Optimizing Reliability for Crane Operations

Maximize Crane Uptime and Efficiency with Acoem

Terminal cranes are crucial assets for port operations, demanding constant monitoring to ensure optimal performance. Challenges like saltwater corrosion, heavy loads, and constant movement make crane operations particularly complex. Acoem’s advanced monitoring solutions are designed to help optimize crane performance, reduce downtime, and enhance safety, ensuring cranes operate at peak efficiency.

Main Crane Types – Ports

- Ship-to-Shore Gantry Cranes (Container Cranes)
- Bulk Handling Cranes
- Container Yard Cranes
- Overhead Cranes

Crane Reliability

years of experience

cranes monitored globally

0 ecosystem

with NEST Vision combining alignment, vibration, oil, thermography, and more Actionable data 24/7

Critical machines requiring constant monitoring to avoid unexpected breakdowns

Main Hoist

1. Main Hoist

Lifts and lowers containers using a spreader attached to wire ropes, handling heavy loads—typically 40–60 tons per container. ACOEM’s crane solution monitors mechanical (bearing, gear) and electrical defects, using real-time process monitoring to capture the right data at the right time.

Trolley

2. Trolley

Moves the spreader (with container) along the boom and girder and runs on rails mounted to the crane’s boom and girder. Susceptible to the rails surface and geometrie defects often impacting the bearings, wheels and gearbox (for motorized trolleys) life expectancy.

Boom Lift

4. Boom Lift

Raises or lowers the boom to allow crane operation over ships or to stow the boom when not in use. Not part of the regular container cycle but crucial during ship arrival/departure. Susceptible to recurring bearing defects due to False brinelling

Wheel's drive

3. Wheel's drive

Moves the entire crane structure along rails embedded in the quay and transfers the massive crane weight and container loads evenly across multiple wheels.

Potential Costs of Crane Failures

Delays and breakdowns in crane operations can lead to significant financial losses. Consider these potential costs:

Delay in Loading and Unloading: Costs between $15,000 and $50,000 per hour for delays.
Penalties for Missed Schedules: $5,000 to $20,000 per day for non-compliance.
Extended Parking Fees: $10,000 to $30,000 per day for additional port stay costs.
Crane Unavailability Penalties: Between $1,000 and $10,000 per hour for crane unavailability.
Loss of Productivity: $100,000 per day can be lost in high-value cargo if cranes are out of service.
Lost Business Opportunities: A single delay can cost ports up to $2-3 million annually in lost contracts.

Discover how Acoem’s MV-x Solution Enhances Crane Monitoring and Fault Detection at a Major Port

Why Is Vibration Monitoring Crucial for Harbor Crane Operations?

Cranes are essential for efficient cargo handling, but malfunctions can lead to severe operational disruptions and safety risks. Preventive maintenance is critical to maintaining uptime.

Vibration is the most effective technique for monitoring rotating machinery, providing early indications of issues.
Frequency of Monitoring: real time monitoring du to around the clock used and criticality of the equipment for the container port operations
Challenges: machine complex to monitor: variable speed, variable loads, very short cycles with extremes speed variations

Early Detection of Defects

Gearbox Defects: Wear, cracks, eccentricity, backlash, loose bearings
Bearing Defects: Wear, cracks, pitting, lubrication issues
Motor Defects: Rotor issues, unbalance, cracked bars
Coupling and Structural Issues: Misalignment, mechanical looseness, resonances

Find more about Acoem Partnership with Leading Heavy-Duty Equipment Manufacturer for Crane Condition Monitoring

How to Get Started with Acoem

On-site: Use of FALCON portable analyzer for parallel data collection of all indicators (vibration, temperature, oil quality, etc.), providing immediate insights for machinery health.
Remote: Continuous online monitoring via MV-x and MCT™(Machine Condition Tracking) for real-time fault detection, including AI-driven Smart Anomaly Detection
Advisor: Expert diagnostic reports tailored for crane applications, supporting maintenance teams with actionable recommendations and root cause analysis.

FALCON

Vibration analyzer

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Acoem MV-x: Black Edition

Predictive maintenance powered by artificial intelligence (AI)

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Key Benefits of Acoem’s Crane Monitoring Solutions

Boost Uptime: 24/7 monitoring and early fault detection minimize disruptions and maximize operational efficiency.
30% Savings on Maintenance: Optimize maintenance schedules and spare parts management to reduce unplanned repairs.
Improved Safety: Proactive maintenance reduces human presence in hazardous environments, ensuring safety and equipment longevity.
Enhanced Operational Efficiency: Real-time data enables proactive crane health management, reducing costly breakdowns.

Discover our Success Story about Continuous Crane Monitoring for a Global Port Operator

Innovative Monitoring Tools for Maximum Reliability

Port and terminal cranes operate under intense mechanical stress, variable loads, and harsh environmental conditions. Acoem MCT™ is a wireless, real-time monitoring system designed to track critical parameters such as:

Structural vibrations to detect early signs of fatigue
Gearbox and motor health to prevent unexpected breakdowns
Load distribution analysis to optimize lifting efficiency
Temperature variations indicating potential overheating

By providing instant alerts on abnormal conditions, MCT™ allows crane operators to act before failures occur, reducing unplanned downtime and ensuring continuous cargo movement.

Crane downtime can lead to significant delays and financial losses in terminal operations. Acoem’s AI-driven anomaly detection system continuously analyzes vibration, torque, and motor performance to identify early failure indicators such as:

Bearing wear in hoisting mechanisms
Gearbox misalignment affecting lifting performance
Unbalanced loads that can damage structural components

By automatically detecting irregularities before they escalate, Smart Anomaly Detection AI helps optimize maintenance schedules, increase equipment longevity, and improve safety standards in harbor environments.

Crane operations involve heavy lifting, fast acceleration, and repetitive impacts, which can cause structural damage and mechanical fatigue over time. Shock Finder™ continuously monitors vibration shocks, detecting:

Excessive load stress that could lead to mechanical failure
Sudden impact events from misaligned cargo handling
Overloading incidents that put strain on crane booms and joints

By providing detailed diagnostic insights, Shock Finder™ helps maintenance teams prevent catastrophic failures, extend equipment life, and optimize crane safety protocols.

For maintenance teams working in port terminals and industrial harbors, the MV-x Portable Vibration Measurement system provides instant, high-precision vibration analysis on cranes and lifting mechanisms.

Detects misalignments, bearing wear, and unbalanced loads in motors and pulleys
Wireless, portable design for quick on-site troubleshooting
Real-time reporting for faster decision-making and minimal downtime

With MV-x, harbor maintenance crews can quickly assess crane health, plan targeted repairs, and ensure smooth cargo handling operations.

Acoem’s NEST Vision is a comprehensive condition monitoring platform designed specifically for harbor and terminal cranes. By integrating multiple diagnostic technologies, it provides a 360-degree assessment of crane health, including:

Vibration analysis to detect mechanical imbalances
Thermal imaging for spotting overheating motors and brakes
Oil quality monitoring to assess gearbox lubrication health
Acoustic emission detection for early-stage structural fatigue

With NEST Vision, port operators can transition from reactive to predictive maintenance, reducing costly downtime, improving safety, and optimizing equipment performance across container terminals, bulk cargo ports, and industrial crane fleets.

Advisor Turnkey Services: Remote Expertise for Faster, Smarter Decisions

Remote Diagnostics: Instant expert feedback and tailored solutions to reduce downtime and improve decision-making.
Wireless Monitoring: Real-time data collection without complex cabling, enabling faster, more accurate analysis.
Global Support: Experts available remotely from locations such as Brazil, India, Thailand, France, and the US to assist with crane needs.

With global support and 24/7 monitoring by certified experts located in the US, Brazil, France, India, and Thailand, Acoem empowers you to enhance your terminal crane operations.

Learn more about Advisor