The Key to Port and Terminal Planning

In port operations, every decision has a direct impact on efficiency and profitability. How many quay cranes should be assigned to a vessel? What effect will a new cargo handling system have on vessel turnaround times? And most importantly, how can these questions be answered without disrupting the daily flow of operations? With port operators grappling with questions like these every day, they need a reliable way to make sure that they’re making the right choices. The key to this is simulation and emulation.

As we learned in our previous article [Optimal Efficiency], digital twin simulation uses digitally constructed visual assets to build virtual models of a physical space. When used in the port setting, designers create virtual models of port terminals or processes that allow operators to evaluate different scenarios before construction or system changes are implemented. By generating a detailed virtual environment, digital twin simulation allows operators to explore how a terminal might handle increased throughput, or how the introduction of new equipment will impact overall efficiency.

In the early stages of port planning, simulation proves to be an invaluable asset. Designers can make key decisions about design and operational capabilities and verify that these choices will work when implemented in real life. The ability to simulate years' worth of data in a short amount of time provides a higher level of insight than the use of historical data alone.

Even from the very first stages of planning, simulation helps planners make important decisions about what choices to make when evaluating the layout of a port or terminal. When determining layout, planners and operators can virtually test multiple design options to understand which arrangement will most efficiently move containers through the system. Simulation also provides insights on process bottlenecks, operational area capacity, and potential inefficiencies ahead of time, helping to avoid costly post-construction errors.

The potential for these operational conflicts is mitigated through simulation, as designers can identify disruptions, such as fluctuating cargo volumes or unexpected equipment failures long before they materialize. These “what-if” scenarios make it possible for terminal operators to preemptively design contingency plans, minimizing the impact of unforeseen, operational setbacks. In the ever-changing world of global trade, simulation empowers planners with the foresight to ensure long-term success.

Optimizing Real-Time Port Operations

Emulation differs to simulation in that it involves connecting a virtual terminal model to a real-world terminal operating system (TOS) and equipment control system, and then allowing the TOS to behave as if it was working with an actual, physical terminal. This process enables port operators to evaluate and optimize live operations without the need to disrupt daily activities.

The strength of emulation lies in its ability to test how the TOS and equipment control system responds to different scenarios, such as handling peak cargo volumes, addressing equipment malfunctions, or adjusting to new processes. By doing so, terminal operators can alter their systems and adjust TOS settings with confidence, knowing that no real-world operations will be affected if something goes wrong. This emulated environment also offers a platform for operators to experiment with potential improvements to their facility, identifying the best configurations and TOS settings to optimize performance.

Adjusting a TOS once it is configured opens the possibility for major, unforeseen operational disruptions, but the use of emulation solves this challenge by providing a risk-free method of testing system adjustments. If a terminal seeks to implement new technologies or expand its facility, the emulated system can simulate these changes to ensure their effectiveness before any live modifications are made.

Outside of evaluating the TOS and equipment control system, digital twin emulation provides a necessary tool for staff training, enabling operators to practice handling real-world scenarios in a controlled environment. While real-world emergencies may be a rare occurrence, an emulated environment allows operators to practice their responses on a regular basis. This develops a highly skilled workforce capable of responding to complex tasks or emergencies should they arise.

Combined Power

The combined use of simulation and emulation provides unlimited potential for port planning and operations. FlexTerm® enables users to access technologies to best suit their project needs, allowing them to test and refine both their plans and live operations. With their ability to provide insights and enhance decision-making, the adoption of these digital tools is set to grow — helping organizations streamline processes, reduce risk, and optimize operational efficiency across their facilities.

Case Study: Port of Cartagena – TOS Testing and Training

At Port of Cartagena in Columbia, Moffatt & Nichol employed FlexTerm® simulation and emulation technologies to safely test TOS configuration changes, including expert decking and prime route adjustments. FlexTerm® allowed the port to explore various quay crane and prime mover ratios, providing flexible solutions for operational challenges. Additionally, it served as a training platform for operation planners and supervisors, improving strategic decision-making through simulated real-world scenarios.