Market Unit Brochure. Ports & Maritime

Transcription

1 Market Unit Brochure Ports & Maritime

2 Introduction Cavotec is a global engineering group that enables industries worldwide to improve productivity, safety and sustainability. Cavotec delivers power transmission, distribution and control technologies that form the link between fixed and mobile equipment in the Ports & Maritime, Airports, Mining & Tunnelling and General Industry sectors. Cavotec in the Ports & Maritime Industry In the ports sector, Cavotec is a leading supplier of automated and electrical power control systems. The Group s product range includes a diverse variety of systems such as its unique automated mooring technology, MoorMaster, shore-to-ship Alternative Maritime Power (AMP), Panzerbelt cable protection, crane controllers, marine propulsion slip rings, power chains and connectors, radio remote controls (RRCs) and motorised and spring driven cable reels. 2 Introduction

3 Cavotec Alfo Cavotec Alfo specialises in the design and manufacture of spring reels and slipring columns used in a large number of industrial sectors. Cavotec Connectors Cavotec Connectors electrical power, power supply, power cable and rotating power connectors serve a vast array of applications including ports and terminals, mines and tunnels, railways, steel and aluminium plants, theatres, sports venues, mobile generator sets and offshore energy applications. Cavotec Dabico Cavotec Dabico s advanced in-ground fuel systems are in use at airports around the world, as they have been for much of the past forty years. Cavotec Dabico has developed a new series of covers specifically for the port industry which permits easier and safer access to the vault in harbor areas. Cavotec Meyerinck Cavotec Meyerinck, based in Germany, supplies a wide range of fuelling systems specifically loading arms for the shipping industry, fluid and surge control, and loading terminal products for the aviation sector. The company also manufactures similar solutions for the petrochemical and food beverage industries. Cavotec Micro-control Cavotec Micro-control supplies a comprehensive range of radio remote control systems (RRCs) designed for a vast range of applications in the offshore, mining, and maritime sectors, as well as general and process industries around the world. Cavotec MoorMaster Based in Christchurch, New Zealand, the Cavotec MoorMaster technical team consists of experienced maritime personnel, naval architects and mechanical and electrical engineers who develop Cavotec s vacuum-based, automated mooring system, MoorMaster. Cavotec Specimas Cavotec Specimas is a well-established developer of motorised cable reel technology for the ports and maritime, mining and tunnelling and general industry sectors. Cavotec s engineers design and manufacture the Group s AMP systems, motorised cable reels, patented Panzerbelt cable protection system, power cables and electric marine propulsion sliprings. Cavotec also works closely with other suppliers such as Gessmann, Brevetti and other dedicated cable suppliers. 3

4 Motorised Cable Reels MOTORISED CABLE REELS TEND TO BE IDENTIFIED BY HORIZONTAL OR VERTICAL REELING APPLICATIONS, AND CONSTANT OR INTERMITTENT USE. CAVOTEC SPECIMAS ENGINEERS SUPPORT CUSTOMERS ALL OVER THE WORLD WITH THEIR SELECTION OF CABLE REELS FOR A WIDE VARIETY OF APPLICATIONS. GUIDELINES FOR CABLE REEL SELECTION Intermittent use Our hydrodynamic system is recommended for intermittent use applications. Key features of this system include compact design, constant torque output in reeling and unreeling mode, standard motor and low maintenance. Normal torque outputs are danm with speeds ranging from 10 to 60 m/min. Continuous use For continuous use applications, we recommend our T- series gearboxes. These can be used with several drive systems and fitted with different drums such as monospiral, random lay, parallel lay and a Pull & Store configuration. Other applications We recommend our Torque Motor units for small reels and slow speed applications (5-40 danm and 0-60 m/ min), while our Cavotec Reel Control (CRC) is best suited for larger reels (torque output danm). 4 Motorised Cable Reels

5 CAVOTEC CABLE REEL SYSTEM Motor (with drive) Standard squirrel cage or torque motors, according to IEC Norms. Hydrodynamic cable reels can be supplied with a pneumatic or hydraulic motor. 2. Gearbox or Torque Unit Seven gearboxes and eight torque units are available with variable output torque from danm. 3. Collector Standard sizes of collectors are available for power and signals. Current ratings vary from 10 to 2400Amp, voltages up to 30kV. We also manufacture customised collectors exceeding the above parameters. 4. Drum The drums are composed of standard elements and can easily be adjusted to required widths. Standard drum diameters range from 300mm to 8700mm. Continuous use Typical cable reel applications Small Cranes 100% ED Small Vertical Applications Large RMGC & ASC Stacker & Reclaimers Vertical Applications Small RMGC Large Vertical Applications Intermittent use Trippers Small Cranes Drill Jumbos & Harbour applications Ship-to-shore Cranes Torque Output (danm) Hydrodynamic Torque Motor CRC The above chart shows different typical cable reel applications related to the most suitable cable reel system and drive. 5

6 Hydrodynamic systems The most unique feature of the Cavotec hydrodynamic system is that the clutch acts directly on the main drum shaft. This gives an even torque output in reeling and unreeling modes, independently of clutch slip or reeling speed, thus assuring long cable life. Due to its unique design, our hydrodynamic system is a simple solution for many cable and hose reel applications. The system is based on a gearbox in which a reduction gear, clutch and brake are built as one unit. It provides a constant torque output, allowing an even recovery of any type of cable. Our hydrodynamic cable reel is driven by a standard squirrel cage motor but can also be supplied with a hydraulic or pneumatic motor. Another major advantage is that the torque can easily be readjusted on site. This way, the force of the cable can be reduced or increased according to requirements. 6 Motorised Cable Reels

7 Torque/speed diagram for hydrodynamic unit Slip/Torque diagram Nominal Torque 2,0 1, Drum Speed (rpm) The chart above shows typical torque/speed for a hydrodynamic torque unit with a completely even torque output. The torque variation due to slip or reeling speed does not exceed 5-10%, depending on the size of the torque unit. 7

8 Cavotec Torque Motor System The Cavotec torque motor for cable reels provides a virtually constant torque in reeling and unreeling mode. The resulting mechanical cable tension is similar to a hydrodynamic system. This has been obtained by using a torque motor with a very flat torque/slip curve. The motors are used up to maximum of ± 400 rpm and, within this range, the torque fluctuation is approximatley 10%. Besides the motor characteristics, the gearbox efficiency also influences the traction at which the cable is submitted. The T-series gearboxes are designed with this in mind. They incorporate a single shaft planetary gear which makes them highly reversible. The torque motors are equipped with an electromagnetic brake and are servo-ventilated Self-breaking torque motor 2. Pre-reducer 3. Gearbox 4. Collector 5. Drum 8 Motorised Cable Reels

9 Cavotec torque control (CRC) drive The Cavotec cable reel incorporating CRC drive is the result of a cooperation between drive manufacturers and Cavotec. The CRC system achieves precise speed and torque control of standard maintenance-free squirrel cage motors. A slipping device between motor and gearbox is not needed. The Cavotec CRC driven cable reel enables an almost constant pull on the cable. In fact, by following the torque reference signal computed on the basis of reeling variables such as cable weight, reeled cable on the drum, acceleration or deceleration of the crane, position on the track the CRC minimises the pulling force on the cable. Cavotec has also chosen to use oversized, not force ventilated, motors for reliability and for simplicity in system layout. The result is a longer cable life and increased reliability of the cable reel system. Power supply Chopper Resistor 1 Signal Cavotec Specimas application software Power Output Torque reference Processing Brake signal Cable reel motor Interlocking for crane Interlocking for crane M 3 ~ Encoder 3 2 AUX power 220V AC Brake control circuit Brake spring app. elect. released 4 1. CRC drive 2. Standard squirrel selfbreaking electric motor (one or more motors can be used in parallel) 3. Pre-reducer 4. Gearbox Transducer Slipring assembly Gearbox Drum 9

10 KP BRUSHES Standstill slipring applications often require a high degree of de-rating of the existing capacity of conventional carbon brush gear. Increasing the physical size of the brushes is not always a solution, since the actual contact area does not increase proportionally. Cavotec has overcome this problem by developing a multi-contact brush gear, which has effectively substantially increased the capacity. This is achieved by the separation of the brush into many independent sections ensuring a larger effective contact area. 10 Motorised Cable Reels

11 Fibre optic rotary accumulator Optical signals are increasingly used in ports and terminals, where both composite and fibre-optic bundles are common. To meet these demands, Cavotec has developed a fibre-optic rotary accumulator. Thanks to its innovative design, this unit can also be used as a stand-alone rotary accumulator if the reel is equipped only with fibre-optic cable. The housing is made of stainless steel and includes anti-condensation heating elements and rotary limit switches. The signal transmission is uninterrupted, and with a fibre length of about 15 m in the rotary connector, fibre dimming can be disregarded. A dimming of less than 3 db must be taken into account for the rotary accumulator (including any bilateral connections). The connection is made on either side via plug connectors in the fixed and rotating terminal boxes. Cable guides Cavotec has developed a range of cable guides designed to ensure smooth cable guideance during crane operation. Engineered to the highest standards, these guides improve the operational life of cables and ensure safe, continuous operations. 11

12 Panzerbelt Panzerbelt is a cable protection system incorporating a continuous semi-flexible belt, fabricated from rubber with inlaid steel reinforcement, which lies over a channel cast in the quay. The belt is riveted to the quay surface along one edge, while the other remains free to be raised by a cable guide and beltlifting device fitted to the crane. Steel reinforcement has been incorporated to retain strength and flexibility of the belt in all directions. Main advantages Panzerbelt guarantees that the cable inside the channel is entirely protected from vehicles crossing the track and from objects falling into the cable duct. The system has several major advantages over other, more conventional cable protection systems: Complete operational safety Low installation cost Full cable protection Maintenance free No load restrictions Channel free from spillage Operates in any climate No crane speed limitations No alignment problems Easily adaptable to existing systems The main components of the Panzerbelt system are: 1. Stainless steel rivets 2. Pre-drilled fixing strip 3. Panzerbelt steel reinforced rubber cover 4. Stainless steel channel profile Technical characteristics The most significant feature of the Panzerbelt system is the belt itself. Defined and perfected after decades of testing and practical experience, it is able to perform apparently conflicting duties: it has a high transversal rigidity necessary to support all vehicle types while simultaneously possessing sufficient longitudinal flexibility to allow the belt to be lifted into a near vertical position. Thanks to its high quality design and manufacture, the belt resists mechanical, ambient and abrasive wear extremely well, requiring virtually no maintenance. 12 Panzerbelt

13 GENERAL CHARACTERISTICS Ambient temperature: -30 C up to 80 C Opening angle: Estimate lifetime: Horizontal bending radius: Maximum load: Maximum breaking load at joint: Elongation: Approx. lenght of rolls: Max force to open the belt to 90 : 90 max > 250,000 cycles (open/close) 35m (minimum) with hinge profile external; 45m (minimum) with hinge profile internal The maximum load applied on a Panzerbelt System with a 100mm wide slot should not exceed 400 N/cm kg for standard Panzerbelt; 2650kg for Super Panzerbelt 2% with load of 3000 N 50m 40kg Type dimension A (mm) Weight (kg/m) PB PB PB PB SPB SPB SPB SPB A Standard Panzerbelt type PB Materials: 80% SBR-Styrene Butadiene Rubber* 15% Steel cord 5% Nylon Reinforcing: Warp: Two layers of RFL dipped nylon yarn - breaking load 50 kn/m Weft: Brass coated steel cord - breaking load 640 kn/m * Other types of rubber and reinforcement layers are available for special working enviroments. Super Panzerbelt type SPB (USA and Europe Patent) Materials: 75% SBR-Styrene Butadiene Rubber 15% Steel cord 10% Nylon Reinforcing: Warp: Two layers of RFL dipped nylon yarn - breaking load 50 kn/m Two layers of RFL dipped nylon fabric - breaking load 160 kn/m Weft: Brass coated steel cord - breaking load 640 kn/m Two layers of RFL dipped nylon fabric - breaking load 55 kn/m 13

14 Simple and fast installation Thanks to its innovative and versatile design, the Panzerbelt system can be installed in any type of port with relative ease. It can be fully customised to meet any given operational requirement. Retrofitting is also possible, even without using the stainless steel channel. A standard Panzerbelt system consists of the following components: Either Standard or Super reinforced belt in rolls of approx. 50m, with joints at their ends Stainless steel channel AISI 304 or AISI 316, 1.5mm thick Hot dip galvanised 30x8mm fixing strips, with 13 pre-drilled holes per metre Stainless steel or nickel copper rivets Earthing copper strips with screws and nuts Anti-filling and alignment system with expanded polystyrene Alignment brackets for channel sections 14 Panzerbelt

15 The standard channel The Panzerbelt channel is made of stainless steel sheet and serves primarily as a framework for the creation of a duct in the quay. It is shaped to provide a recess for the belt thereby ensuring protection of its edges. It is also provided with an additional profile allowing the belt to be firmly fixed to the concrete quay. Belt sections are supplied with galvanised steel joints already fixed at one end. The rivets used to connect the joints to the belt sections are the same as those used to fix the belt to the channel. System accessories Panzerbelt can be supplied with several optional items including: Stainless steel turnover anchors (single or double) Junction boxes Fixed Panzerbelt opening devices Belt lifting devices Easy lift access covers (spring loaded) Thanks to the characteristics of the flexible rubber cover, the belt-lifting device has a simple and light construction. The device is made of stainless steel with rollers in nylon charged with molybdenum and is easily adaptable to existing cable guides or pick-up systems. 15

16 MoorMaster Automated Mooring System MoorMaster is a vacuum-based automated mooring technology that eliminates the need for conventional mooring lines. Remote controlled vacuum pads recessed in, or mounted on, the quayside, moor and release vessels in seconds. The automated mooring solutions developed by Cavotec MoorMaster now bring mooring up to speed with the pace of the modern shipping industry. A UNIQUE TECHNOLOGY MoorMaster dramatically improves safety and operational efficiency, and also enables ports to make infrastructure savings. It has performed more than 40,000 mooring operations at ferry, bulk handling, Ro-Ro, container and lock applications around the world. Key advantages of the system include: Safety Reduced risk of mooring accidents as personnel are removed from hazardous working zones. Real-time monitoring of mooring process and forces during stay in port. Infrastructure Improved pier utilisation due to closer vessel spacing. Quay length can be virtually extended as the ship s bow can overhang the end of the quay. MoorMaster can reduce the requirement for extension of breakwater protection. Efficiency Higher container transfer rates. Vessels are held securely alongside, which may allow for the automation to shore cranes in future. Ship motion due to swell, surge, passing ships etc is dampened. Improved continuity of work processes. Shorter operating times for tugs. No mooring teams required, harbour pilots able to disembark faster. Environment Reduced emissions as ships engines can be shut down earlier, tugs able to leave earlier. Furthermore, once in port, vessels are not required to reposition along the berth as MoorMaster dampens vessel motion so considerably. Quicker connection to shore power if available. 16 MoorMaster

17 Solutions for container terminals Container terminals have become a crucial link in today s global economy. Often they are the main logistics hub for a large geographical region ensuring the smooth exchange of consumer goods, commodities and industrial products. Gains in efficiency and productivity from improvement of the ship to shore interface is potentially significant further down the logistics chain and can have a profound impact on the commercial success of terminal operators, shipping lines and their customers. Container ships are becoming larger and in many ports the mooring time of these huge vessels with ropes can easily exceed 30 minutes. With MoorMaster the vessels are moored in a matter of seconds, allowing shore personnel faster access to the vessel to begin cargo operations. In surge affected ports, MoorMaster holds ships steady, providing a stable platform for faster crane and cargo movements. 17

18 Solutions for RoRo and Ferry Terminals Transport of RoRo cargo by sea plays an increasingly important role in reducing road congestion. Good examples are the specialised pure car carriers (PCTC) which form an integral part of the logistics chain within global car manufacturing, and passenger ferries which are mostly employed on short sea routes where reliability of schedule and quick crossing times are of vital importance. While many RoRo ships and ferries trade on fixed routes, adaptability to different ports remains important to ship owners and terminal operators. With increasing ship sizes, the challenge is often to safely moor in adverse environmental conditions, especially where pier space for ropes is restricted. MoorMaster reduces the amount of time vessels need to spend in port and enables terminals to operate in adverse environmental conditions that are incompatible with traditional rope mooring. Retrofitting existing terminals with MoorMaster allows usage by vessel sizes beyond the original design envelope, without the need for investment in expensive pier extensions or dolphin contructions that also may disturb restricted waterways in the port. 18 MoorMaster

19 Solutions for Dry Bulk and Tanker terminals MoorMaster is now in service at two major bulk handling ports in Western Australia. At the time of printing, two more applications are due to come online shortly. The existing applications have improved productivity and reduced infrastructure costs considerably. Solutions FOR LOCK SYSTEMs The MoorMaster 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways. MoorMaster cuts vessel transit times and creates a safer environment for those working on ships and shore-side. 19

20 Alternative Maritime Power (AMP) ALTERNATIVE MARITIME POWER HELPS US REDUCE EMISSIONS NOT JUST AT THE PORT BUT THROUGHOUT THE ENTIRE LOS ANGELES REGION. PHILIP SANFIELD, PORT OF LOS ANGELES. SWITCHING ON TO CLEANER PORTS Cavotec supplies two types of shore-to-ship power systems. One incorporates a ship-based or shore-mounted cable management system with shore connection made via high voltage cables to a pit fit into the quay or to a ship socket outlet JB. Our shore-side pits are designed to occupy the minimum amount of space. The ship-based cable management system consists of electrical connectors (up to 12kV), flexible cables, slipring, optical fibre accumulator, motor reducer, cable drum, electrical control panel and a retractable hydraulic cable guide. The second alternative is similar to the ship-based version, although fits inside a standard container and stored on board ship, either aft or forward of the accommodation block. As the system is entirely modular, the container can be moved according to vessel or loading requirements. 20 Alternative Maritime Power

21 Solutions for container SHips (Ship integrated solution 6,6kV) Quayside space in container terminals is at a premium, so our shore-to-ship power cable management systems are vessel-based and include two types: Ship-integrated system Semi-fixed containerised system The ship-integrated system includes all equipment necessary for shore connection, including the cable management system, installed on board, often near crew quarters and in the vicinity of the electrical room. This option tends to be recommended for new-build projects. Solution for container ships (Semi Fix Container 6,6kV or 6,6kV/440V) Space constraints on vessels can preclude the installation of a fixed module. Seeking to overcome this, Cavotec has developed a shore-to-ship power system housed in either one 40ft container or two 20ft containers. The cable management system and all electrical components are also installed in the container(s). Operators therefore have the option of moving the containers according to loading and other requirements. 21

22 SOLUTIONS FOR CRUISE SHIPS (6,6kV / 11kV) For cruise ships, power cables are handled on shore. The socket outlet receiving panel is normally installed in a dedicated room on the lower decks which can be accessed from the shore through a water tight hatch. Cavotec has developed a specific range of solutions for these types of applications. AMP Mobile guarantees the highest operational flexibility along the berth: accommodating a wide range of vessel types and shore connection points. When not in use, AMP Mobile can easily be moved from the quayside and parked elsewhere. SHORE Pit In order to supply power to each individual cable management system, a shore pit must be installed on the quay. This connection pit serves as the main connection point for all the cables leading from the main quay power supply up to the cable management system. Cavotec shore pits consist of: One-Hand Lift, Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame. Stainless steel shore power junction box (IP66). Electrical sockets up to 12kV (fitted with safety features such as pilots and interlocks). Optical fibre connectors. 22 Alternative Maritime Power

23 EASY LIFT COVER ASSEMBLY Bringing more than 40 years experience of high-load rated, one-hand lift covers, Cavotec has designed the Easy Lift Cover Assembly. This robust, cost-effective, marine grade assembly enables operators to safely open the covers with a lift weight of only approx. 15kg. Furthermore, the Easy Lift covers require a positive force to close so they can not accidentally slam close on an operator. Cavotec Easy Lift Covers can be produced to meet specific size and loadbearing requirements. We also manufacture a fibreglass pit form for use in conjunction with the Easy Lift Cover. Use of this pre-formed fibreglass enclosure can result in significant on site labour savings since time consuming forming of the concrete vault is no longer required, and internal components, such as the stainless steel junction box, can be factory installed prior to shipment. SHORE BASED SOLUTION Since 1988, Cavotec has also engineered numerous state of the art shore based cable management systems for Ro-Ro vessels and ferries, that tend to use dedicated berths and dock in the same positions. In these cases, the degree of flexibility required from cable management systems is not as great, allowing the equipment to be integrated into the berth. Cavotec has also developed similar systems for integration into dolphins specifically for tankers and LNG vessels. 23

24 Marine Slipring Systems CAVOTEC HAS WORKED CLOSELY WITH ENGINEERING GROUP ABB SINCE THE 1990s ON DEVELOPING ELECTRIC POD PROPULSION FOR CRUISE SHIPS, ICE BREAKERS AND OTHER ICE CLASS SPECIAL PURPOSE VESSELS. Marine Propulsion Systems (MPS) With more than 80 vessels using the Azipod propulsion with Cavotec slip rings installed, the system has accumulated more than four million hours of operational service. Cavotec MPS slipring: Slipring design range from data and signal voltages to 6kV power phase voltage Slipring design range from ma data and signals to 6000Amp power phase currents Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure All in one, complete slip ring with hydraulic joint and auxiliary equipment, supplied in one easily mounted unit Simple installation using standard mechanical, electric and pipe interfaces Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system Self-cleaning ring and brush system Basic design test at resonance frequencies of up to 2G and at shock loads of up to 5G Low maintenance with easy and fast replacement of rings and brushes if required Customised design Client-specific auxiliary equipment available, for example: steering feedback, control and support equipment 24 Marine Slipring Systems

25 A revolution IN propulsion Since the mid-1990s, when ABB approached Cavotec to work on power feeding including signal and data transmission, hydraulic and pneumatic supply, more than 160 slip ring and hydraulic swivel joints have been delivered to ABB and other major poded propulsion and thruster suppliers. Our slip ring units are used to supply signals, power, fluids and air from and to the rotating poded electric motor beneath the vessel. EX-PROOF VERTICAL COLLECTOR Drawing on extensive experience from the mining industry, Cavotec has developed a series of vertical slip ring for the maritime sector. Depending on the current rating and type of application, the vertical collectors are available with flameproof enclosure or pressurised enclosure. The vertical collector are suitable for data and/or power transmission up to 600A and 7,2kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification: IIA, IIB and IIC). 25

26 DATA TRANSMISSION SLIP RINGS Cavotec frequently supplies marine collectors equipped with slip rings for data transmission. These slip rings are specifically designed for the transfer of low level data and measurement signals. Six gold-coated contact fingers guarantee secure transmission in a wide variety of applications including all standard field bus systems such as CAN bus, ASI-Bus and Profibus. They can also transfer Category 5e and 6 Ethernet signals of up to 1Gbit and audio and video signals. Modular design enables assembly specific to customer requirements. There are different ring diameters available, ring spacing is determined by specific voltage requirements, and it is possible to incorporate power rings. The integration of encoders and limit switches is also possible. 26 Marine Slipring Systems

27 27

28 Power Connectors Cavotec connectors low and medium voltage electrical power UNITS are designed to meet the intense demands of the ports and maritime sector, and meet a vast array of industry requirements. introduction Customers have the option of ordering our power connectors and plug & sockets pre-fitted in standard units, including circuit breakers. Cavotec also produces a comprehensive range of multi-pin outlets for control cables, manufactured for an upper limit of 50 pins and 40Amps. The range of connectors can be divided into two different operating systems: Push & Pull and Screw Ring types. Cavotec power connectors make use of a special technique using lamellar technology with multi-contacts (Multi-Way Technology). The lamellar system MWT greatly improves the contact between the male pin and female contact. When the MWT becomes warm it expands thus increasing the contact pressure between the surfaces. This additional contact pressure allows for an exceptional current-carrying capacity relative to the size of the contacts and makes connecting and disconnecting the plug and socket easier. 12mm MWT system contacts 28 Power Connectors

29 Norms and Regulations All Cavotec connectors are provided with interlocking pilot contacts. The pilots are last to connect and first to disconnect, so that inserted in a proper safety wiring, this insures that no disconnection under load can take place. Mechanical interlocking can be provided on request. All connectors are manufactured in accordance with NFC rules and additionally confirm to the following standards NFC , VDE 0110, NFC IEC 309-1, CEE 17, BS 4343 IEC 529, DIN 40050, NFC The Cavotec high voltage Push & Pull connectors are tested according to VDE List 2. All Cavotec power connectors have a standard protection class of IP667, while our range of power units have a standard protection class of IP557. Type size N Pins Max current AMP Max voltage kv Screw Ring/Push&Pull PC4 4/ ,1 YES / YES PC5 4/ ,1 YES / YES PC ,1 NO / YES PC5_K ,2 YES / YES PC6_K ,2 NO / YES PC6_L NO / YES PC YES / NO 29

30 Low Voltage Power Connectors up to 1100V Cavotec power connectors for low voltage applications are robustly designed for use in harsh and demanding environments. They have a standard protection class of IP667 and have a standard working ambient temperature of 80 C. On request, the temperature range can be extended to a maximum of 250 C. Their robust versatility makes our power connectors ideal for offshore, railway, port, bulk and container handling applications. Medium voltage Power Connectors up to 25000V Electrical power connectors provide a flexible, convenient and reliable means of extending cables from fixed or mobile powers sources to ships, cranes and other cargo handling equipment. They are also often used for portable junction boxes either in above- or under-ground applications. 30 Power Connectors

31 POWER UNits Cavotec Connectors has also developed a standard range of power units made in 2mm stainless steel plate designed for the same harsh environments as the plugs and sockets. The cabinets are custom made to fit any requirements. Cavotec has designed standard outlet panels for 150A to 630A with a voltage range of 380V to 1100V. These are equipped with molded-case circuit breakers interlocked via the pilot contacts in plug and socket. EXPLOSION PROOF POWER CONNECTOR The Cavotec PC2-EX is an Ex-rated connector designed for use in the oil and gas industry and for petrochemical applications. Used on offshore and land-based oil rigs to power top drives, and magnets and motors as well as low current applications like lights and signalings. Other applications include pits in aircraft maintenance hangars. Made from marine grade aluminium, the unit is uniquely light and compact and can be fitted with a wide range of insulator assemblies covering any cable size from 1,5mm 2 up to 300mm 2. Maximum voltage is 690V, and currents of up to 660A are possible. The body can be anodised and painted to protect against extreme operating conditions. 31

32 FLT - Spring Driven Cable Reels Cavotec spring reels are used in ports all over the world for a wide range of applications. Designed and manufactured to withstand the exacting demands of this sector, OUR ELECTRIC CABLE REELS ARE INDUSTRY STANDARDS ACROSS THE GLOBAL PORTS INDUSTRY. OVERVIEW Spring driven cable reels are subject to the standards set out in VDE 0100 and the most recent edition of UVV in Europe countries. Our warranty follows the general industry delivery conditions for products and services. Cavotec s spring driven electric cable reels meet all applicable IEC international norms and standards and comply with the latest EU requirements (CE marking). Our cable range includes a wide variety of flexible cables for reeling applications that withstand the highest mechanical stresses and harshest ambient conditions. Standard protection for drums and slipring bodies is IP66, with the drums being hot-dip galvanised and the slip ring assemblies housing made from glass fibre reinforced polyamide. Installation instructions The drum should be installed in such a way to ensure that the cable is reeled and unreeled to and from the drum freely. Forced guidance and too small bending radii on sheaves and roller guides should be avoided. The design of the reel allows the feeding point of the cable to be placed on either side of the drum. In order to make the correct reel selection, it is necessary to know the nature of the application. It is important to take in consideration the heating of the cable due to the number of layers on the drum. Lower temperatures may require a higher spring force due to the higher rigidity of the cable. Operating conditions Particular care should be taken regarding operating conditions, especially in extreme environments. The following factors are of primary importance: extreme temperatures substantial temperature variation humidity levels vibration emission 32 FLT - Spring Driven Cable Reels

33 Reeling cable on drum It is imperative to reel the cable onto the drum without twists or bends. To this end, lay out the complete cable straight along the travel length. When reeling the cable on the drum be sure to maintain the same reeling direction used on the wooden drum delivered by the manufacture. 33

34 Loading Technology Cavotec Meyerinck Loading Arms are used wherever liquid PRODUCTS ARE TRANSFERRED. CHEMICALS, PETROCHEMICALS, FOODSTUFFS - SEA, ROAD OR RAIL: CAVOTEC LOADING ARMS ENSURE SAFE, RELIABLE TRANSFER OF FLUIDS REGARDLESS OF MEDIA. Loading Arms Quality standard Swivel Joints 3-32 Sturdy, maintenance-free and longlife Cavotec Meyerinck Swivel Joints are used wherever rigid pipes have to follow three dimensional movements. Two, three or four bearings combined with two active seals provide highest safety and easy operation. More than 3,000 Cavotec loading arms, with some 25,000 swivel joints have entered service at applications worldwide since Loading Arms sizes 3 to 8 Pressure class: 125 PSI / 10 bar to 300 PSI / 25 bar Material for piping: our standard is stainless steel, carbon steel or aluminum, others on request. Material Swivel Joint: our standard is stainless steel or with internal coating acc. to customers specification on request. Sealings: NBR, FKM, PTFE and others. Temperature: -50 C +220 C 34 Loading Technology

35 Filter / Water Separators Pumps Pumps Filter / Water Separators Tanks Suction Arms Tanks Tanks Ship Receiving Station Ship Suction Arms Suction Arms Ship Receiving Station Ship Pumps Pumps Filter / Water Separators Filter / Water Separators Pumps Pumps Filter / Water Separators Ship Unloading Station Pump Control System Filter / Water Separators Pump Control System Rail Car Receiving Station Pump and Filter Station Receiving Filter Station Pump Pump Control and Filter Station System Receiving Filter Station Rail Car Receiving Station Pump and Filter Station Receiving Filter Station Tank Truck Receiving Station Tank Truck Receiving Station Port Fuelling Solutions Tank Truck Receiving Station Marine Loading Arms Cavotec Meyerinck Marine loading arms are fully counterweighted. Moreover, our loading arms have a self supporting design and are also manually operated due to the high quality of the swivel joints. The stainless steel Marine Loading Arms can be manufactured with a maximum diameter of 8. They can be equipped with special couplers for a quick connection to the ship. In-Tank Floating Suction Units Cavotec Meyerinck floating suction units are used in storage tanks for liquid products. Float operated they draw off clean product near from the product surface. Our floating suction units are available for horizontal and vertical tanks but also for floating roofs. They are also available as a single or a double suction arm. Cavotec floating suction units are made of stainless steel and are available from 3 to 32. Other materials are available on request. 35

36 Radio Remote Controls CAVOTEC RADIO REMOTE CONTROL (RRC) SYSTEMS ARE BUILT FOR THE TOUGHEST OPERATING ENVIRONMENTS IN THE PORTS AND MARITIME SECTOR. WITH BOTH ATEX AND IEC CERTIFICATIONS, OUR RRCs GUARANTEE SAFE AND SECURE COMMUNICATIONS AT ALL TIMES, IN ALL CONDITIONS. SAFETY, RELIABILITY AND INNOVATION Safety, reliability and innovation have been our three guiding principles throughout Cavotec Micro-control s 20 years experience in the industry. Our systems serve a vast array of applications in a broad range of industries, including the offshore oil industry, an indication of our units matching the world s most stringent safety requirements. Directives and Standards Cavotec Micro-control RRCs comply with a variety of international rules and regulations. All units are CE marked and can be used with our FCC Part 90 approved radio. The systems are designed in accordance with the European Machinery Directive and comply with IEC and ISO Cavotec RRCs also comply with standards in specific countries. For example: IC for Canada, KCC for Korea, TELEC/COSMOS for Japan, C-tick for Australia, GOST-R for Russia, CMII for China, MSHA for mining in the US. 36 Radio Remote Controls

37 Radio terminal and base unit 1. Full system check at power-up. 2. Stop button ensures immediate stop of all operations. Redundant monitoring of stop button. 3. Redundant monitoring of joystick activity. 4. Two way radio link with unique ID-coding, CRC check and radio operating distance of 6m. 5. High priority stop button message ensures immediate stop. 6. Continuous radio link monitoring. Activation of stop button if communication is lost Radio terminal 7. Dual processor system with surveillance of all safety functions. 8. Radio signal filtering that blocks out all other radio emitters (W-Lan, Bluetooth, GSM). 9. Double monitoring of stop button relays. 10. Dual processor system implemented according to IEC61508 ensuring independent processor operation. 5 6 Base unit

38 PRODUCT RANGE MC-2-3 & MC-2-5 The MC-2-3 and MC-2-5 terminals are designed to be the safest, most ergonomic, best value for money, push-button RRCs on the market. Both models are equipped with displays showing operational information. The MC-2-3 has six-two step push-buttons, four single step push-buttons, and one stop button. The MC-2-5 has an additional four-two step push-buttons. The units are powered by two AA batteries, providing 40 hours continuous operation. MC-3-4 The MC-3-4 is designed specifically for hydraulic truck loader applications and can be used hand-held or belt mounted. The special v-shaped joystick will allow operation with either thumb or index finger for precise control of crane movement. Primarily designed to interface with automotive CAN Bus systems, the MC-3-4 can be delivered with any of Cavotec extensive range of base units. This allows its use with any industry standard outputs, from simple relays, direct connection to solenoids and communication with advanced PLC systems. MC-3-5 The MC-3-5 is available in digital, analogue, hand-held and belt-mounted versions. All operations, from simple control tasking, to complete process supervision, can be carried out from this one unit. MC 3-6 The MC-3-6 is designed for use in hazardous applications requiring complete reliability. The system is especially suited to material handling, where long start-up procedures are the unavoidable consequences of a plant stop. To guarantee uninterrupted operation, the terminal has a twin battery option, and allows users to hot swap batteries. The MC-3-6 is particularly useful for two-way communication, and can be adapted to house Cavotec Micro-control popular semi-duplex radio. MC 3200 & MC 3300 Two of the most flexible, compact RRCs on the market, the MC-3200 & MC 3300 offering simple control functions through to comprehensive overviews of entire processes. The systems can handle any direct hydraulic and electric control function and serial communication with most known PLC and frequency converters. The MC-3300 & MC-3200 are specially suited for tough maritime environments. The housing exceeds ingress protection class IP66/67 and is made from high impact, chemical resistant plastic. 38 Radio Remote Controls

39 EX-PROOF RADIO REMOTE CONTROLS The MC-3000 Ex and MC-3-6 RRCs provide secure and flexible control for a vast range of machinery. In addition to including similar features common to standard RRCs, these units can also be adapted to use cable control. These systems provide users with an extra guarantee against shutdown if other communication links fail. Both systems can be delivered with simplex or duplex communication. The duplex communication option allows operators to receive messages, such as alarms and status indications, via LEDs, control display and indicator instruments. Typical applications for these radio remote controls are offshore oil and gas equipment, mining applications and maritime cranes and winches. 39

40 Cable Chains ESTABLISHED IN 1976, ITALY S BREVETTI STENDALTO WAS one of THE FIRST COMPANY ever TO PRODUCE NYLON CABLE CHAINS. THE INTRODUCTION OF THIS REVOLUTIONARY ADVANCE IN CABLE AND HOSE PROTECTION HAS MADE BREVETTI one of THE LEADING SUPPLIERs OF NYLON AND STEEL CABLE CHAINS IN EUROPE. Overview Our nylon cable chains create substantial efficiency gains by speeding the movement of equipment, while fully protecting the cables and hoses inside. Cavotec cable chains permit any cable combination and are easy to maintain. Extensive endurance tests carried out by leading crane manufacturers and certification institutes have proven the reliability of the system even in the most extreme working conditions. Our cable chains offer users the following advantages: Hydraulic hoses and electric cables Uninterrupted operation in harsh environments High speed and acceleration Reduced maintenance costs and installation time Turnkey systems equipped with pre-inserted cables and hoses 40 Cable Chains

41 STEEL CHAINS Specific applications, characterised by particularly harsh working conditions, require steel cable chains. Brevetti offers a comprehensive range of steel cable chains designed to meet the increasingly sophisticated demands of industry. Our steel chains are found in all types of applications throughout the world. The internal and external links used in Brevetti steel chains are made of mild steel that is bright zinc plated. These are separated by anti-friction spacers or with bronze spacers for high temperature applications. If required, steel components can be made from stainless steel AISI 316. Internal cross elements are either two aluminium blocks, pre-cut with openings for cables and hoses, or special rods with moving separators. Special disc springs are installed to compensate for any play between pivot points. For special applications with long travel distances, Brevetti has developed its own system based on a travelling internal support frame. 41

42 Crane Controllers Gessmann industrial controllers and switches marketed by Cavotec are used in a wide range of applications, including crane operating systems, remote controls and welding machine controls. Our range of industrial controllers also comprises crane technology and crane controllers for specialised maritime applications, and for sites with a high explosion risk. GENERAL INFORMATION The large range of different controllers designed and manufactured by Gessman solve the majority of interface issues between operators and machines. Once the physical size and features are determined for an application, the ergonomic issues become an important part of designing the controller for a specific machine. In addition to the high quality mechanical systems, a number of electronic solutions have been developed and manufactured by Gessmann, such as Opto-electronic encoders and BUS systems. Gessmann products are marketed by Cavotec in the following countries: Argentina, Australia, China, Hong Kong, New Zealand, Norway, the UAE, the UK and the US. 42 Crane Controllers

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44 1 Flexible Cables Cavotec supplies a wide range of cables standard power cables to highly advanced power and signal cables. Depending on customer requirements, our cables can also be supplied with fiber optic And/or reinforcing elements. General information Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables, including special configurations. Cavotec s experience supports customers worldwide in selecting the most suitable cable according to the demands of specific applications. On request, cables are supplied terminated with lugs or connectors (both Medium and Low voltage types) for easier application. Spreader and festooning cables are also available. 44 Flexible Cables

45 CABLE SELECTION The correct choise of cable is vital to maximise performance and service life. Bending radius Precise calculation of the bending radius is a determining factor for cable reliability. A decrease in minimum bending radius has a major effect on the life of a cable because it causes stretching and internal distortions. Another important factor is the frequency of the cable movements. If movement is slow and infrequent a tighter bending radius can be considered. Special attention should also be paid to installations where flexing and torsion is present. Tensile strength The maximum admissible tensile force is stated by the cable manufacturer. Greater forces will result in permanent elongation of the conductors, which would shorten the life of the cable considerably. Operating speed and acceleration All cables are normally designed, manufactured and tested for the operating speeds and accelerations commonly in use today. Please note that high acceleration in combination with high operating speeds should be taken into account when calculating the tensile stress in the cable. Intermediate sheaves If possible, reduce the number intermediate pulleys and keep changes of direction to a minimum. Should the route of the cable require more than one change of direction, the distance between two sheaves or rollers must be selected according to the manufacturer specifications. Cable anchoring The anchoring systems must be designed to distribute the tensile stress over a wide area of the outer cable sheath. This prevents localised faults or damage. According to the cable handling system typology, different methods may be used. Current carrying capacity For the calculation of the current carrying capacity, the main factors to be taken in consideration are: Max Ambient temperature Typology of the cable handling system Type of duty Voltage drop For the calculation of the voltage drop, the main factors to be taken in consideration are: Length of cable Operating frequency Operating voltage To guarantee a long service life and a suitable service of the cable, the manufacturer instruction about storing, handling and installation must be followed strictly. Cable installation must be carried out by expert personnel, which shall ensure during this operation that undesired twist and torsion are removed, in order to avoid negative effect when in service. 45

46 Installation & Maintenance EXPERT CUSTOMER SERVICE IS A CRITICAL COMPONENT OF CAVOTEC S APPROACH. OUR SALES OFFICES AROUND THE WORLD DELIVER LOCAL EXPERTISE TO OUR CUSTOMERS; AND THESE ARE BACKED BY OUR GLOBAL NETWORK OF ENGINEERING CENTRES OF EXCELLENCE. SERVICE AND SUPPORT Cavotec s service teams support your installation, commissioning and maintenance requirements, and are available around the clock to deliver on- or off-site assistance. We also provide on-site commissioning and training, as well as dedicated training classes at our own Centres of Excellence. Using in-depth manuals and system documentation, our highly qualified engineers provide all training levels and maintenance instruction, according to your operational requirements. 46 Installation & Maintenance

47 Reference List ACROSS OUR MARKET UNITS AND AROUND THE GLOBE, CAVOTEC SEEKS TO DELIVER SAFE, RELIABLE, COST-EFFICIENT AND SUSTAINABLE SOLUTIONS. CAVOTEC AROUND THE WORLD ABB Aker Solutions Port of Antwerp APL APM Terminals BP British Royal Navy Port of Buenos Aires Port of Buzan Port of Chennai Cargotec China Shipping Lines Contship/Eurokay Doosan Heavy Ind. DP World Cochin JNPT Port of Dubai Port of El Callao Port of Everglades Evergreen Fantuzzi-Reggiane Port of Felixstowe Fels crane FMC Technologies Port of Gioia Tauro Port of Gothenburg Port of Guanghzou Port of Hamburg Port of Heidland Port of Helsinki Port of Ho Ci Minh Port of Hong Kong Hyundai Heavy Industry Impsa Italia Marittima Koch Konecranes Kuwait oil Co Port of Long Beach Port of Los Angeles MacGregor MAERSK Drilling Maher Terminal Port of Manzanillo Matson Shipping Port of Miami Mitsubishi Heavy Industry Mitsui MOL MSC Port of Mumbai National Oilwell Port of Ningbo Noell NYK Odim Port of Piraeus P.S.A. Qatar Petroleum Co Port of Qingdao Port of Rotterdam Port of Salalah Samsung Port of San Antonio Port of Santos Seawell Siemens Port of Singapore Port of Shanghai Port of Shenzhen StatoilHydro Port of St Laurence Stora Enso Port of St Petersburg Port of Stockholm STX Shipyard Sumimoto Swedish Navy Techint Port of Tianjin TTS U.S. Coast Guard U.S. Navy Port of Vancouver Port of Virginia Yang Ming ZPMC Reference List 47

48 With a global presence of sales and manufacturing companies across six continents, Cavotec ensures each of our clients receives personal and local service. Cavotec s creativity and professionalism is founded on teamwork: working closely with clients, exchanging knowledge and ideas. We are present in: Argentina Australia Bahrain Belgium Brazil Canada China Denmark Finland France Germany Hong Kong India Italy the Netherlands New Zealand Norway Russia Singapore South Africa South Korea Spain Sweden Switzerland UAE UK USA For more information please visit our website or contact us directly at info@cavotec.com February 2012 X2EN PORTS 04