The Sumitomo

Sybrid System
For Environmentally Friendly RTGs

Sumitomo Heavy Industries Engineering & Services Co. Ltd.

 Distinguishing Features of the
Sybrid System
Uses Li-ION Batteries as the Energy Storage Medium

Engine Size can be 1/3 of what is normally needed

Can be Adapted to any AC Drive Control

A Static System, without any moving parts

Sumitomo Heavy Industries Engineering & Services Co. Ltd.

System Installation

Sumitomo Heavy Industries Engineering & Services Co. Ltd.

 System Configuration
Engine Generator

DE
DE GG Others
Others
Aux. /Lighting
System Diagram
Converter Inverter
Charging &
Charging &
Discharging
Discharging
IM
IM
Controller
Controller
DBU
DBU

AC
Resistor
Resistor DC
Electrical
Room Storage
Battery
Li-Ion Battery
Gen-Set
Core System

No moving parts. Simple to install on existing RTGs

Sumitomo Heavy Industries Engineering & Services Co. Ltd.
 Operating Principle
Battery Discharges during Hoisting

Engine Generator Electrical Room

DE
DE GG Others
Others
Aux. /Lighting
System Diagram
Inverter
Charging &
Charging &
Discharging
Discharging IM
IM
Controller
Controller
Converter

AC
Storage
Battery
DC

Sumitomo Heavy Industries Engineering & Services Co. Ltd.

 Operating Principle
Battery Discharges during Hoisting

Engine Generator Electrical Room

DE
DE GG Others
Others
Aux. /Lighting
System Diagram
Inverter
Charging &
Charging &
Discharging
Discharging IM
IM
Controller
Controller
Converter

AC
Storage
Battery
DC

Sumitomo Heavy Industries Engineering & Services Co. Ltd.

 Smoke Emission

Without Sybrid System With Sybrid System

Comparison in Black Smoke Emission during Hoisting (30t load)

Significant reduction in smoke emission.

Sumitomo Heavy Industries Engineering & Services Co. Ltd.

 The Lithium Ion Battery System
Each Battery
Terminal (-) Terminal (-)
Unit consists of Insulation Cover

８ individual
Terminal (+)
cells.
Positive Plate
Connection Bar Separator
Negative Plate
Fixing Bolt
Side Plate
Side Plate
Insulated Resin Frame
Separator
Terminal (+)
Cell
Safety Valve
Insulation Film
Cover for BMU BMU Individual cell
Battery Management Unit
The BMU :
- Monitors temperature and SOC for overcharge or over-discharge
- Communicates with the charging/ discharging controller to regulate system 　　
　current and voltage.

Sumitomo Heavy Industries Engineering & Services Co. Ltd.

 Battery Life
Present operational data supports service life of about 7.5 years.

% Approx. 7.5 Years

Expected Lifetime (Operation of RTG will be impossible)

Calculation Condition (20h x 330 days cont. RTG Operation)

System: LIM30H-8R x 18 Serial
Ambient Temp.: 25C Constant
Cooling Air Capacity: 1.0m3/min
RMS Current: 120A
DC Internal Resistance Initial Setup SOC: 40%

Months

Sumitomo Heavy Industries Engineering & Services Co. Ltd.

Development & Testing Program
First Prototype Functional Testing on 1 over 4 RTG
Matsuyama Port (Japan) Dec 2006~Mar 2007
First Prototype Operational Testing on 1 over 5 RTG
Hongkong International Terminals Aug 2007

First Operational Testing on 1 over 5 RTG of Production Model

Daikoku Terminal (Japan) Feb 2008
Operational Testing on 1 over 6 RTG of Production Model
Hongkong International Terminals Mar 2008
Operational Testing on 1 over 5 RTG of Production Model
Yantian International Container Terminal April 2008

Sumitomo Heavy Industries Engineering & Services Co. Ltd.

 Operational Testing (Hong Kong)
Operational Testing on a 1-over-5 RTG at Hongkong International Terminals.

Battery Bank

Sybrid System Cubicle

Existing RTGC E-House

Charging &
Discharging
Controller

Rigorous testing under operational conditions

Continuous testing to prove stability and
Proving at the world’s busiest terminal

Sumitomo Heavy Industries Engineering & Services Co. Ltd.

 Engine Downsizing (Hong Kong)
Power Requirement
130 kW 100 kW 370~310 kW 310~370 kW

Gen- Charging & Inverter

Discharging IM The flowchart shows
Set Drive
Controller that the engine can be
downsized to only
Output 210~270 kW Main Power
30 kW 130kW, as the battery
power can cover the
Aux. Power
Battery maximum power
demand.
IM

Item Original (1500rpm) New (1500 rpm)

Based on the flowchart,
the engine was downsized Diesel Engine Volvo Penta TWD1630G Cummins 6CTA8.3-G2
to 163kW (prime power) , Standby Power 391kW / 532 hp 180 kW / 241 hp
and further to 114 kW. Prime Power 352 kW / 479 hp 163 kW / 219 hp
Generator Leroy Sommer LSA49.1M6 Marathon MP 200AA
Engine downsized Rating 834 kVA 250 kVA

by 67%
Sumitomo Heavy Industries Engineering & Services Co. Ltd.
Gen-Set Comparison

Downsized Engine WITH generator

and radiator
Original Engine
Downsized Gen-set is very compact.

Sumitomo Heavy Industries Engineering & Services Co. Ltd.

“Survival” Test
With the downsized engine, does the RTGC have enough power
to return to the Maintenance Area if the Sybrid fails?
• The Worst Case was tested : a failure after locking onto container
on a chassis in the truck lane.
• The Sybrid was isolated so that only the Gen-Set supplies power.
• A 41 ton load was hoisted off from ground level to simulate a
container being lifted off a chassis .

Power from the Downsized Gen-set was sufficient to lift

41tons to upper limit, at low speed.
Lowering, trolley and gantry travel require less power, so the
RTGC can safely return to Maintenance Area.

Means to quickly isolate the Sybrid will be provided.

Sumitomo Heavy Industries Engineering & Services Co. Ltd.

 Operating Test Results (Hong Kong)
Fuel Savings Data with downsized engine
Test Original New Engine Fuel Savings
1 Static (no crane operation) 6.97 liters 2.95 liters 57.13%
2 Empty Spreader 9.56 liters 4.22 liters 55.89%
3 41 tons (rated load) - 9.26 liters No data with original engine
4 30 tons 16.86 liters 6.86 liters 59.27%
5 15 tons 12.65 liters 5.18 liters 59.09%

Test Data show more than 55% fuel savings over the original
engine, and exceeded predicted levels.
Fuel Savings from Extended Container Yard Operation:
Period : November 1, 2007 to February 1, 2008
Fuel Savings of 58.6% (average)
Total 22,959 moves

Sumitomo Heavy Industries Engineering & Services Co. Ltd.

Advantages of the SYBRID SYSTEM
Fuel Savings of 50~60% with Downsized Gen-Set
Substantial Reduction of Emissions

System maintains a safe Reservoir of Energy for

Stable Operation.

Smaller Gen-Set means Less Maintenance

Good Return on Investment

Sumitomo Heavy Industries Engineering & Services Co. Ltd.

 Delivery and Order List of SYBRID SYSTEM as of August 2011
Crane Electrical
User Crane Size Q'ty Delivery
Manufacturer System
HIT Hong Kong Sumitomo 1 over 5 Yaskawa 1 August, 2007
HIT Hong Kong ZPMC 1 over 6 Fuji 1 March, 2008
HIT Hong Kong ZPMC 1 over 6 Fuji 15 April, 2009
HIT Hong Kong Sumitomo 1 over 5 Yaskawa 2 December, 2008
YICT P.R. China ZPMC 1 over 5 ABB 1 March, 2008
YICT P.R. China ZPMC 1 over 5 Fuji + Yaskawa 2 January, 2009
ACT Hong Kong ZPMC 1 over 7 GE 1 April, 2009
ACT Hong Kong ZPMC 1 over 7 GE 3 December, 2009
UNI-X Japan MHI 1 over 5 Fuji 2 January, 2010
HIT Hong Kong Sumitomo 1 over 5 Yaskawa 1 March, 2010
CHT Hong Kong Sumitomo 1 over 5 Yaskawa 5 March, 2010
MN Japan - - - 1 July, 2010
ACT Hong Kong ZPMC 1 over 7 GE 8 October, 2010
JICT Indonesia ZPMC 1 over 6 Fuji 12 October, 2010
UNI-X Japan MHI 1 over 5 Fuji 2 October, 2010
YICT P.R. China ZPMC 1 over 5 Fuji 10 December, 2010
Nippon Express Japan Mitsui 1 over 5 Fuji 1 October, 2010
HIT Hong Kong ZPMC 1 over 6 Fuji 10 July, 2011
PPC Panama Noell China 1 over 6 Fuji 7 October, 2011
TIMSA Mexico ZPMC 1 over 6 Fuji 4 November, 2011
PPC Panama ZPMC 1 over 5 Fuji 5 November, 2011
TOTAL 94
 Thank You
for your Attention !

Sumitomo Heavy Industries Engineering & Services Co. Ltd.