles or equipment were added to the site, it was simply a matter of installing new sensors which will then integrate them into the rest of the 3D network.

RESULT:

Ship Loading Facilities can utilise GROUP’s original cutting-edge solution to reduce collisions to zero. As a result, the safety risks to operators is virtually non-existent and the potential cost savings are substantial. This solution is unique in the way it addresses the problem and can be applied to any environment where there are moving vehicles or equipment.