A major Malaysian port has successfully completed a pilot project to upgrade its Quay Crane Anti Snag System
CUSTOMER
Major Port in Malaysia
APPLICATION
Quay Crane Anti Snag System Upgrade – Pilot Project Using Dellner Bubenzer Brake Only Snag System (BOSS)
OVERVIEW
A major Malaysian port has successfully completed a pilot project to upgrade its Quay Crane Anti Snag System using the Dellner Bubenzer Brake Only Snag System (BOSS). This retrofit project marks a significant step forward in enhancing crane reliability, reducing downtime, and minimizing maintenance costs.
BACKGROUND
Previously, the port’s Quay Crane was equipped with a Mechanical Anti Snag Overload System (SOS), which disengaged a mechanical coupling when the snag force exceeded a preset threshold. While functional, the legacy system required manual resetting and was prone to nuisance tripping, resulting in unplanned downtime and high maintenance demands.
To address these issues, the port implemented the BOSS — a modern solution that eliminates the need for a mechanical coupling altogether. Installed on one of the port’s quay cranes, the BOSS was designed to improve performance, simplify maintenance, and increase system availability.
RETROFIT SOLUTION AND BENEFITS
- Improved Hoist Anti Snag System: The BOSS system, paired with a BOSS PLC and the latest generation hoist brake featuring an ultra-fast acting BUEL thruster, enables immediate hoist stoppage within 100–267ms upon snag detection.
- Upgraded Components: Obsolete brake discs were replaced with standard steel discs, which are always readily available in the market.
The existing mechanical SOS coupling was replaced with the maintenance-friendly Bubenzer KBS Coupling. Notably, the gear cartridge can now be replaced without moving the motor-side hub. - Reduced Maintenance & Downtime: The upgrade significantly enhanced crane availability and cut down maintenance efforts and costs. The BOSS system’s faster and more reliable snag detection also reduces stress on wire ropes and crane structures, contributing to longer equipment lifespan.
CONCLUSION
This successful BOSS retrofit has proven to be a reliable and efficient solution for the port’s crane operations. With reduced downtime, simplified maintenance, and enhanced safety, the upgrade delivered both operational and financial benefits — setting the stage for broader implementation across the port’s crane fleet.
- BOSS PLC Control Panel with SIMATIC HMI
- Installed with new KBS 170 Gear Coupling with Steel disc 900 mm