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INTERVIEW HANDLING
PT20- 29/1
I n order to assist ports and intermodal operators with A good average value for the cost of consumable parts for one
their quest to understand the true capital costs STS crane per year ranges between US$ 50,000-100,000.
associated with crane management, Port Technology A major factor to influence this cost component is the
reliability of the system and the degree of system standardization.
International interviewed Gerhard Fischer, Siemens A&D
A large variety of different cranes in a yard require stocking a
MC Cranes (Germany) and Laurens Franken, A&D MC wide range of spares and consumables.
Cranes (The Netherlands), about crane life cycle costs and
Are there any indirect costs of downtime?
issues relating to their reduction. The article is a
Actual crane breakdown data is difficult to get since often
continuation of the crane life cycle cost considerations maintenance systems are not computerized and maintenance
presented in Port Technology International, issue 17. departments are keen to prove that they have well functioning
cranes.
• Depending on factors such as system reliability, maintenance
and usage etc. the accumulated crane breakdown time per year
What are the most relevant cost factors to be considered? is about 50 hours. Based on 4,500 operation hours per year this
corresponds to around 98.9 % availability.
• Depreciation of initial capital investment.
• The hourly cost of a Panamax Ship is in the range of US$ 1,250
• Cost of labour. per hour.
• Consumables, i.e. spare parts. • The cost for the crane driver, deckman and checker are assumed
• Cost of downtime. as US$ 140 per hour.
• Cost of energy. • The consequential cost for 50 accumulated breakdown hours
with regard to stevedoring staff amounts to US$ 7,000.
The following graph illustrates the relative weight of the
various cost components. • The consequential cost for 50 accumulated breakdown hours
for the shipping line amounts to US$ 62,500.
How do you calculate energy costs?
Unfortunately terminal operators often take energy consumption
for granted. The following calculation example is to demonstrate
that energy cost indeed is relevant. To keep the calculation
simple, it is based only on the energy consumption of the crane’s
hoisting system without consideration of the other motions.
a) Average weight of containers (twin-lift): 2 x 22.5 = 45 tons with
spreader/headblock 19 tons.
b) Average lifting height assumed: 20 meters.
c) Containers handled per hour: 30.
d) Operating hours per year: 4,500.
The energy needed for one move is 2 kWh. This figure is
Figure 1. Annual split of operational cost for a typical STS crane.
relatively low due to the fact that power is regenerated during
lowering.
The figures were calculated as detailed in the following:
Assuming an electricity price per kW/h of 0.2 US$ over an
Why is cost of labour the most important item? entire year the electricity cost results as:
STS crane operation requires a crane drivers, checkers and the
lasher crew. Assuming a crane is operating 4,500 hours per year Costen_drives = 4500 . 30 . 2kWh . 0.2US$/ kWh = 54,000 US$
and US$ 140/hour for personnel allocated to the crane, the
annual labour cost runs up to US$ 630,000. For detailed calculation see the box on the following page.
What is the average initial cost of purchasing a crane and Is there any other energy consumed?
what depreciation is expected? The second most relevant item for crane energy consumption is
A STS crane twin lift with 22 rows outreach cost about the flood lighting. For example a modern super post Panamax
US$ 5,000,000 dependant upon detailed specification. Over container crane with 20 boxes outreach has a total installed
an assumed life span of 20 years the annual depreciation is floodlight capacity of:
US$ 250,000. At 6% interest rate, the total depreciation will be Trolley: 4 x 400 W
US$ 407,500. Girder, Legs: 26 x 1,000 W
P O RT T E C H N O L O G Y I N T E R N AT I O N A L 1
CONTAINER
HANDLING INTERVIEW
PT20- 29/1
Considering that the floodlights are only on during the night
then the energy cost of the lighting system depends on the total
night-time operation hours of the crane. Assuming that the crane
is active during the night, maybe 25% of its total operating hours,
i.e. 1,125 hours.
2 P O RT T E C H N O L O G Y I N T E R N AT I O N A L www.p o r t t e c h n o l o g y. o r g
CONTAINER
HANDLING
PT20- 29/1
P O RT T E C H N O L O G Y I N T E R N AT I O N A L 3