Ports amp Maritime
Market Unit Brochure
In the ports sector Cavotec is a leading supplier of automated and electrical power control systems
The Grouprsquos product range includes a diverse variety of systems such as its unique automated mooring technology MoorMastertrade 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
Introduction
CavoteC in the Ports amp MaritiMeindustry
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 amp MaritiMe airPorts Mining amp tunnelling and general industry seCtors
2 Introduction
3
Cavotec Connectorsrsquo 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 Alfo specialises in the design and manufacture of spring reels and slipring columns used in a large number of industrial sectors
Cavotec Dabicorsquos 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 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 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
Based in Christchurch New Zealand the Cavotec MoorMaster technical team consists of experienced maritime personnel naval architects and mechanical and electrical engineers who develop Cavotecrsquos vacuum-based automated mooring system MoorMastertrade
Cavotec Specimas is a well-established developer of motorised cable reel technology for the ports and maritime mining and tunnelling and general industry sectors Cavotecrsquos engineers design and manufacture the Grouprsquos 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
Cavotec Connectors
Cavotec alfo
Cavotec dabico
Cavotec Meyerinck
Cavotec Micro-control
Cavotec MoorMaster
Cavotec specimas
Intermittent useOur hydrodynamic system is recommended for intermittent use applications Key features of this system include com-pact design constant torque output in reeling and unree-ling mode standard motor and low maintenance Normal torque outputs are 10-700 daNm with speeds ranging from 10 to 60 mmin
Continuous useFor continuous use applications we recommend our T-series gearboxes These can be used with several drive sy-stems and fitted with different drums such as monospiral random lay parallel lay and a Pull amp Store configuration
Other applicationsWe recommend our Torque Motor units for small reels and slow speed applications (5-40 daNm and 0-60 mmin) while our Cavotec Reel Control (CRC) is best suited for larger reels (torque output 40-750 daNm)
Motorised Cable Reels
guidelines for Cable reel seleCtion
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
4 Motorised Cable Reels
5
The above chart shows different typical cable reel applications related to the most suitable cable reel system and drive
1
3
4
2
1 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 10-1200 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
CavoteC Cable reel systeM
Typical cable reel applications
Continuoususe
Intermittentuse
10 20 40 80 160 320 640 1280Torque Output (daNm)
Large RMGC amp ASC bullbull Small Cranes 100 EDbull Small Vertical Applications
bull Drill Jumbos amp Harbour applications
bull Stacker amp Reclaimersbull Vertical Applications
bull Ship-to-shore Cranesbull Trippers bull Small Cranes
Hydrodynamic Torque Motor CRC
bull Small RMGCbull Large Vertical Applications
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
hydrodynaMiCsysteMs
6 Motorised Cable Reels
The chart above shows typical torquespeed 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
SlipTorquediagram
Nominal Torque
Drum Speed (rpm)
-30 -20 -10 0 +10 +20 +30
10
20
7
Torquespeed diagram for hydrodynamic unit
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 torqueslip curve The motors are used up to maximum of plusmn 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
1 Self-breaking torque motor2 Pre-reducer3 Gearbox4 Collector5 Drum
CavoteC torqueMotor systeM
1
2
345
8 Motorised Cable Reels
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 ndash such as cable weight reeled cable on the drum acceleration or deceleration of the crane position on the track ndash 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
CavoteC torque Control (CrC) drive
9
1
2
3
4 1 CRC drive2 Standard squirrel self-
breaking electric motor (one or more motors can be used in parallel)
3 Pre-reducer4 Gearbox
M3 ~
Power supply
Interlocking for crane
SignalCavotecSpecimas
applicationsoftware
PowerOutput
Interlocking for crane
Brakesignal
Chopper Resistor
Encoder
Brake spring appelect released
AUX power
220V AC
Drum
Gearbox
Transducer
Torque reference
Processing
Cablereel motor
Brake controlcircuit
Slipringassembly
1 CRC drive2 Standard squirrel cage electric motor On or more motors can be used in parallel3 Pre-reducer and holding brake4 Main gear-box
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
kP brushes
10 Motorised Cable Reels
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
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
fibre oPtiCrotaryaCCuMulator
Cable guides
11
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
bull Complete operational safetybull Low installation costbull Full cable protectionbull Maintenance freebull No load restrictionsbull Channel free from spillagebull Operates in any climatebull No crane speed limitationsbull No alignment problemsbull Easily adaptable to existing systems
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
Main advantages
teChniCalCharaCteristiCs
Panzerbelt
The main components of the Panzerbelt system are 1 Stainless steel rivets2 Pre-drilled fixing strip3 Panzerbelt steel reinforced rubber cover4 Stainless steel channel profile
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 belt-lifting deviCe fitted to the Crane steel reinforCeMent has been inCorPorated to retain strength and flexibility of the belt in all direCtions
Ambient temperature -30degC up to 80degC
Opening angle 90deg max
Estimate lifetime gt 250000 cycles (openclose)
Horizontal bending radius 35m (minimum) with hinge profile external 45m (minimum) with hinge profile internal
Maximum load The maximum load applied on a Panzerbelt System with a 100mm wide slot should not exceed 400 Ncm2
Maximum breaking load at joint 1750kg for standard Panzerbelt 2650kg for Super Panzerbelt
Elongation 2 with load of 3000 N
Approx lenght of rolls 50m
Max force to open the belt to 90deg 40kg
13
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
general CharaCteristiCs
siMPle and fastinstallation
14 Panzerbelt
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
bull EitherStandardorSuperreinforcedbeltinrollsofapprox 50m with joints at their ends
bull StainlesssteelchannelAISI304orAISI316 15mm thick
bull Hotdipgalvanised30x8mmfixingstripswith 13 pre-drilled holes per metre
bull Stainlesssteelornickelcopperrivetsbull Earthingcopperstripswithscrewsandnutsbull Anti-fillingandalignmentsystemwithexpanded
polystyrenebull Alignmentbracketsforchannelsections
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
Panzerbelt can be supplied with several optional items includingbullStainlesssteelturnoveranchors(singleordouble)bullJunctionboxesbullFixedPanzerbeltopeningdevicesbullBeltliftingdevicesbullEasyliftaccesscovers(springloaded)
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
systeMaCCessories
15
the standard Channel
MoorMastertrade ndash Automated Mooring System
MoorMastertrade dramatically improves safety and operational efficiency and also enables ports to make infrastructure savings It has performed more than 40000 mooring operations at ferry bulk handling Ro-Ro container and lock applications around the world
Key advantages of the system include
Safety bullReducedriskofmooringaccidentsaspersonnelareremovedfromhazardousworkingzones1048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644
bullReal-timemonitoringofmooringprocessandforcesduring stay in port
Infrastructure bull Improvedpierutilisationduetocloservesselspacing bullQuaylengthcanbelsquovirtuallyextendedrsquoastheshiprsquos bow can overhang the end of the quay bullMoorMastertrade1048644canreducetherequirementforextension of breakwater protection
Efficiency bullHighercontainertransferrates Vesselsareheldsecurely
alongside which may allow for the automation to shore cranes in futurebullShipmotionduetoswellsurgepassingshipsetc is dampenedbull Improvedcontinuityofworkprocesses bullShorteroperatingtimesfortugs bullNomooringteamsrequiredharbourpilotsable to disembark faster
Environment bullReducedemissionsasshipsacuteenginescanbeshutdown
earlier tugs able to leave earlier Furthermore once in port vessels are not required to reposition along the berth as MoorMastertrade dampens vessel motion so considerably
bullQuickerconnectiontoshorepowerifavailable
a unique teChnology
16 MoorMastertrade
MoorMastertrade 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
Container terminals have become a crucial link in todayrsquos 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 MoorMastertrade 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 MoorMastertrade holds ships steady providing a stable platform for faster crane and cargo movements
solutionsfor ContainerterMinals
17
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
MoorMastertrade 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 MoorMastertrade 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
solutionsfor roro and ferry terMinals
18 MoorMastertrade
solutionsfor dry bulk and tanker terMinals
The MoorMastertrade 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways MoorMastertrade cuts vessel transit times and creates a safer environment for those working on ships and shore-side
MoorMastertrade 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
19
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
In the ports sector Cavotec is a leading supplier of automated and electrical power control systems
The Grouprsquos product range includes a diverse variety of systems such as its unique automated mooring technology MoorMastertrade 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
Introduction
CavoteC in the Ports amp MaritiMeindustry
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 amp MaritiMe airPorts Mining amp tunnelling and general industry seCtors
2 Introduction
3
Cavotec Connectorsrsquo 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 Alfo specialises in the design and manufacture of spring reels and slipring columns used in a large number of industrial sectors
Cavotec Dabicorsquos 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 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 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
Based in Christchurch New Zealand the Cavotec MoorMaster technical team consists of experienced maritime personnel naval architects and mechanical and electrical engineers who develop Cavotecrsquos vacuum-based automated mooring system MoorMastertrade
Cavotec Specimas is a well-established developer of motorised cable reel technology for the ports and maritime mining and tunnelling and general industry sectors Cavotecrsquos engineers design and manufacture the Grouprsquos 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
Cavotec Connectors
Cavotec alfo
Cavotec dabico
Cavotec Meyerinck
Cavotec Micro-control
Cavotec MoorMaster
Cavotec specimas
Intermittent useOur hydrodynamic system is recommended for intermittent use applications Key features of this system include com-pact design constant torque output in reeling and unree-ling mode standard motor and low maintenance Normal torque outputs are 10-700 daNm with speeds ranging from 10 to 60 mmin
Continuous useFor continuous use applications we recommend our T-series gearboxes These can be used with several drive sy-stems and fitted with different drums such as monospiral random lay parallel lay and a Pull amp Store configuration
Other applicationsWe recommend our Torque Motor units for small reels and slow speed applications (5-40 daNm and 0-60 mmin) while our Cavotec Reel Control (CRC) is best suited for larger reels (torque output 40-750 daNm)
Motorised Cable Reels
guidelines for Cable reel seleCtion
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
4 Motorised Cable Reels
5
The above chart shows different typical cable reel applications related to the most suitable cable reel system and drive
1
3
4
2
1 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 10-1200 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
CavoteC Cable reel systeM
Typical cable reel applications
Continuoususe
Intermittentuse
10 20 40 80 160 320 640 1280Torque Output (daNm)
Large RMGC amp ASC bullbull Small Cranes 100 EDbull Small Vertical Applications
bull Drill Jumbos amp Harbour applications
bull Stacker amp Reclaimersbull Vertical Applications
bull Ship-to-shore Cranesbull Trippers bull Small Cranes
Hydrodynamic Torque Motor CRC
bull Small RMGCbull Large Vertical Applications
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
hydrodynaMiCsysteMs
6 Motorised Cable Reels
The chart above shows typical torquespeed 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
SlipTorquediagram
Nominal Torque
Drum Speed (rpm)
-30 -20 -10 0 +10 +20 +30
10
20
7
Torquespeed diagram for hydrodynamic unit
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 torqueslip curve The motors are used up to maximum of plusmn 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
1 Self-breaking torque motor2 Pre-reducer3 Gearbox4 Collector5 Drum
CavoteC torqueMotor systeM
1
2
345
8 Motorised Cable Reels
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 ndash such as cable weight reeled cable on the drum acceleration or deceleration of the crane position on the track ndash 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
CavoteC torque Control (CrC) drive
9
1
2
3
4 1 CRC drive2 Standard squirrel self-
breaking electric motor (one or more motors can be used in parallel)
3 Pre-reducer4 Gearbox
M3 ~
Power supply
Interlocking for crane
SignalCavotecSpecimas
applicationsoftware
PowerOutput
Interlocking for crane
Brakesignal
Chopper Resistor
Encoder
Brake spring appelect released
AUX power
220V AC
Drum
Gearbox
Transducer
Torque reference
Processing
Cablereel motor
Brake controlcircuit
Slipringassembly
1 CRC drive2 Standard squirrel cage electric motor On or more motors can be used in parallel3 Pre-reducer and holding brake4 Main gear-box
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
kP brushes
10 Motorised Cable Reels
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
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
fibre oPtiCrotaryaCCuMulator
Cable guides
11
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
bull Complete operational safetybull Low installation costbull Full cable protectionbull Maintenance freebull No load restrictionsbull Channel free from spillagebull Operates in any climatebull No crane speed limitationsbull No alignment problemsbull Easily adaptable to existing systems
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
Main advantages
teChniCalCharaCteristiCs
Panzerbelt
The main components of the Panzerbelt system are 1 Stainless steel rivets2 Pre-drilled fixing strip3 Panzerbelt steel reinforced rubber cover4 Stainless steel channel profile
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 belt-lifting deviCe fitted to the Crane steel reinforCeMent has been inCorPorated to retain strength and flexibility of the belt in all direCtions
Ambient temperature -30degC up to 80degC
Opening angle 90deg max
Estimate lifetime gt 250000 cycles (openclose)
Horizontal bending radius 35m (minimum) with hinge profile external 45m (minimum) with hinge profile internal
Maximum load The maximum load applied on a Panzerbelt System with a 100mm wide slot should not exceed 400 Ncm2
Maximum breaking load at joint 1750kg for standard Panzerbelt 2650kg for Super Panzerbelt
Elongation 2 with load of 3000 N
Approx lenght of rolls 50m
Max force to open the belt to 90deg 40kg
13
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
general CharaCteristiCs
siMPle and fastinstallation
14 Panzerbelt
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
bull EitherStandardorSuperreinforcedbeltinrollsofapprox 50m with joints at their ends
bull StainlesssteelchannelAISI304orAISI316 15mm thick
bull Hotdipgalvanised30x8mmfixingstripswith 13 pre-drilled holes per metre
bull Stainlesssteelornickelcopperrivetsbull Earthingcopperstripswithscrewsandnutsbull Anti-fillingandalignmentsystemwithexpanded
polystyrenebull Alignmentbracketsforchannelsections
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
Panzerbelt can be supplied with several optional items includingbullStainlesssteelturnoveranchors(singleordouble)bullJunctionboxesbullFixedPanzerbeltopeningdevicesbullBeltliftingdevicesbullEasyliftaccesscovers(springloaded)
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
systeMaCCessories
15
the standard Channel
MoorMastertrade ndash Automated Mooring System
MoorMastertrade dramatically improves safety and operational efficiency and also enables ports to make infrastructure savings It has performed more than 40000 mooring operations at ferry bulk handling Ro-Ro container and lock applications around the world
Key advantages of the system include
Safety bullReducedriskofmooringaccidentsaspersonnelareremovedfromhazardousworkingzones1048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644
bullReal-timemonitoringofmooringprocessandforcesduring stay in port
Infrastructure bull Improvedpierutilisationduetocloservesselspacing bullQuaylengthcanbelsquovirtuallyextendedrsquoastheshiprsquos bow can overhang the end of the quay bullMoorMastertrade1048644canreducetherequirementforextension of breakwater protection
Efficiency bullHighercontainertransferrates Vesselsareheldsecurely
alongside which may allow for the automation to shore cranes in futurebullShipmotionduetoswellsurgepassingshipsetc is dampenedbull Improvedcontinuityofworkprocesses bullShorteroperatingtimesfortugs bullNomooringteamsrequiredharbourpilotsable to disembark faster
Environment bullReducedemissionsasshipsacuteenginescanbeshutdown
earlier tugs able to leave earlier Furthermore once in port vessels are not required to reposition along the berth as MoorMastertrade dampens vessel motion so considerably
bullQuickerconnectiontoshorepowerifavailable
a unique teChnology
16 MoorMastertrade
MoorMastertrade 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
Container terminals have become a crucial link in todayrsquos 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 MoorMastertrade 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 MoorMastertrade holds ships steady providing a stable platform for faster crane and cargo movements
solutionsfor ContainerterMinals
17
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
MoorMastertrade 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 MoorMastertrade 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
solutionsfor roro and ferry terMinals
18 MoorMastertrade
solutionsfor dry bulk and tanker terMinals
The MoorMastertrade 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways MoorMastertrade cuts vessel transit times and creates a safer environment for those working on ships and shore-side
MoorMastertrade 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
19
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
3
Cavotec Connectorsrsquo 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 Alfo specialises in the design and manufacture of spring reels and slipring columns used in a large number of industrial sectors
Cavotec Dabicorsquos 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 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 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
Based in Christchurch New Zealand the Cavotec MoorMaster technical team consists of experienced maritime personnel naval architects and mechanical and electrical engineers who develop Cavotecrsquos vacuum-based automated mooring system MoorMastertrade
Cavotec Specimas is a well-established developer of motorised cable reel technology for the ports and maritime mining and tunnelling and general industry sectors Cavotecrsquos engineers design and manufacture the Grouprsquos 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
Cavotec Connectors
Cavotec alfo
Cavotec dabico
Cavotec Meyerinck
Cavotec Micro-control
Cavotec MoorMaster
Cavotec specimas
Intermittent useOur hydrodynamic system is recommended for intermittent use applications Key features of this system include com-pact design constant torque output in reeling and unree-ling mode standard motor and low maintenance Normal torque outputs are 10-700 daNm with speeds ranging from 10 to 60 mmin
Continuous useFor continuous use applications we recommend our T-series gearboxes These can be used with several drive sy-stems and fitted with different drums such as monospiral random lay parallel lay and a Pull amp Store configuration
Other applicationsWe recommend our Torque Motor units for small reels and slow speed applications (5-40 daNm and 0-60 mmin) while our Cavotec Reel Control (CRC) is best suited for larger reels (torque output 40-750 daNm)
Motorised Cable Reels
guidelines for Cable reel seleCtion
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
4 Motorised Cable Reels
5
The above chart shows different typical cable reel applications related to the most suitable cable reel system and drive
1
3
4
2
1 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 10-1200 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
CavoteC Cable reel systeM
Typical cable reel applications
Continuoususe
Intermittentuse
10 20 40 80 160 320 640 1280Torque Output (daNm)
Large RMGC amp ASC bullbull Small Cranes 100 EDbull Small Vertical Applications
bull Drill Jumbos amp Harbour applications
bull Stacker amp Reclaimersbull Vertical Applications
bull Ship-to-shore Cranesbull Trippers bull Small Cranes
Hydrodynamic Torque Motor CRC
bull Small RMGCbull Large Vertical Applications
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
hydrodynaMiCsysteMs
6 Motorised Cable Reels
The chart above shows typical torquespeed 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
SlipTorquediagram
Nominal Torque
Drum Speed (rpm)
-30 -20 -10 0 +10 +20 +30
10
20
7
Torquespeed diagram for hydrodynamic unit
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 torqueslip curve The motors are used up to maximum of plusmn 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
1 Self-breaking torque motor2 Pre-reducer3 Gearbox4 Collector5 Drum
CavoteC torqueMotor systeM
1
2
345
8 Motorised Cable Reels
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 ndash such as cable weight reeled cable on the drum acceleration or deceleration of the crane position on the track ndash 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
CavoteC torque Control (CrC) drive
9
1
2
3
4 1 CRC drive2 Standard squirrel self-
breaking electric motor (one or more motors can be used in parallel)
3 Pre-reducer4 Gearbox
M3 ~
Power supply
Interlocking for crane
SignalCavotecSpecimas
applicationsoftware
PowerOutput
Interlocking for crane
Brakesignal
Chopper Resistor
Encoder
Brake spring appelect released
AUX power
220V AC
Drum
Gearbox
Transducer
Torque reference
Processing
Cablereel motor
Brake controlcircuit
Slipringassembly
1 CRC drive2 Standard squirrel cage electric motor On or more motors can be used in parallel3 Pre-reducer and holding brake4 Main gear-box
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
kP brushes
10 Motorised Cable Reels
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
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
fibre oPtiCrotaryaCCuMulator
Cable guides
11
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
bull Complete operational safetybull Low installation costbull Full cable protectionbull Maintenance freebull No load restrictionsbull Channel free from spillagebull Operates in any climatebull No crane speed limitationsbull No alignment problemsbull Easily adaptable to existing systems
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
Main advantages
teChniCalCharaCteristiCs
Panzerbelt
The main components of the Panzerbelt system are 1 Stainless steel rivets2 Pre-drilled fixing strip3 Panzerbelt steel reinforced rubber cover4 Stainless steel channel profile
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 belt-lifting deviCe fitted to the Crane steel reinforCeMent has been inCorPorated to retain strength and flexibility of the belt in all direCtions
Ambient temperature -30degC up to 80degC
Opening angle 90deg max
Estimate lifetime gt 250000 cycles (openclose)
Horizontal bending radius 35m (minimum) with hinge profile external 45m (minimum) with hinge profile internal
Maximum load The maximum load applied on a Panzerbelt System with a 100mm wide slot should not exceed 400 Ncm2
Maximum breaking load at joint 1750kg for standard Panzerbelt 2650kg for Super Panzerbelt
Elongation 2 with load of 3000 N
Approx lenght of rolls 50m
Max force to open the belt to 90deg 40kg
13
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
general CharaCteristiCs
siMPle and fastinstallation
14 Panzerbelt
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
bull EitherStandardorSuperreinforcedbeltinrollsofapprox 50m with joints at their ends
bull StainlesssteelchannelAISI304orAISI316 15mm thick
bull Hotdipgalvanised30x8mmfixingstripswith 13 pre-drilled holes per metre
bull Stainlesssteelornickelcopperrivetsbull Earthingcopperstripswithscrewsandnutsbull Anti-fillingandalignmentsystemwithexpanded
polystyrenebull Alignmentbracketsforchannelsections
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
Panzerbelt can be supplied with several optional items includingbullStainlesssteelturnoveranchors(singleordouble)bullJunctionboxesbullFixedPanzerbeltopeningdevicesbullBeltliftingdevicesbullEasyliftaccesscovers(springloaded)
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
systeMaCCessories
15
the standard Channel
MoorMastertrade ndash Automated Mooring System
MoorMastertrade dramatically improves safety and operational efficiency and also enables ports to make infrastructure savings It has performed more than 40000 mooring operations at ferry bulk handling Ro-Ro container and lock applications around the world
Key advantages of the system include
Safety bullReducedriskofmooringaccidentsaspersonnelareremovedfromhazardousworkingzones1048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644
bullReal-timemonitoringofmooringprocessandforcesduring stay in port
Infrastructure bull Improvedpierutilisationduetocloservesselspacing bullQuaylengthcanbelsquovirtuallyextendedrsquoastheshiprsquos bow can overhang the end of the quay bullMoorMastertrade1048644canreducetherequirementforextension of breakwater protection
Efficiency bullHighercontainertransferrates Vesselsareheldsecurely
alongside which may allow for the automation to shore cranes in futurebullShipmotionduetoswellsurgepassingshipsetc is dampenedbull Improvedcontinuityofworkprocesses bullShorteroperatingtimesfortugs bullNomooringteamsrequiredharbourpilotsable to disembark faster
Environment bullReducedemissionsasshipsacuteenginescanbeshutdown
earlier tugs able to leave earlier Furthermore once in port vessels are not required to reposition along the berth as MoorMastertrade dampens vessel motion so considerably
bullQuickerconnectiontoshorepowerifavailable
a unique teChnology
16 MoorMastertrade
MoorMastertrade 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
Container terminals have become a crucial link in todayrsquos 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 MoorMastertrade 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 MoorMastertrade holds ships steady providing a stable platform for faster crane and cargo movements
solutionsfor ContainerterMinals
17
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
MoorMastertrade 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 MoorMastertrade 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
solutionsfor roro and ferry terMinals
18 MoorMastertrade
solutionsfor dry bulk and tanker terMinals
The MoorMastertrade 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways MoorMastertrade cuts vessel transit times and creates a safer environment for those working on ships and shore-side
MoorMastertrade 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
19
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
Intermittent useOur hydrodynamic system is recommended for intermittent use applications Key features of this system include com-pact design constant torque output in reeling and unree-ling mode standard motor and low maintenance Normal torque outputs are 10-700 daNm with speeds ranging from 10 to 60 mmin
Continuous useFor continuous use applications we recommend our T-series gearboxes These can be used with several drive sy-stems and fitted with different drums such as monospiral random lay parallel lay and a Pull amp Store configuration
Other applicationsWe recommend our Torque Motor units for small reels and slow speed applications (5-40 daNm and 0-60 mmin) while our Cavotec Reel Control (CRC) is best suited for larger reels (torque output 40-750 daNm)
Motorised Cable Reels
guidelines for Cable reel seleCtion
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
4 Motorised Cable Reels
5
The above chart shows different typical cable reel applications related to the most suitable cable reel system and drive
1
3
4
2
1 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 10-1200 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
CavoteC Cable reel systeM
Typical cable reel applications
Continuoususe
Intermittentuse
10 20 40 80 160 320 640 1280Torque Output (daNm)
Large RMGC amp ASC bullbull Small Cranes 100 EDbull Small Vertical Applications
bull Drill Jumbos amp Harbour applications
bull Stacker amp Reclaimersbull Vertical Applications
bull Ship-to-shore Cranesbull Trippers bull Small Cranes
Hydrodynamic Torque Motor CRC
bull Small RMGCbull Large Vertical Applications
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
hydrodynaMiCsysteMs
6 Motorised Cable Reels
The chart above shows typical torquespeed 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
SlipTorquediagram
Nominal Torque
Drum Speed (rpm)
-30 -20 -10 0 +10 +20 +30
10
20
7
Torquespeed diagram for hydrodynamic unit
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 torqueslip curve The motors are used up to maximum of plusmn 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
1 Self-breaking torque motor2 Pre-reducer3 Gearbox4 Collector5 Drum
CavoteC torqueMotor systeM
1
2
345
8 Motorised Cable Reels
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 ndash such as cable weight reeled cable on the drum acceleration or deceleration of the crane position on the track ndash 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
CavoteC torque Control (CrC) drive
9
1
2
3
4 1 CRC drive2 Standard squirrel self-
breaking electric motor (one or more motors can be used in parallel)
3 Pre-reducer4 Gearbox
M3 ~
Power supply
Interlocking for crane
SignalCavotecSpecimas
applicationsoftware
PowerOutput
Interlocking for crane
Brakesignal
Chopper Resistor
Encoder
Brake spring appelect released
AUX power
220V AC
Drum
Gearbox
Transducer
Torque reference
Processing
Cablereel motor
Brake controlcircuit
Slipringassembly
1 CRC drive2 Standard squirrel cage electric motor On or more motors can be used in parallel3 Pre-reducer and holding brake4 Main gear-box
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
kP brushes
10 Motorised Cable Reels
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
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
fibre oPtiCrotaryaCCuMulator
Cable guides
11
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
bull Complete operational safetybull Low installation costbull Full cable protectionbull Maintenance freebull No load restrictionsbull Channel free from spillagebull Operates in any climatebull No crane speed limitationsbull No alignment problemsbull Easily adaptable to existing systems
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
Main advantages
teChniCalCharaCteristiCs
Panzerbelt
The main components of the Panzerbelt system are 1 Stainless steel rivets2 Pre-drilled fixing strip3 Panzerbelt steel reinforced rubber cover4 Stainless steel channel profile
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 belt-lifting deviCe fitted to the Crane steel reinforCeMent has been inCorPorated to retain strength and flexibility of the belt in all direCtions
Ambient temperature -30degC up to 80degC
Opening angle 90deg max
Estimate lifetime gt 250000 cycles (openclose)
Horizontal bending radius 35m (minimum) with hinge profile external 45m (minimum) with hinge profile internal
Maximum load The maximum load applied on a Panzerbelt System with a 100mm wide slot should not exceed 400 Ncm2
Maximum breaking load at joint 1750kg for standard Panzerbelt 2650kg for Super Panzerbelt
Elongation 2 with load of 3000 N
Approx lenght of rolls 50m
Max force to open the belt to 90deg 40kg
13
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
general CharaCteristiCs
siMPle and fastinstallation
14 Panzerbelt
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
bull EitherStandardorSuperreinforcedbeltinrollsofapprox 50m with joints at their ends
bull StainlesssteelchannelAISI304orAISI316 15mm thick
bull Hotdipgalvanised30x8mmfixingstripswith 13 pre-drilled holes per metre
bull Stainlesssteelornickelcopperrivetsbull Earthingcopperstripswithscrewsandnutsbull Anti-fillingandalignmentsystemwithexpanded
polystyrenebull Alignmentbracketsforchannelsections
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
Panzerbelt can be supplied with several optional items includingbullStainlesssteelturnoveranchors(singleordouble)bullJunctionboxesbullFixedPanzerbeltopeningdevicesbullBeltliftingdevicesbullEasyliftaccesscovers(springloaded)
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
systeMaCCessories
15
the standard Channel
MoorMastertrade ndash Automated Mooring System
MoorMastertrade dramatically improves safety and operational efficiency and also enables ports to make infrastructure savings It has performed more than 40000 mooring operations at ferry bulk handling Ro-Ro container and lock applications around the world
Key advantages of the system include
Safety bullReducedriskofmooringaccidentsaspersonnelareremovedfromhazardousworkingzones1048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644
bullReal-timemonitoringofmooringprocessandforcesduring stay in port
Infrastructure bull Improvedpierutilisationduetocloservesselspacing bullQuaylengthcanbelsquovirtuallyextendedrsquoastheshiprsquos bow can overhang the end of the quay bullMoorMastertrade1048644canreducetherequirementforextension of breakwater protection
Efficiency bullHighercontainertransferrates Vesselsareheldsecurely
alongside which may allow for the automation to shore cranes in futurebullShipmotionduetoswellsurgepassingshipsetc is dampenedbull Improvedcontinuityofworkprocesses bullShorteroperatingtimesfortugs bullNomooringteamsrequiredharbourpilotsable to disembark faster
Environment bullReducedemissionsasshipsacuteenginescanbeshutdown
earlier tugs able to leave earlier Furthermore once in port vessels are not required to reposition along the berth as MoorMastertrade dampens vessel motion so considerably
bullQuickerconnectiontoshorepowerifavailable
a unique teChnology
16 MoorMastertrade
MoorMastertrade 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
Container terminals have become a crucial link in todayrsquos 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 MoorMastertrade 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 MoorMastertrade holds ships steady providing a stable platform for faster crane and cargo movements
solutionsfor ContainerterMinals
17
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
MoorMastertrade 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 MoorMastertrade 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
solutionsfor roro and ferry terMinals
18 MoorMastertrade
solutionsfor dry bulk and tanker terMinals
The MoorMastertrade 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways MoorMastertrade cuts vessel transit times and creates a safer environment for those working on ships and shore-side
MoorMastertrade 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
19
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
5
The above chart shows different typical cable reel applications related to the most suitable cable reel system and drive
1
3
4
2
1 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 10-1200 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
CavoteC Cable reel systeM
Typical cable reel applications
Continuoususe
Intermittentuse
10 20 40 80 160 320 640 1280Torque Output (daNm)
Large RMGC amp ASC bullbull Small Cranes 100 EDbull Small Vertical Applications
bull Drill Jumbos amp Harbour applications
bull Stacker amp Reclaimersbull Vertical Applications
bull Ship-to-shore Cranesbull Trippers bull Small Cranes
Hydrodynamic Torque Motor CRC
bull Small RMGCbull Large Vertical Applications
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
hydrodynaMiCsysteMs
6 Motorised Cable Reels
The chart above shows typical torquespeed 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
SlipTorquediagram
Nominal Torque
Drum Speed (rpm)
-30 -20 -10 0 +10 +20 +30
10
20
7
Torquespeed diagram for hydrodynamic unit
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 torqueslip curve The motors are used up to maximum of plusmn 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
1 Self-breaking torque motor2 Pre-reducer3 Gearbox4 Collector5 Drum
CavoteC torqueMotor systeM
1
2
345
8 Motorised Cable Reels
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 ndash such as cable weight reeled cable on the drum acceleration or deceleration of the crane position on the track ndash 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
CavoteC torque Control (CrC) drive
9
1
2
3
4 1 CRC drive2 Standard squirrel self-
breaking electric motor (one or more motors can be used in parallel)
3 Pre-reducer4 Gearbox
M3 ~
Power supply
Interlocking for crane
SignalCavotecSpecimas
applicationsoftware
PowerOutput
Interlocking for crane
Brakesignal
Chopper Resistor
Encoder
Brake spring appelect released
AUX power
220V AC
Drum
Gearbox
Transducer
Torque reference
Processing
Cablereel motor
Brake controlcircuit
Slipringassembly
1 CRC drive2 Standard squirrel cage electric motor On or more motors can be used in parallel3 Pre-reducer and holding brake4 Main gear-box
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
kP brushes
10 Motorised Cable Reels
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
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
fibre oPtiCrotaryaCCuMulator
Cable guides
11
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
bull Complete operational safetybull Low installation costbull Full cable protectionbull Maintenance freebull No load restrictionsbull Channel free from spillagebull Operates in any climatebull No crane speed limitationsbull No alignment problemsbull Easily adaptable to existing systems
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
Main advantages
teChniCalCharaCteristiCs
Panzerbelt
The main components of the Panzerbelt system are 1 Stainless steel rivets2 Pre-drilled fixing strip3 Panzerbelt steel reinforced rubber cover4 Stainless steel channel profile
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 belt-lifting deviCe fitted to the Crane steel reinforCeMent has been inCorPorated to retain strength and flexibility of the belt in all direCtions
Ambient temperature -30degC up to 80degC
Opening angle 90deg max
Estimate lifetime gt 250000 cycles (openclose)
Horizontal bending radius 35m (minimum) with hinge profile external 45m (minimum) with hinge profile internal
Maximum load The maximum load applied on a Panzerbelt System with a 100mm wide slot should not exceed 400 Ncm2
Maximum breaking load at joint 1750kg for standard Panzerbelt 2650kg for Super Panzerbelt
Elongation 2 with load of 3000 N
Approx lenght of rolls 50m
Max force to open the belt to 90deg 40kg
13
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
general CharaCteristiCs
siMPle and fastinstallation
14 Panzerbelt
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
bull EitherStandardorSuperreinforcedbeltinrollsofapprox 50m with joints at their ends
bull StainlesssteelchannelAISI304orAISI316 15mm thick
bull Hotdipgalvanised30x8mmfixingstripswith 13 pre-drilled holes per metre
bull Stainlesssteelornickelcopperrivetsbull Earthingcopperstripswithscrewsandnutsbull Anti-fillingandalignmentsystemwithexpanded
polystyrenebull Alignmentbracketsforchannelsections
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
Panzerbelt can be supplied with several optional items includingbullStainlesssteelturnoveranchors(singleordouble)bullJunctionboxesbullFixedPanzerbeltopeningdevicesbullBeltliftingdevicesbullEasyliftaccesscovers(springloaded)
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
systeMaCCessories
15
the standard Channel
MoorMastertrade ndash Automated Mooring System
MoorMastertrade dramatically improves safety and operational efficiency and also enables ports to make infrastructure savings It has performed more than 40000 mooring operations at ferry bulk handling Ro-Ro container and lock applications around the world
Key advantages of the system include
Safety bullReducedriskofmooringaccidentsaspersonnelareremovedfromhazardousworkingzones1048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644
bullReal-timemonitoringofmooringprocessandforcesduring stay in port
Infrastructure bull Improvedpierutilisationduetocloservesselspacing bullQuaylengthcanbelsquovirtuallyextendedrsquoastheshiprsquos bow can overhang the end of the quay bullMoorMastertrade1048644canreducetherequirementforextension of breakwater protection
Efficiency bullHighercontainertransferrates Vesselsareheldsecurely
alongside which may allow for the automation to shore cranes in futurebullShipmotionduetoswellsurgepassingshipsetc is dampenedbull Improvedcontinuityofworkprocesses bullShorteroperatingtimesfortugs bullNomooringteamsrequiredharbourpilotsable to disembark faster
Environment bullReducedemissionsasshipsacuteenginescanbeshutdown
earlier tugs able to leave earlier Furthermore once in port vessels are not required to reposition along the berth as MoorMastertrade dampens vessel motion so considerably
bullQuickerconnectiontoshorepowerifavailable
a unique teChnology
16 MoorMastertrade
MoorMastertrade 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
Container terminals have become a crucial link in todayrsquos 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 MoorMastertrade 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 MoorMastertrade holds ships steady providing a stable platform for faster crane and cargo movements
solutionsfor ContainerterMinals
17
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
MoorMastertrade 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 MoorMastertrade 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
solutionsfor roro and ferry terMinals
18 MoorMastertrade
solutionsfor dry bulk and tanker terMinals
The MoorMastertrade 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways MoorMastertrade cuts vessel transit times and creates a safer environment for those working on ships and shore-side
MoorMastertrade 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
19
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
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
hydrodynaMiCsysteMs
6 Motorised Cable Reels
The chart above shows typical torquespeed 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
SlipTorquediagram
Nominal Torque
Drum Speed (rpm)
-30 -20 -10 0 +10 +20 +30
10
20
7
Torquespeed diagram for hydrodynamic unit
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 torqueslip curve The motors are used up to maximum of plusmn 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
1 Self-breaking torque motor2 Pre-reducer3 Gearbox4 Collector5 Drum
CavoteC torqueMotor systeM
1
2
345
8 Motorised Cable Reels
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 ndash such as cable weight reeled cable on the drum acceleration or deceleration of the crane position on the track ndash 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
CavoteC torque Control (CrC) drive
9
1
2
3
4 1 CRC drive2 Standard squirrel self-
breaking electric motor (one or more motors can be used in parallel)
3 Pre-reducer4 Gearbox
M3 ~
Power supply
Interlocking for crane
SignalCavotecSpecimas
applicationsoftware
PowerOutput
Interlocking for crane
Brakesignal
Chopper Resistor
Encoder
Brake spring appelect released
AUX power
220V AC
Drum
Gearbox
Transducer
Torque reference
Processing
Cablereel motor
Brake controlcircuit
Slipringassembly
1 CRC drive2 Standard squirrel cage electric motor On or more motors can be used in parallel3 Pre-reducer and holding brake4 Main gear-box
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
kP brushes
10 Motorised Cable Reels
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
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
fibre oPtiCrotaryaCCuMulator
Cable guides
11
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
bull Complete operational safetybull Low installation costbull Full cable protectionbull Maintenance freebull No load restrictionsbull Channel free from spillagebull Operates in any climatebull No crane speed limitationsbull No alignment problemsbull Easily adaptable to existing systems
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
Main advantages
teChniCalCharaCteristiCs
Panzerbelt
The main components of the Panzerbelt system are 1 Stainless steel rivets2 Pre-drilled fixing strip3 Panzerbelt steel reinforced rubber cover4 Stainless steel channel profile
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 belt-lifting deviCe fitted to the Crane steel reinforCeMent has been inCorPorated to retain strength and flexibility of the belt in all direCtions
Ambient temperature -30degC up to 80degC
Opening angle 90deg max
Estimate lifetime gt 250000 cycles (openclose)
Horizontal bending radius 35m (minimum) with hinge profile external 45m (minimum) with hinge profile internal
Maximum load The maximum load applied on a Panzerbelt System with a 100mm wide slot should not exceed 400 Ncm2
Maximum breaking load at joint 1750kg for standard Panzerbelt 2650kg for Super Panzerbelt
Elongation 2 with load of 3000 N
Approx lenght of rolls 50m
Max force to open the belt to 90deg 40kg
13
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
general CharaCteristiCs
siMPle and fastinstallation
14 Panzerbelt
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
bull EitherStandardorSuperreinforcedbeltinrollsofapprox 50m with joints at their ends
bull StainlesssteelchannelAISI304orAISI316 15mm thick
bull Hotdipgalvanised30x8mmfixingstripswith 13 pre-drilled holes per metre
bull Stainlesssteelornickelcopperrivetsbull Earthingcopperstripswithscrewsandnutsbull Anti-fillingandalignmentsystemwithexpanded
polystyrenebull Alignmentbracketsforchannelsections
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
Panzerbelt can be supplied with several optional items includingbullStainlesssteelturnoveranchors(singleordouble)bullJunctionboxesbullFixedPanzerbeltopeningdevicesbullBeltliftingdevicesbullEasyliftaccesscovers(springloaded)
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
systeMaCCessories
15
the standard Channel
MoorMastertrade ndash Automated Mooring System
MoorMastertrade dramatically improves safety and operational efficiency and also enables ports to make infrastructure savings It has performed more than 40000 mooring operations at ferry bulk handling Ro-Ro container and lock applications around the world
Key advantages of the system include
Safety bullReducedriskofmooringaccidentsaspersonnelareremovedfromhazardousworkingzones1048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644
bullReal-timemonitoringofmooringprocessandforcesduring stay in port
Infrastructure bull Improvedpierutilisationduetocloservesselspacing bullQuaylengthcanbelsquovirtuallyextendedrsquoastheshiprsquos bow can overhang the end of the quay bullMoorMastertrade1048644canreducetherequirementforextension of breakwater protection
Efficiency bullHighercontainertransferrates Vesselsareheldsecurely
alongside which may allow for the automation to shore cranes in futurebullShipmotionduetoswellsurgepassingshipsetc is dampenedbull Improvedcontinuityofworkprocesses bullShorteroperatingtimesfortugs bullNomooringteamsrequiredharbourpilotsable to disembark faster
Environment bullReducedemissionsasshipsacuteenginescanbeshutdown
earlier tugs able to leave earlier Furthermore once in port vessels are not required to reposition along the berth as MoorMastertrade dampens vessel motion so considerably
bullQuickerconnectiontoshorepowerifavailable
a unique teChnology
16 MoorMastertrade
MoorMastertrade 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
Container terminals have become a crucial link in todayrsquos 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 MoorMastertrade 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 MoorMastertrade holds ships steady providing a stable platform for faster crane and cargo movements
solutionsfor ContainerterMinals
17
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
MoorMastertrade 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 MoorMastertrade 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
solutionsfor roro and ferry terMinals
18 MoorMastertrade
solutionsfor dry bulk and tanker terMinals
The MoorMastertrade 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways MoorMastertrade cuts vessel transit times and creates a safer environment for those working on ships and shore-side
MoorMastertrade 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
19
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
The chart above shows typical torquespeed 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
SlipTorquediagram
Nominal Torque
Drum Speed (rpm)
-30 -20 -10 0 +10 +20 +30
10
20
7
Torquespeed diagram for hydrodynamic unit
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 torqueslip curve The motors are used up to maximum of plusmn 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
1 Self-breaking torque motor2 Pre-reducer3 Gearbox4 Collector5 Drum
CavoteC torqueMotor systeM
1
2
345
8 Motorised Cable Reels
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 ndash such as cable weight reeled cable on the drum acceleration or deceleration of the crane position on the track ndash 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
CavoteC torque Control (CrC) drive
9
1
2
3
4 1 CRC drive2 Standard squirrel self-
breaking electric motor (one or more motors can be used in parallel)
3 Pre-reducer4 Gearbox
M3 ~
Power supply
Interlocking for crane
SignalCavotecSpecimas
applicationsoftware
PowerOutput
Interlocking for crane
Brakesignal
Chopper Resistor
Encoder
Brake spring appelect released
AUX power
220V AC
Drum
Gearbox
Transducer
Torque reference
Processing
Cablereel motor
Brake controlcircuit
Slipringassembly
1 CRC drive2 Standard squirrel cage electric motor On or more motors can be used in parallel3 Pre-reducer and holding brake4 Main gear-box
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
kP brushes
10 Motorised Cable Reels
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
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
fibre oPtiCrotaryaCCuMulator
Cable guides
11
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
bull Complete operational safetybull Low installation costbull Full cable protectionbull Maintenance freebull No load restrictionsbull Channel free from spillagebull Operates in any climatebull No crane speed limitationsbull No alignment problemsbull Easily adaptable to existing systems
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
Main advantages
teChniCalCharaCteristiCs
Panzerbelt
The main components of the Panzerbelt system are 1 Stainless steel rivets2 Pre-drilled fixing strip3 Panzerbelt steel reinforced rubber cover4 Stainless steel channel profile
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 belt-lifting deviCe fitted to the Crane steel reinforCeMent has been inCorPorated to retain strength and flexibility of the belt in all direCtions
Ambient temperature -30degC up to 80degC
Opening angle 90deg max
Estimate lifetime gt 250000 cycles (openclose)
Horizontal bending radius 35m (minimum) with hinge profile external 45m (minimum) with hinge profile internal
Maximum load The maximum load applied on a Panzerbelt System with a 100mm wide slot should not exceed 400 Ncm2
Maximum breaking load at joint 1750kg for standard Panzerbelt 2650kg for Super Panzerbelt
Elongation 2 with load of 3000 N
Approx lenght of rolls 50m
Max force to open the belt to 90deg 40kg
13
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
general CharaCteristiCs
siMPle and fastinstallation
14 Panzerbelt
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
bull EitherStandardorSuperreinforcedbeltinrollsofapprox 50m with joints at their ends
bull StainlesssteelchannelAISI304orAISI316 15mm thick
bull Hotdipgalvanised30x8mmfixingstripswith 13 pre-drilled holes per metre
bull Stainlesssteelornickelcopperrivetsbull Earthingcopperstripswithscrewsandnutsbull Anti-fillingandalignmentsystemwithexpanded
polystyrenebull Alignmentbracketsforchannelsections
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
Panzerbelt can be supplied with several optional items includingbullStainlesssteelturnoveranchors(singleordouble)bullJunctionboxesbullFixedPanzerbeltopeningdevicesbullBeltliftingdevicesbullEasyliftaccesscovers(springloaded)
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
systeMaCCessories
15
the standard Channel
MoorMastertrade ndash Automated Mooring System
MoorMastertrade dramatically improves safety and operational efficiency and also enables ports to make infrastructure savings It has performed more than 40000 mooring operations at ferry bulk handling Ro-Ro container and lock applications around the world
Key advantages of the system include
Safety bullReducedriskofmooringaccidentsaspersonnelareremovedfromhazardousworkingzones1048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644
bullReal-timemonitoringofmooringprocessandforcesduring stay in port
Infrastructure bull Improvedpierutilisationduetocloservesselspacing bullQuaylengthcanbelsquovirtuallyextendedrsquoastheshiprsquos bow can overhang the end of the quay bullMoorMastertrade1048644canreducetherequirementforextension of breakwater protection
Efficiency bullHighercontainertransferrates Vesselsareheldsecurely
alongside which may allow for the automation to shore cranes in futurebullShipmotionduetoswellsurgepassingshipsetc is dampenedbull Improvedcontinuityofworkprocesses bullShorteroperatingtimesfortugs bullNomooringteamsrequiredharbourpilotsable to disembark faster
Environment bullReducedemissionsasshipsacuteenginescanbeshutdown
earlier tugs able to leave earlier Furthermore once in port vessels are not required to reposition along the berth as MoorMastertrade dampens vessel motion so considerably
bullQuickerconnectiontoshorepowerifavailable
a unique teChnology
16 MoorMastertrade
MoorMastertrade 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
Container terminals have become a crucial link in todayrsquos 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 MoorMastertrade 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 MoorMastertrade holds ships steady providing a stable platform for faster crane and cargo movements
solutionsfor ContainerterMinals
17
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
MoorMastertrade 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 MoorMastertrade 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
solutionsfor roro and ferry terMinals
18 MoorMastertrade
solutionsfor dry bulk and tanker terMinals
The MoorMastertrade 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways MoorMastertrade cuts vessel transit times and creates a safer environment for those working on ships and shore-side
MoorMastertrade 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
19
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
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 torqueslip curve The motors are used up to maximum of plusmn 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
1 Self-breaking torque motor2 Pre-reducer3 Gearbox4 Collector5 Drum
CavoteC torqueMotor systeM
1
2
345
8 Motorised Cable Reels
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 ndash such as cable weight reeled cable on the drum acceleration or deceleration of the crane position on the track ndash 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
CavoteC torque Control (CrC) drive
9
1
2
3
4 1 CRC drive2 Standard squirrel self-
breaking electric motor (one or more motors can be used in parallel)
3 Pre-reducer4 Gearbox
M3 ~
Power supply
Interlocking for crane
SignalCavotecSpecimas
applicationsoftware
PowerOutput
Interlocking for crane
Brakesignal
Chopper Resistor
Encoder
Brake spring appelect released
AUX power
220V AC
Drum
Gearbox
Transducer
Torque reference
Processing
Cablereel motor
Brake controlcircuit
Slipringassembly
1 CRC drive2 Standard squirrel cage electric motor On or more motors can be used in parallel3 Pre-reducer and holding brake4 Main gear-box
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
kP brushes
10 Motorised Cable Reels
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
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
fibre oPtiCrotaryaCCuMulator
Cable guides
11
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
bull Complete operational safetybull Low installation costbull Full cable protectionbull Maintenance freebull No load restrictionsbull Channel free from spillagebull Operates in any climatebull No crane speed limitationsbull No alignment problemsbull Easily adaptable to existing systems
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
Main advantages
teChniCalCharaCteristiCs
Panzerbelt
The main components of the Panzerbelt system are 1 Stainless steel rivets2 Pre-drilled fixing strip3 Panzerbelt steel reinforced rubber cover4 Stainless steel channel profile
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 belt-lifting deviCe fitted to the Crane steel reinforCeMent has been inCorPorated to retain strength and flexibility of the belt in all direCtions
Ambient temperature -30degC up to 80degC
Opening angle 90deg max
Estimate lifetime gt 250000 cycles (openclose)
Horizontal bending radius 35m (minimum) with hinge profile external 45m (minimum) with hinge profile internal
Maximum load The maximum load applied on a Panzerbelt System with a 100mm wide slot should not exceed 400 Ncm2
Maximum breaking load at joint 1750kg for standard Panzerbelt 2650kg for Super Panzerbelt
Elongation 2 with load of 3000 N
Approx lenght of rolls 50m
Max force to open the belt to 90deg 40kg
13
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
general CharaCteristiCs
siMPle and fastinstallation
14 Panzerbelt
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
bull EitherStandardorSuperreinforcedbeltinrollsofapprox 50m with joints at their ends
bull StainlesssteelchannelAISI304orAISI316 15mm thick
bull Hotdipgalvanised30x8mmfixingstripswith 13 pre-drilled holes per metre
bull Stainlesssteelornickelcopperrivetsbull Earthingcopperstripswithscrewsandnutsbull Anti-fillingandalignmentsystemwithexpanded
polystyrenebull Alignmentbracketsforchannelsections
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
Panzerbelt can be supplied with several optional items includingbullStainlesssteelturnoveranchors(singleordouble)bullJunctionboxesbullFixedPanzerbeltopeningdevicesbullBeltliftingdevicesbullEasyliftaccesscovers(springloaded)
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
systeMaCCessories
15
the standard Channel
MoorMastertrade ndash Automated Mooring System
MoorMastertrade dramatically improves safety and operational efficiency and also enables ports to make infrastructure savings It has performed more than 40000 mooring operations at ferry bulk handling Ro-Ro container and lock applications around the world
Key advantages of the system include
Safety bullReducedriskofmooringaccidentsaspersonnelareremovedfromhazardousworkingzones1048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644
bullReal-timemonitoringofmooringprocessandforcesduring stay in port
Infrastructure bull Improvedpierutilisationduetocloservesselspacing bullQuaylengthcanbelsquovirtuallyextendedrsquoastheshiprsquos bow can overhang the end of the quay bullMoorMastertrade1048644canreducetherequirementforextension of breakwater protection
Efficiency bullHighercontainertransferrates Vesselsareheldsecurely
alongside which may allow for the automation to shore cranes in futurebullShipmotionduetoswellsurgepassingshipsetc is dampenedbull Improvedcontinuityofworkprocesses bullShorteroperatingtimesfortugs bullNomooringteamsrequiredharbourpilotsable to disembark faster
Environment bullReducedemissionsasshipsacuteenginescanbeshutdown
earlier tugs able to leave earlier Furthermore once in port vessels are not required to reposition along the berth as MoorMastertrade dampens vessel motion so considerably
bullQuickerconnectiontoshorepowerifavailable
a unique teChnology
16 MoorMastertrade
MoorMastertrade 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
Container terminals have become a crucial link in todayrsquos 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 MoorMastertrade 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 MoorMastertrade holds ships steady providing a stable platform for faster crane and cargo movements
solutionsfor ContainerterMinals
17
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
MoorMastertrade 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 MoorMastertrade 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
solutionsfor roro and ferry terMinals
18 MoorMastertrade
solutionsfor dry bulk and tanker terMinals
The MoorMastertrade 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways MoorMastertrade cuts vessel transit times and creates a safer environment for those working on ships and shore-side
MoorMastertrade 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
19
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
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 ndash such as cable weight reeled cable on the drum acceleration or deceleration of the crane position on the track ndash 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
CavoteC torque Control (CrC) drive
9
1
2
3
4 1 CRC drive2 Standard squirrel self-
breaking electric motor (one or more motors can be used in parallel)
3 Pre-reducer4 Gearbox
M3 ~
Power supply
Interlocking for crane
SignalCavotecSpecimas
applicationsoftware
PowerOutput
Interlocking for crane
Brakesignal
Chopper Resistor
Encoder
Brake spring appelect released
AUX power
220V AC
Drum
Gearbox
Transducer
Torque reference
Processing
Cablereel motor
Brake controlcircuit
Slipringassembly
1 CRC drive2 Standard squirrel cage electric motor On or more motors can be used in parallel3 Pre-reducer and holding brake4 Main gear-box
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
kP brushes
10 Motorised Cable Reels
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
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
fibre oPtiCrotaryaCCuMulator
Cable guides
11
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
bull Complete operational safetybull Low installation costbull Full cable protectionbull Maintenance freebull No load restrictionsbull Channel free from spillagebull Operates in any climatebull No crane speed limitationsbull No alignment problemsbull Easily adaptable to existing systems
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
Main advantages
teChniCalCharaCteristiCs
Panzerbelt
The main components of the Panzerbelt system are 1 Stainless steel rivets2 Pre-drilled fixing strip3 Panzerbelt steel reinforced rubber cover4 Stainless steel channel profile
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 belt-lifting deviCe fitted to the Crane steel reinforCeMent has been inCorPorated to retain strength and flexibility of the belt in all direCtions
Ambient temperature -30degC up to 80degC
Opening angle 90deg max
Estimate lifetime gt 250000 cycles (openclose)
Horizontal bending radius 35m (minimum) with hinge profile external 45m (minimum) with hinge profile internal
Maximum load The maximum load applied on a Panzerbelt System with a 100mm wide slot should not exceed 400 Ncm2
Maximum breaking load at joint 1750kg for standard Panzerbelt 2650kg for Super Panzerbelt
Elongation 2 with load of 3000 N
Approx lenght of rolls 50m
Max force to open the belt to 90deg 40kg
13
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
general CharaCteristiCs
siMPle and fastinstallation
14 Panzerbelt
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
bull EitherStandardorSuperreinforcedbeltinrollsofapprox 50m with joints at their ends
bull StainlesssteelchannelAISI304orAISI316 15mm thick
bull Hotdipgalvanised30x8mmfixingstripswith 13 pre-drilled holes per metre
bull Stainlesssteelornickelcopperrivetsbull Earthingcopperstripswithscrewsandnutsbull Anti-fillingandalignmentsystemwithexpanded
polystyrenebull Alignmentbracketsforchannelsections
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
Panzerbelt can be supplied with several optional items includingbullStainlesssteelturnoveranchors(singleordouble)bullJunctionboxesbullFixedPanzerbeltopeningdevicesbullBeltliftingdevicesbullEasyliftaccesscovers(springloaded)
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
systeMaCCessories
15
the standard Channel
MoorMastertrade ndash Automated Mooring System
MoorMastertrade dramatically improves safety and operational efficiency and also enables ports to make infrastructure savings It has performed more than 40000 mooring operations at ferry bulk handling Ro-Ro container and lock applications around the world
Key advantages of the system include
Safety bullReducedriskofmooringaccidentsaspersonnelareremovedfromhazardousworkingzones1048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644
bullReal-timemonitoringofmooringprocessandforcesduring stay in port
Infrastructure bull Improvedpierutilisationduetocloservesselspacing bullQuaylengthcanbelsquovirtuallyextendedrsquoastheshiprsquos bow can overhang the end of the quay bullMoorMastertrade1048644canreducetherequirementforextension of breakwater protection
Efficiency bullHighercontainertransferrates Vesselsareheldsecurely
alongside which may allow for the automation to shore cranes in futurebullShipmotionduetoswellsurgepassingshipsetc is dampenedbull Improvedcontinuityofworkprocesses bullShorteroperatingtimesfortugs bullNomooringteamsrequiredharbourpilotsable to disembark faster
Environment bullReducedemissionsasshipsacuteenginescanbeshutdown
earlier tugs able to leave earlier Furthermore once in port vessels are not required to reposition along the berth as MoorMastertrade dampens vessel motion so considerably
bullQuickerconnectiontoshorepowerifavailable
a unique teChnology
16 MoorMastertrade
MoorMastertrade 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
Container terminals have become a crucial link in todayrsquos 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 MoorMastertrade 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 MoorMastertrade holds ships steady providing a stable platform for faster crane and cargo movements
solutionsfor ContainerterMinals
17
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
MoorMastertrade 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 MoorMastertrade 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
solutionsfor roro and ferry terMinals
18 MoorMastertrade
solutionsfor dry bulk and tanker terMinals
The MoorMastertrade 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways MoorMastertrade cuts vessel transit times and creates a safer environment for those working on ships and shore-side
MoorMastertrade 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
19
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
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
kP brushes
10 Motorised Cable Reels
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
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
fibre oPtiCrotaryaCCuMulator
Cable guides
11
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
bull Complete operational safetybull Low installation costbull Full cable protectionbull Maintenance freebull No load restrictionsbull Channel free from spillagebull Operates in any climatebull No crane speed limitationsbull No alignment problemsbull Easily adaptable to existing systems
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
Main advantages
teChniCalCharaCteristiCs
Panzerbelt
The main components of the Panzerbelt system are 1 Stainless steel rivets2 Pre-drilled fixing strip3 Panzerbelt steel reinforced rubber cover4 Stainless steel channel profile
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 belt-lifting deviCe fitted to the Crane steel reinforCeMent has been inCorPorated to retain strength and flexibility of the belt in all direCtions
Ambient temperature -30degC up to 80degC
Opening angle 90deg max
Estimate lifetime gt 250000 cycles (openclose)
Horizontal bending radius 35m (minimum) with hinge profile external 45m (minimum) with hinge profile internal
Maximum load The maximum load applied on a Panzerbelt System with a 100mm wide slot should not exceed 400 Ncm2
Maximum breaking load at joint 1750kg for standard Panzerbelt 2650kg for Super Panzerbelt
Elongation 2 with load of 3000 N
Approx lenght of rolls 50m
Max force to open the belt to 90deg 40kg
13
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
general CharaCteristiCs
siMPle and fastinstallation
14 Panzerbelt
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
bull EitherStandardorSuperreinforcedbeltinrollsofapprox 50m with joints at their ends
bull StainlesssteelchannelAISI304orAISI316 15mm thick
bull Hotdipgalvanised30x8mmfixingstripswith 13 pre-drilled holes per metre
bull Stainlesssteelornickelcopperrivetsbull Earthingcopperstripswithscrewsandnutsbull Anti-fillingandalignmentsystemwithexpanded
polystyrenebull Alignmentbracketsforchannelsections
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
Panzerbelt can be supplied with several optional items includingbullStainlesssteelturnoveranchors(singleordouble)bullJunctionboxesbullFixedPanzerbeltopeningdevicesbullBeltliftingdevicesbullEasyliftaccesscovers(springloaded)
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
systeMaCCessories
15
the standard Channel
MoorMastertrade ndash Automated Mooring System
MoorMastertrade dramatically improves safety and operational efficiency and also enables ports to make infrastructure savings It has performed more than 40000 mooring operations at ferry bulk handling Ro-Ro container and lock applications around the world
Key advantages of the system include
Safety bullReducedriskofmooringaccidentsaspersonnelareremovedfromhazardousworkingzones1048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644
bullReal-timemonitoringofmooringprocessandforcesduring stay in port
Infrastructure bull Improvedpierutilisationduetocloservesselspacing bullQuaylengthcanbelsquovirtuallyextendedrsquoastheshiprsquos bow can overhang the end of the quay bullMoorMastertrade1048644canreducetherequirementforextension of breakwater protection
Efficiency bullHighercontainertransferrates Vesselsareheldsecurely
alongside which may allow for the automation to shore cranes in futurebullShipmotionduetoswellsurgepassingshipsetc is dampenedbull Improvedcontinuityofworkprocesses bullShorteroperatingtimesfortugs bullNomooringteamsrequiredharbourpilotsable to disembark faster
Environment bullReducedemissionsasshipsacuteenginescanbeshutdown
earlier tugs able to leave earlier Furthermore once in port vessels are not required to reposition along the berth as MoorMastertrade dampens vessel motion so considerably
bullQuickerconnectiontoshorepowerifavailable
a unique teChnology
16 MoorMastertrade
MoorMastertrade 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
Container terminals have become a crucial link in todayrsquos 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 MoorMastertrade 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 MoorMastertrade holds ships steady providing a stable platform for faster crane and cargo movements
solutionsfor ContainerterMinals
17
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
MoorMastertrade 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 MoorMastertrade 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
solutionsfor roro and ferry terMinals
18 MoorMastertrade
solutionsfor dry bulk and tanker terMinals
The MoorMastertrade 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways MoorMastertrade cuts vessel transit times and creates a safer environment for those working on ships and shore-side
MoorMastertrade 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
19
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
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
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
fibre oPtiCrotaryaCCuMulator
Cable guides
11
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
bull Complete operational safetybull Low installation costbull Full cable protectionbull Maintenance freebull No load restrictionsbull Channel free from spillagebull Operates in any climatebull No crane speed limitationsbull No alignment problemsbull Easily adaptable to existing systems
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
Main advantages
teChniCalCharaCteristiCs
Panzerbelt
The main components of the Panzerbelt system are 1 Stainless steel rivets2 Pre-drilled fixing strip3 Panzerbelt steel reinforced rubber cover4 Stainless steel channel profile
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 belt-lifting deviCe fitted to the Crane steel reinforCeMent has been inCorPorated to retain strength and flexibility of the belt in all direCtions
Ambient temperature -30degC up to 80degC
Opening angle 90deg max
Estimate lifetime gt 250000 cycles (openclose)
Horizontal bending radius 35m (minimum) with hinge profile external 45m (minimum) with hinge profile internal
Maximum load The maximum load applied on a Panzerbelt System with a 100mm wide slot should not exceed 400 Ncm2
Maximum breaking load at joint 1750kg for standard Panzerbelt 2650kg for Super Panzerbelt
Elongation 2 with load of 3000 N
Approx lenght of rolls 50m
Max force to open the belt to 90deg 40kg
13
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
general CharaCteristiCs
siMPle and fastinstallation
14 Panzerbelt
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
bull EitherStandardorSuperreinforcedbeltinrollsofapprox 50m with joints at their ends
bull StainlesssteelchannelAISI304orAISI316 15mm thick
bull Hotdipgalvanised30x8mmfixingstripswith 13 pre-drilled holes per metre
bull Stainlesssteelornickelcopperrivetsbull Earthingcopperstripswithscrewsandnutsbull Anti-fillingandalignmentsystemwithexpanded
polystyrenebull Alignmentbracketsforchannelsections
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
Panzerbelt can be supplied with several optional items includingbullStainlesssteelturnoveranchors(singleordouble)bullJunctionboxesbullFixedPanzerbeltopeningdevicesbullBeltliftingdevicesbullEasyliftaccesscovers(springloaded)
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
systeMaCCessories
15
the standard Channel
MoorMastertrade ndash Automated Mooring System
MoorMastertrade dramatically improves safety and operational efficiency and also enables ports to make infrastructure savings It has performed more than 40000 mooring operations at ferry bulk handling Ro-Ro container and lock applications around the world
Key advantages of the system include
Safety bullReducedriskofmooringaccidentsaspersonnelareremovedfromhazardousworkingzones1048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644
bullReal-timemonitoringofmooringprocessandforcesduring stay in port
Infrastructure bull Improvedpierutilisationduetocloservesselspacing bullQuaylengthcanbelsquovirtuallyextendedrsquoastheshiprsquos bow can overhang the end of the quay bullMoorMastertrade1048644canreducetherequirementforextension of breakwater protection
Efficiency bullHighercontainertransferrates Vesselsareheldsecurely
alongside which may allow for the automation to shore cranes in futurebullShipmotionduetoswellsurgepassingshipsetc is dampenedbull Improvedcontinuityofworkprocesses bullShorteroperatingtimesfortugs bullNomooringteamsrequiredharbourpilotsable to disembark faster
Environment bullReducedemissionsasshipsacuteenginescanbeshutdown
earlier tugs able to leave earlier Furthermore once in port vessels are not required to reposition along the berth as MoorMastertrade dampens vessel motion so considerably
bullQuickerconnectiontoshorepowerifavailable
a unique teChnology
16 MoorMastertrade
MoorMastertrade 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
Container terminals have become a crucial link in todayrsquos 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 MoorMastertrade 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 MoorMastertrade holds ships steady providing a stable platform for faster crane and cargo movements
solutionsfor ContainerterMinals
17
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
MoorMastertrade 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 MoorMastertrade 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
solutionsfor roro and ferry terMinals
18 MoorMastertrade
solutionsfor dry bulk and tanker terMinals
The MoorMastertrade 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways MoorMastertrade cuts vessel transit times and creates a safer environment for those working on ships and shore-side
MoorMastertrade 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
19
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
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
bull Complete operational safetybull Low installation costbull Full cable protectionbull Maintenance freebull No load restrictionsbull Channel free from spillagebull Operates in any climatebull No crane speed limitationsbull No alignment problemsbull Easily adaptable to existing systems
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
Main advantages
teChniCalCharaCteristiCs
Panzerbelt
The main components of the Panzerbelt system are 1 Stainless steel rivets2 Pre-drilled fixing strip3 Panzerbelt steel reinforced rubber cover4 Stainless steel channel profile
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 belt-lifting deviCe fitted to the Crane steel reinforCeMent has been inCorPorated to retain strength and flexibility of the belt in all direCtions
Ambient temperature -30degC up to 80degC
Opening angle 90deg max
Estimate lifetime gt 250000 cycles (openclose)
Horizontal bending radius 35m (minimum) with hinge profile external 45m (minimum) with hinge profile internal
Maximum load The maximum load applied on a Panzerbelt System with a 100mm wide slot should not exceed 400 Ncm2
Maximum breaking load at joint 1750kg for standard Panzerbelt 2650kg for Super Panzerbelt
Elongation 2 with load of 3000 N
Approx lenght of rolls 50m
Max force to open the belt to 90deg 40kg
13
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
general CharaCteristiCs
siMPle and fastinstallation
14 Panzerbelt
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
bull EitherStandardorSuperreinforcedbeltinrollsofapprox 50m with joints at their ends
bull StainlesssteelchannelAISI304orAISI316 15mm thick
bull Hotdipgalvanised30x8mmfixingstripswith 13 pre-drilled holes per metre
bull Stainlesssteelornickelcopperrivetsbull Earthingcopperstripswithscrewsandnutsbull Anti-fillingandalignmentsystemwithexpanded
polystyrenebull Alignmentbracketsforchannelsections
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
Panzerbelt can be supplied with several optional items includingbullStainlesssteelturnoveranchors(singleordouble)bullJunctionboxesbullFixedPanzerbeltopeningdevicesbullBeltliftingdevicesbullEasyliftaccesscovers(springloaded)
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
systeMaCCessories
15
the standard Channel
MoorMastertrade ndash Automated Mooring System
MoorMastertrade dramatically improves safety and operational efficiency and also enables ports to make infrastructure savings It has performed more than 40000 mooring operations at ferry bulk handling Ro-Ro container and lock applications around the world
Key advantages of the system include
Safety bullReducedriskofmooringaccidentsaspersonnelareremovedfromhazardousworkingzones1048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644
bullReal-timemonitoringofmooringprocessandforcesduring stay in port
Infrastructure bull Improvedpierutilisationduetocloservesselspacing bullQuaylengthcanbelsquovirtuallyextendedrsquoastheshiprsquos bow can overhang the end of the quay bullMoorMastertrade1048644canreducetherequirementforextension of breakwater protection
Efficiency bullHighercontainertransferrates Vesselsareheldsecurely
alongside which may allow for the automation to shore cranes in futurebullShipmotionduetoswellsurgepassingshipsetc is dampenedbull Improvedcontinuityofworkprocesses bullShorteroperatingtimesfortugs bullNomooringteamsrequiredharbourpilotsable to disembark faster
Environment bullReducedemissionsasshipsacuteenginescanbeshutdown
earlier tugs able to leave earlier Furthermore once in port vessels are not required to reposition along the berth as MoorMastertrade dampens vessel motion so considerably
bullQuickerconnectiontoshorepowerifavailable
a unique teChnology
16 MoorMastertrade
MoorMastertrade 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
Container terminals have become a crucial link in todayrsquos 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 MoorMastertrade 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 MoorMastertrade holds ships steady providing a stable platform for faster crane and cargo movements
solutionsfor ContainerterMinals
17
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
MoorMastertrade 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 MoorMastertrade 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
solutionsfor roro and ferry terMinals
18 MoorMastertrade
solutionsfor dry bulk and tanker terMinals
The MoorMastertrade 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways MoorMastertrade cuts vessel transit times and creates a safer environment for those working on ships and shore-side
MoorMastertrade 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
19
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
Ambient temperature -30degC up to 80degC
Opening angle 90deg max
Estimate lifetime gt 250000 cycles (openclose)
Horizontal bending radius 35m (minimum) with hinge profile external 45m (minimum) with hinge profile internal
Maximum load The maximum load applied on a Panzerbelt System with a 100mm wide slot should not exceed 400 Ncm2
Maximum breaking load at joint 1750kg for standard Panzerbelt 2650kg for Super Panzerbelt
Elongation 2 with load of 3000 N
Approx lenght of rolls 50m
Max force to open the belt to 90deg 40kg
13
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
Weight (kgm)dimension A (mm)TypePB 300 295 asymp 60PB 400 395 asymp 75PB 500 495 asymp 95PB 600 595 asymp 115
Standard Panzerbelt type PB
rebbuR eneidatuB enerytS-RBS 08slairetaM15 Steel cord
5 Nylon
Other types of rubber and reinforcement layers are available for special working enviroments
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
A
15
15 305 805
A
15
15 305 805
Weight (kgm)dimension A (mm)TypeSPB 300 295 asymp 65SPB 400 395 asymp 80SPB 500 495 asymp 100SPB 600 595 asymp 120
Super Panzerbelt type SPB (USA and Europe Patent)
slairetaM15 Steel cord10 Nylon
Reinforcing Warp bull Two layers of RFL dipped nylon yarn - breaking load 50 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 55 kNm
bull Two layers of RFL dipped nylon fabric - breaking load 160 kNm
Weft bull Brass coated steel cord - breaking load 640 kNm
rebbuR eneidatuB enerytS-RBS 57
general CharaCteristiCs
siMPle and fastinstallation
14 Panzerbelt
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
bull EitherStandardorSuperreinforcedbeltinrollsofapprox 50m with joints at their ends
bull StainlesssteelchannelAISI304orAISI316 15mm thick
bull Hotdipgalvanised30x8mmfixingstripswith 13 pre-drilled holes per metre
bull Stainlesssteelornickelcopperrivetsbull Earthingcopperstripswithscrewsandnutsbull Anti-fillingandalignmentsystemwithexpanded
polystyrenebull Alignmentbracketsforchannelsections
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
Panzerbelt can be supplied with several optional items includingbullStainlesssteelturnoveranchors(singleordouble)bullJunctionboxesbullFixedPanzerbeltopeningdevicesbullBeltliftingdevicesbullEasyliftaccesscovers(springloaded)
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
systeMaCCessories
15
the standard Channel
MoorMastertrade ndash Automated Mooring System
MoorMastertrade dramatically improves safety and operational efficiency and also enables ports to make infrastructure savings It has performed more than 40000 mooring operations at ferry bulk handling Ro-Ro container and lock applications around the world
Key advantages of the system include
Safety bullReducedriskofmooringaccidentsaspersonnelareremovedfromhazardousworkingzones1048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644
bullReal-timemonitoringofmooringprocessandforcesduring stay in port
Infrastructure bull Improvedpierutilisationduetocloservesselspacing bullQuaylengthcanbelsquovirtuallyextendedrsquoastheshiprsquos bow can overhang the end of the quay bullMoorMastertrade1048644canreducetherequirementforextension of breakwater protection
Efficiency bullHighercontainertransferrates Vesselsareheldsecurely
alongside which may allow for the automation to shore cranes in futurebullShipmotionduetoswellsurgepassingshipsetc is dampenedbull Improvedcontinuityofworkprocesses bullShorteroperatingtimesfortugs bullNomooringteamsrequiredharbourpilotsable to disembark faster
Environment bullReducedemissionsasshipsacuteenginescanbeshutdown
earlier tugs able to leave earlier Furthermore once in port vessels are not required to reposition along the berth as MoorMastertrade dampens vessel motion so considerably
bullQuickerconnectiontoshorepowerifavailable
a unique teChnology
16 MoorMastertrade
MoorMastertrade 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
Container terminals have become a crucial link in todayrsquos 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 MoorMastertrade 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 MoorMastertrade holds ships steady providing a stable platform for faster crane and cargo movements
solutionsfor ContainerterMinals
17
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
MoorMastertrade 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 MoorMastertrade 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
solutionsfor roro and ferry terMinals
18 MoorMastertrade
solutionsfor dry bulk and tanker terMinals
The MoorMastertrade 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways MoorMastertrade cuts vessel transit times and creates a safer environment for those working on ships and shore-side
MoorMastertrade 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
19
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
siMPle and fastinstallation
14 Panzerbelt
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
bull EitherStandardorSuperreinforcedbeltinrollsofapprox 50m with joints at their ends
bull StainlesssteelchannelAISI304orAISI316 15mm thick
bull Hotdipgalvanised30x8mmfixingstripswith 13 pre-drilled holes per metre
bull Stainlesssteelornickelcopperrivetsbull Earthingcopperstripswithscrewsandnutsbull Anti-fillingandalignmentsystemwithexpanded
polystyrenebull Alignmentbracketsforchannelsections
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
Panzerbelt can be supplied with several optional items includingbullStainlesssteelturnoveranchors(singleordouble)bullJunctionboxesbullFixedPanzerbeltopeningdevicesbullBeltliftingdevicesbullEasyliftaccesscovers(springloaded)
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
systeMaCCessories
15
the standard Channel
MoorMastertrade ndash Automated Mooring System
MoorMastertrade dramatically improves safety and operational efficiency and also enables ports to make infrastructure savings It has performed more than 40000 mooring operations at ferry bulk handling Ro-Ro container and lock applications around the world
Key advantages of the system include
Safety bullReducedriskofmooringaccidentsaspersonnelareremovedfromhazardousworkingzones1048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644
bullReal-timemonitoringofmooringprocessandforcesduring stay in port
Infrastructure bull Improvedpierutilisationduetocloservesselspacing bullQuaylengthcanbelsquovirtuallyextendedrsquoastheshiprsquos bow can overhang the end of the quay bullMoorMastertrade1048644canreducetherequirementforextension of breakwater protection
Efficiency bullHighercontainertransferrates Vesselsareheldsecurely
alongside which may allow for the automation to shore cranes in futurebullShipmotionduetoswellsurgepassingshipsetc is dampenedbull Improvedcontinuityofworkprocesses bullShorteroperatingtimesfortugs bullNomooringteamsrequiredharbourpilotsable to disembark faster
Environment bullReducedemissionsasshipsacuteenginescanbeshutdown
earlier tugs able to leave earlier Furthermore once in port vessels are not required to reposition along the berth as MoorMastertrade dampens vessel motion so considerably
bullQuickerconnectiontoshorepowerifavailable
a unique teChnology
16 MoorMastertrade
MoorMastertrade 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
Container terminals have become a crucial link in todayrsquos 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 MoorMastertrade 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 MoorMastertrade holds ships steady providing a stable platform for faster crane and cargo movements
solutionsfor ContainerterMinals
17
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
MoorMastertrade 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 MoorMastertrade 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
solutionsfor roro and ferry terMinals
18 MoorMastertrade
solutionsfor dry bulk and tanker terMinals
The MoorMastertrade 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways MoorMastertrade cuts vessel transit times and creates a safer environment for those working on ships and shore-side
MoorMastertrade 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
19
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
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
Panzerbelt can be supplied with several optional items includingbullStainlesssteelturnoveranchors(singleordouble)bullJunctionboxesbullFixedPanzerbeltopeningdevicesbullBeltliftingdevicesbullEasyliftaccesscovers(springloaded)
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
systeMaCCessories
15
the standard Channel
MoorMastertrade ndash Automated Mooring System
MoorMastertrade dramatically improves safety and operational efficiency and also enables ports to make infrastructure savings It has performed more than 40000 mooring operations at ferry bulk handling Ro-Ro container and lock applications around the world
Key advantages of the system include
Safety bullReducedriskofmooringaccidentsaspersonnelareremovedfromhazardousworkingzones1048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644
bullReal-timemonitoringofmooringprocessandforcesduring stay in port
Infrastructure bull Improvedpierutilisationduetocloservesselspacing bullQuaylengthcanbelsquovirtuallyextendedrsquoastheshiprsquos bow can overhang the end of the quay bullMoorMastertrade1048644canreducetherequirementforextension of breakwater protection
Efficiency bullHighercontainertransferrates Vesselsareheldsecurely
alongside which may allow for the automation to shore cranes in futurebullShipmotionduetoswellsurgepassingshipsetc is dampenedbull Improvedcontinuityofworkprocesses bullShorteroperatingtimesfortugs bullNomooringteamsrequiredharbourpilotsable to disembark faster
Environment bullReducedemissionsasshipsacuteenginescanbeshutdown
earlier tugs able to leave earlier Furthermore once in port vessels are not required to reposition along the berth as MoorMastertrade dampens vessel motion so considerably
bullQuickerconnectiontoshorepowerifavailable
a unique teChnology
16 MoorMastertrade
MoorMastertrade 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
Container terminals have become a crucial link in todayrsquos 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 MoorMastertrade 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 MoorMastertrade holds ships steady providing a stable platform for faster crane and cargo movements
solutionsfor ContainerterMinals
17
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
MoorMastertrade 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 MoorMastertrade 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
solutionsfor roro and ferry terMinals
18 MoorMastertrade
solutionsfor dry bulk and tanker terMinals
The MoorMastertrade 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways MoorMastertrade cuts vessel transit times and creates a safer environment for those working on ships and shore-side
MoorMastertrade 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
19
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
MoorMastertrade ndash Automated Mooring System
MoorMastertrade dramatically improves safety and operational efficiency and also enables ports to make infrastructure savings It has performed more than 40000 mooring operations at ferry bulk handling Ro-Ro container and lock applications around the world
Key advantages of the system include
Safety bullReducedriskofmooringaccidentsaspersonnelareremovedfromhazardousworkingzones1048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644104864410486441048644
bullReal-timemonitoringofmooringprocessandforcesduring stay in port
Infrastructure bull Improvedpierutilisationduetocloservesselspacing bullQuaylengthcanbelsquovirtuallyextendedrsquoastheshiprsquos bow can overhang the end of the quay bullMoorMastertrade1048644canreducetherequirementforextension of breakwater protection
Efficiency bullHighercontainertransferrates Vesselsareheldsecurely
alongside which may allow for the automation to shore cranes in futurebullShipmotionduetoswellsurgepassingshipsetc is dampenedbull Improvedcontinuityofworkprocesses bullShorteroperatingtimesfortugs bullNomooringteamsrequiredharbourpilotsable to disembark faster
Environment bullReducedemissionsasshipsacuteenginescanbeshutdown
earlier tugs able to leave earlier Furthermore once in port vessels are not required to reposition along the berth as MoorMastertrade dampens vessel motion so considerably
bullQuickerconnectiontoshorepowerifavailable
a unique teChnology
16 MoorMastertrade
MoorMastertrade 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
Container terminals have become a crucial link in todayrsquos 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 MoorMastertrade 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 MoorMastertrade holds ships steady providing a stable platform for faster crane and cargo movements
solutionsfor ContainerterMinals
17
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
MoorMastertrade 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 MoorMastertrade 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
solutionsfor roro and ferry terMinals
18 MoorMastertrade
solutionsfor dry bulk and tanker terMinals
The MoorMastertrade 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways MoorMastertrade cuts vessel transit times and creates a safer environment for those working on ships and shore-side
MoorMastertrade 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
19
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
Container terminals have become a crucial link in todayrsquos 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 MoorMastertrade 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 MoorMastertrade holds ships steady providing a stable platform for faster crane and cargo movements
solutionsfor ContainerterMinals
17
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
MoorMastertrade 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 MoorMastertrade 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
solutionsfor roro and ferry terMinals
18 MoorMastertrade
solutionsfor dry bulk and tanker terMinals
The MoorMastertrade 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways MoorMastertrade cuts vessel transit times and creates a safer environment for those working on ships and shore-side
MoorMastertrade 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
19
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
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
MoorMastertrade 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 MoorMastertrade 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
solutionsfor roro and ferry terMinals
18 MoorMastertrade
solutionsfor dry bulk and tanker terMinals
The MoorMastertrade 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways MoorMastertrade cuts vessel transit times and creates a safer environment for those working on ships and shore-side
MoorMastertrade 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
19
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
solutionsfor dry bulk and tanker terMinals
The MoorMastertrade 200LS (Lock System) is designed specifically for use in locks in harbours and inland waterways MoorMastertrade cuts vessel transit times and creates a safer environment for those working on ships and shore-side
MoorMastertrade 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
19
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
Alternative Maritime Power (AMP)
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 shipsocketoutletJB Ourshore-sidepitsaredesignedtooccupy 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
switChing on to Cleaner Ports
20 Alternative Maritime Power
ldquoalternative MaritiMe Power helPs us reduCe eMissions not Just at the Port but throughout the entire los angeles regionrdquo
PhiliP sanfield Port of los angeles
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
Quaysidespaceincontainerterminalsisatapremiumsoour shore-to-ship power cable management systems are vessel-based and include two typesbullShip-integratedsystembullSemi-fixedcontainerisedsystem
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
solutions for Container shiPs (shiP integratedsolution 66kv)
21
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
solution forContainer shiPs(seMi fix Container 66kv or 66kv440v)
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
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
bull One-Hand Lift Load-Rated Cover Assembly (with optional Fiberglass Pit Form and Cable Roller Guide) and concrete embedded frame
bull Stainless steel shore power junction box (IP66)bull Electrical sockets up to 12kV (fitted with safety features
such as pilots and interlocks)bull Optical fibre connectors
shore Pit
22 Alternative Maritime Power
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
solutions forCruise shiPs(66kv 11kv)
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
Bringing more than 40 yearsrsquo experience of high-load rated one-hand lift covers Cavotec has designed the ldquoEasy Lift Cover Assemblyrdquo 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 load-bearing 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
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
easy lift CoverasseMbly
shore basedsolution
23
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
Marine Slipring Systems
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
bull Slipring design range from data and signal voltages to 6kV power phase voltage
bull Slipring design range from mA data and signals to 6000Amp power phase currents
bull Hydraulic swivel joint design range from low pressure pneumatic or hydraulics to 350 Bar pressure
bull All in one complete slip ring with hydraulic joint and auxiliary equipment supplied in one easily mounted unit
bull Simple installation using standard mechanical electric and pipe interfaces
bull Carefully designed bus-bar system with symmetric current flow and multi contact point carbon brush system
bull Self-cleaning ring and brush systembull Basic design test at resonance frequencies of up to 2G
and at shock loads of up to 5Gbull Low maintenance with easy and fast replacement of rings
and brushes if requiredbull Customised designbull Client-specific auxiliary equipment available for example
steering feedback control and support equipment
Marine ProPulsion systeMs (MPs)
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
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
25
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
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 andor power transmission up to 600A and 72kV and can be used in Zone 21 and 22 (Dust) or Zone 1 and 2 (Gas classification IIA IIB and IIC)
a revolutionin ProPulsion
ex-Proof vertiCal ColleCtor
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
26 Marine Slipring Systems
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
data transMission sliP rings
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
27
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
Power Connectors
Customers have the option of ordering our power connectors and plug amp 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 amp 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
MWT system contacts
introduCtion
28 Power Connectors
CavoteC ConneCtorsrsquo 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
12mm
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
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 63300 rules and additionally confirm to the following standards NFC 20 040 VDE 0110 NFC 63300 IEC 309-1 CEE 17 BS 4343 IEC 529 DIN 40050 NFC 20010 The Cavotec high voltage Push amp Pull connectors are tested according to VDE 0432 - 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
norMs andregulations
Type size Ndeg Pins Max current AMP Max voltage kV Screw RingPushampPull
PC4 45 250 11 YES YES
PC5 45 420 11 YES YES
PC6 4 660 11 NO YES
PC5_K 4 350 72 YES YES
PC6_K 4 540 72 NO YES
PC6_L 4 500 12 NO YES
PC8 4 500 25 YES NO
29
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
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 80degC On request the temperature range can be extended to a maximum of 250degC
Their robust versatility makes our power connectors ideal for offshore railway port bulk and container handling applications
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
low voltagePower ConneCtors uP to 1100v
MediuM voltage Power ConneCtors uP to 25000v
30 Power Connectors
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
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
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 15mm2 up to 300mm2 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
Power units
exPlosion ProofPower ConneCtor
31
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
FLT - Spring Driven Cable Reels
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 servicesCavotecrsquos 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
overview
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 conditionsParticular care should be taken regarding operating conditions especially in extreme environments The following factors are of primary importance
bull extreme temperaturesbull substantial temperature variationbull humidity levelsbull vibrationbull emission
installationinstruCtions
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
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
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
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
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 Technology
loading arMs Quality standard Swivel Joints 3rdquo - 32rdquoSturdy maintenance-free and longlife Cavotec Meyerinck SwivelJointsareusedwhereverrigidpipeshavetofollowthree dimensional movements Two three or four bearings combined with two active seals provide highest safety and easy operation
More than 3000 Cavotec loading arms with some 25000 swivel joints have entered service at applications worldwide since 1980
Loading Arms sizes 3rdquo to 8rdquoPressure class 125 PSI 10 bar to 300 PSI 25 barMaterial for piping our standard is stainless steel carbon steel or aluminum others on requestMaterial Swivel Joint our standard is stainless steel or with internal coating acc to customers specification on requestSealings NBR FKM PTFE and othersTemperature -50degC divide +220degC
34 Loading Technology
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
PumpsPumps
Receiving Filter Station
Ship Receiving StationShip Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Loading Technology
Cavotec Meyerinck Marine loading arms are fully counter-weighted
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 8rdquo They can be equipped with special couplers for a quick connection to the ship
Marine loading arMs
in-tank floating suCtion units
35
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 3rdquo to 32rdquo
Other materials are available on request
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Port Fuelling Solutions
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Filter WaterSeparators
Filter WaterSeparators
PumpControlSystem
Pumps Pumps
Receiving Filter Station
Ship Receiving Station Ship Unloading Station
Rail Car Receiving Station
Tank Truck Receiving Station
Pump and Filter Station
Suction Arms
Tanks
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
Radio Remote Controls
Safety reliability and innovation have been our three guiding principles throughout Cavotec Micro-controlrsquos 20 yearsrsquo 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 worldrsquos most stringent safety requirements
Directives and StandardsCavotec 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 60204 and ISO 13849
Cavotec RRCs also comply with standards in specific countries For example IC for Canada KCC for Korea TELECCOSMOSforJapanC-tickforAustraliaGOST-RforRussia CMII for China MSHA for mining in the US
safety reliability and innovation
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
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
Base unit
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 and base unit
1 Full system check at power-up2 Stop button ensures immediate stop of all
operations Redundant monitoring of stop button
3 Redundant monitoring of joystick activity
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
12
3
4
5
6
710
8
9
37
10 Dual processor system implemented according to IEC61508 ensuring independent processor operation
Radio terminal
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
38 Radio Remote Controls
MC-2-3 amp MC-2-5The 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 hoursrsquo continuous operation
MC-3-4The 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-3-5The MC-3-5 is available in digital analogue hand-held and belt-mounted versionsAll operations from simple control tasking to complete process supervision can be carried out from this one unit
MC 3-6The 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 batteryoptionandallowsuserstolsquohotswaprsquobatteries TheMC-3-6 is particularly useful for two-way communication and can be adapted to house Cavotec Micro-control popular semi-duplex radio
MC 3200 amp MC 3300Two of the most flexible compact RRCs on the market the MC-3200 amp 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 amp MC-3200 are specially suited for tough maritime environments The housing exceeds ingress protection class IP6667 and is made from high impact chemical resistant plastic
ProduCt range
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
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
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
Cable Chains
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
bull Hydraulic hoses and electric cablesbull Uninterrupted operation in harsh environmentsbull High speed and accelerationbull Reduced maintenance costs and installation timebull Turnkey systems equipped with pre-inserted cables
and hoses
overview
40 Cable Chains
established in 1976 italyrsquos 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
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
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 platedThese 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
steel Chains
41
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
Crane Controllers
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
generalinforMation
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
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
43
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
Cavotec supplies a wide range of flexible cables from standard to highly advanced power and signal cables including special configurations
Cavotecrsquos 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
Flexible Cables
general inforMation
1
44 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 andor reinforCing eleMents
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
The correct choise of cable is vital to maximise performance and service life
Bending radius Precise calculation of the bending radius is a determiningfactor for cable reliability A decrease in minimum bendingradius has a major effect on the life of a cable becauseit causes stretching and internal distortions Anotherimportant factor is the frequency of the cable movementsIf movement is slow and infrequent a tighter bending radiuscan be considered Special attention should also be paid toinstallations where flexing and torsion is present
Tensile strengthThe maximum admissible tensile force is stated by the cable manufacturer
Greater forces will result in permanent elongationof the conductors which would shorten the life of thecable considerably
Operating speed and accelerationAll 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 sheavesIf possible reduce the number intermediate pulleys andkeep 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 anchoringThe 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 capacityFor the calculation of the current carrying capacity the main factors to be taken in consideration arebullMaxAmbienttemperaturebullTypologyofthecablehandlingsystembullTypeofduty
Voltage dropFor the calculation of the voltage drop the main factors to be taken in consideration arebullLengthofcablebullOperatingfrequencybullOperatingvoltage
To guarantee a long service life and a suitable service of thecable the manufacturer instruction about storing handlingand installation must be followed strictly Cable installationmust be carried out by expert personnel which shall ensureduring this operation that undesired twist and torsion areremoved in order to avoid negative effect when in service
Cable seleCtion
45
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
Cavotecrsquos 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
Installation amp Maintenance
serviCe and suPPort
46 Installation amp Maintenance
exPert CustoMer serviCe is a CritiCal CoMPonent of CavoteCrsquos 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
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
ABBAker SolutionsPort of AntwerpAPLAPM TerminalsBPBritish Royal NavyPort of Buenos AiresPort of BuzanPort of ChennaiCargotecChina Shipping LinesContshipEurokayDoosan Heavy IndDPWorldCochinJNPTPort of DubaiPort of El CallaoPort of EvergladesEvergreenFantuzzi-ReggianePort of FelixstoweFels craneFMC TechnologiesPort of Gioia TauroPort of GothenburgPort of GuanghzouPort of HamburgPort of HeidlandPort of Helsinki Port of Ho Ci MinhPort of Hong KongHyundai Heavy Industry
ImpsaItalia MarittimaKochKonecranesKuwait oil CoPort of Long BeachPort of Los AngelesMacGregorMAERSK DrillingMaher TerminalPort of ManzanilloMatson ShippingPort of MiamiMitsubishi Heavy IndustryMitsuiMOLMSCPort of MumbaiNational OilwellPort of NingboNoellNYKOdimPort of PiraeusPSAQatarPetroleumCoPortofQingdaoPort of RotterdamPort of SalalahSamsungPort of San AntonioPort of Santos
SeawellSiemensPort of SingaporePort of ShanghaiPort of ShenzhenStatoilHydroPort of St LaurenceStora EnsoPort of St PetersburgPort of StockholmSTX ShipyardSumimotoSwedish NavyTechintPort of TianjinTTSUS Coast GuardUS NavyPort of VancouverPort of VirginiaYang MingZPMC
CavoteC around the world
Reference List 47
aCross our Market units and around the globe
CavoteC seeks to deliver safe reliable Cost-effiCient and sustainable solutions
Reference List
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom
febr
uary
201
2 ndash
x2e
n ndash
Po
rts
ndash 04
with a global presence of sales and manufacturing companies across six continents Cavotec ensures each of our clients receives personal and local service
Cavotecrsquos creativity and professionalism is founded on teamwork working closely with clients exchanging knowledge and ideas
we are present in argentinaaustraliabahrain belgium brazil Canada China denmark
finland france germany hong kong india italy the netherlands new Zealand
norway russia singapore south africasouth korea spainsweden switzerland
uae uk usa
For more information please visit our website wwwcavoteccom or contact us directly at infocavoteccom