OCR Camera System Install at Major Port
Project Overview
A major port operator managing a large container terminal undertook a project to improve the efficiency and accuracy of its container handling process by installing an Optical Character Recognition (OCR) camera system on their ship-to-shore (STS) cranes. The OCR system automates container identification, enhances tracking, and improves security at the port.
The project required installation of fiber optic cables, lighting, control panels, and all associated infrastructure in a harsh environment with seawater exposure, moisture, and wind, necessitating careful attention to weatherproofing and corrosion resistance.
Our experience with welding, painting, control panel installation, fiber optic cabling, and the integration of power and data systems to support the cameras and lights made Sasco the right contractor to complete the project.
The Port Operator’s Requirements
1. Scope of Work
The scope of work for the OCR camera system installation included:
- Installation of OCR cameras on several STS cranes.
- Routing and termination of fiber optic cables to support the high-speed data transmission required for the cameras.
- Installation of portal beam control panels for centralized power distribution and data management.
- Welding and mechanical mounting of camera brackets on cranes to ensure vibration resistance and long-term durability.
- Application of special weatherproof paint to protect equipment and structures from corrosion due to saltwater exposure.
- Installation of LED floodlights for nighttime visibility and integration with the control panel for automated control.
- Ensuring compliance with all safety and operational standards required for a working port.
2. Key Challenges
- Harsh Environmental Conditions
The port’s proximity to saltwater posed a significant challenge. Corrosion resistance, weatherproofing, and protection from high winds and salt spray were critical to the long-term success of the system. - Complex Infrastructure
The system involved a combination of high-voltage power distribution, fiber optic data transmission, and mechanical installations. Coordinating these elements required specialized expertise in multiple disciplines. - Dynamic Equipment
The STS cranes are constantly in motion, requiring the camera mounts, fiber optic cables, and control panels to be installed in a way that ensures flexibility, vibration resistance, and long-term durability. - Minimal Downtime
The installation had to be completed without causing significant operational disruptions at the port, where timing is crucial, and any delays in cargo handling could lead to costly inefficiencies.
3. Contractor Requirements
The port operator needed to hire a contractor or group of contractors with the following skills:
- Industrial Electrical Expertise
The contractor had to manage the installation of both high-voltage and low-voltage power systems, ensuring that the cameras, lights, and control panels were fully operational and safe. - Fiber Optic Installation Expertise
The contractor needed experience with routing, terminating, and testing fiber optic cables for high-speed data transmission. - Welding and Mechanical Installation
Welding would be necessary for securely mounting camera brackets and support structures on the cranes. The contractor also needed to ensure that the mounts were vibration-resistant and weatherproof. - Corrosion-Resistant Painting
The contractor had to apply special marine-grade paint to prevent corrosion from saltwater exposure, ensuring the longevity of the installed equipment. - Control Panel Integration
The contractor had to install and configure portal beam control panels to manage power distribution and data transmission to the cameras and lights. - Lighting and Network Integration
The contractor needed to install LED lights and integrate them with the control panel to allow for automated and remote operation.
The Hiring Process
Step 1
Defining the Scope and Specializations Needed
The port operator’s project management team worked closely with engineers to define the complete scope of work. They identified that the installation required a multi-disciplinary team with expertise in electrical systems, fiber optics, mechanical installations (welding), painting for corrosion protection, and control panel integration. The project needed to be completed in phases to minimize crane downtime and ensure the port continued operating efficiently.
Step 2
Contractor Selection Criteria
The port operator developed the following criteria for selecting the contractor:
- Proven Experience in Marine Environments
Contractors had to demonstrate previous experience working in coastal or port environments, showing knowledge of corrosion-resistant materials and weatherproofing techniques. - Multi-Disciplinary Team
Preference was given to contractors with an in-house team capable of handling electrical installations, fiber optics, welding, and painting. This would minimize the need for multiple sub-contractors and streamline project management. - Technical Expertise
Contractors had to show expertise in installing and integrating OCR camera systems or similar technologies in industrial environments. - Project Management and Coordination
The ability to coordinate with the port’s operational teams and complete the project with minimal disruption was critical.
Step 3
Contractor Selection Criteria
The port operator issued an RFP outlining the project scope, technical requirements, and desired timeline. Contractors were asked to provide:
- Detailed descriptions of their approach to handling the electrical, mechanical, and fiber optic work.
- Plans for weatherproofing and corrosion protection.
- Previous project examples demonstrating their experience in similar environments.
- A detailed timeline and strategies for minimizing disruption to crane operations.
The Port Operator’s Requirements
1. Contractor Chosen: Sasco Contractors Ltd.
After evaluating proposals, the port operator selected Sasco, a contractor with extensive experience in port and marine environments. This contractor met all the technical criteria and had previously completed similar projects involving fiber optics, industrial control systems, and OCR camera installations.
2. Welding and Camera Mounting
The contractor’s mechanical team began by welding custom camera brackets onto the cranes’ portal beams. They used vibration-resistant welds and installed the cameras in weatherproof housings. The mounts were designed to withstand the dynamic movements of the crane and included provisions for easy maintenance access.
3. Fiber Optic and Power Installation
The fiber optic cables were routed from the portal beam control panels to the OCR cameras. Fiber termination points were installed in a secure enclosure in the control panel, ensuring minimal signal loss. The electrical team installed Power over Ethernet (PoE) injectors to power the cameras and manage data transmission through the fiber network.
4. Lighting and Control Panel Integration
The contractor installed LED floodlights around the OCR cameras for optimal visibility in low-light conditions. The lights were connected to the portal beam control panel, allowing them to be remotely operated based on the terminal’s automation system. All systems were linked to a centralized control room where operators could monitor and control the cameras and lighting remotely.
5. Corrosion-Resistant Painting
Finally, the contractor applied a marine-grade epoxy paint to all exposed metal surfaces, including the camera mounts, cable conduits, and crane structural components. This paint was specifically chosen to protect against the corrosive effects of saltwater exposure.
Results
The OCR camera system installation was completed on time and within budget, with minimal downtime to crane operations. The cameras and lights integrated seamlessly with the port’s existing automation system, enhancing efficiency and improving container tracking accuracy. Thanks to the contractor’s expertise in fiber optics, power systems, and corrosion protection, the system was built to withstand the harsh marine environment, ensuring long-term operational reliability.
The project demonstrated the importance of hiring a contractor with the right combination of technical skills, industry experience, and project management capabilities to handle complex industrial installations.
Conclusion
The port operator’s successful installation of the OCR camera system on its STS cranes highlights the importance of selecting a specialized contractor with experience in marine environments and industrial automation. By focusing on key needs such as corrosion resistance, fiber optic expertise, and control panel integration, the port ensured a smooth and efficient upgrade to its container tracking capabilities.
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