| PowerRun

Technical Specification

Document number: 052368-TS02

Revision: A
Technical Specification PowerRun |

1. OVERVIEW ......................................................................................................................................................................... 2
2. STANDARDS ....................................................................................................................................................................... 2
3. SYSTEM MAIN FEATURES ................................................................................................................................................... 2
4. OPERATIONAL INSTRUCTIONS ........................................................................................................................................... 3
5. SYSTEM MAIN COMPONENTS ............................................................................................................................................ 4
5.1. FRAME ......................................................................................................................................................................... 4
5.2. CABLES ......................................................................................................................................................................... 5
5.3. DRUM .......................................................................................................................................................................... 5
5.4. CABLE GUIDE ................................................................................................................................................................. 5
5.5. ROOF ........................................................................................................................................................................... 5
5.6. PLUGS .......................................................................................................................................................................... 6
5.7. COLLECTORS .................................................................................................................................................................. 6
5.8. HYDRODYNAMIC DRIVE ..................................................................................................................................................... 7
5.9. REEL CONTROL CENTRE ..................................................................................................................................................... 7
5.10. GEARED ROTARY LIMIT SWITCHES ........................................................................................................................................ 7
6. DATASHEET ........................................................................................................................................................................ 9
7. LIMITS OF SUPPLY ............................................................................................................................................................ 11
8. ANNEX ............................................................................................................................................................................. 12
8.1. CABLE DATASHEET ......................................................................................................................................................... 12
8.2. PRELIMINARY DRAWING .................................................................................................................................................. 13

A Issued for proposal 05 December 2022 DR DR

Rev Comment Date By Approved

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Technical Specification PowerRun |

1. Overview

The Cable Management System (CMS) PowerRun is installed on the berth and is designed to handle the electrical cables that
connect the ship to a land-based power source when ship is moored. This allows the vessel to switch off its generators, thereby
giving significant reductions in noise, air pollution and fuel consumption.
The system makes it possible to pay out one or more multicore power and signal cables safely, lay them up on a ship and establish
connection to the electrical grid with Cavotec Power Connector PC4, up to 250A, or PC5, up to 400A.
PowerRun’s hydrodynamic technology maintains cable tension, preventing cables from slacking when vessels move due to
displacement, waves, and tidal motion.

2. Standards
PowerRun has been designed in compliance with Cable Management System (CMS) standard (as far as applicable):

• IEC PAS 80005-3 “Utility connections in port – Part 3: Low Voltage Shore Connection (LVSC) Systems – General
requirements”.

3. System main features

The system includes a number of features to ensure safe operation:

• Audible and visual alarms activate when last two turns of cable are available on the drum, with cam limit switch
for sensing drum full/empty contacts. Alarms may be suitable for customer remote supervision as well;
• Hydrodynamic slipping clutch integrated into gearbox: active CMS incorporating tide compensation function as
defined by Cable Management System (CMS) requirements (PAS/IEC 80005:3 and IEC/ISO/IEEE 80005-1);
• Cable guide: multi-rollers guiding system that allow for proper bending radius of cables;
• Emergency stop via dedicated circuit integrated within system control panel.

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Technical Specification PowerRun |

4. Operational instructions
In manual mode, an operator can unwind and wind the cable(s) by using the push buttons on the pendant or the ones
on the Reel Control Centre. In automatic mode, the reel will cycle on/off in order to recover any cable slack that has
resulted from changes in elevation between the wharf and the ship.

In presence of a cable guide, it is possible place the plug(s) onto the guide and transfer them to the ship by releasing
the needed cable(s) length for reaching the socket(s) on ship.

Plug(s) will be connected to relative socket(s) on ship while cable grip(s) will be anchored to the vessel for safety
reasons.
In some cases, due to vessel power demand, only one plug might be connected to the socket on ship while the others
(if any) has to be anchored on the drum (via a suitable locking system) and will rotate with it.

Reel will be set in auto mode to retrieve automatically cables for 10 second every 10 minutes (time settable),
eventually recovering slack of cable due to the tide or ship movements (in case of tightened cable, the clutch inside
gearbox will slip).
Whenever an over tension should occur on cable(s), the cable reel will release cable(s) until last two turns will be
available on drum; the feedback for supervision is supplied in two step, second last turn and last turn.

During unmooring activities, circuit breakers on shore must be opened, the reel sets in manual mode, plug(s)
disconnected from socket(s) and cable grip(s) disengaged, therefore it is possible to retrieve cable(s) on cable reel.

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Technical Specification PowerRun |

5. System main components

PowerRun cable reel system is made up of several main components which are briefly described in the following
sections.
5.1 Frame
5.2 Cables
5.3 Drum
5.4 Cable guide
5.5 Plugs
5.6 Collectors
5.7 Hydrodynamic drive
5.8 Reel control centre
5.3
5.9 Geared rotary limit switches

5.6

5.1
5.4

5.7

5.9
5.2

5.5

Figure 1: PowerRun general drawing for information only

Note: for preliminary indication only.

5.1. Frame
The frame is the main structure on which all the other components are installed. It provides protection to the
equipment and allow an easy lifting of the PowerRun for placing it onto shore installation site.

Frame optional:

• Twist lock foundation: four corner blocks permit to anchor PowerRun to the wharf by using four twist locks.

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Technical Specification PowerRun |

5.2. Cables
The cables act as conduit for electrical power and fibre optic communications. It is specifically designed for reeling
purposes, having exceptional flexibility and high tensile strength. A special sheathing compound provides high
resistance to the harsh marine environment.
The cable is manufactured in accordance with:

• IEC PAS 80005-3 “Utility connections in port – Part 3: Low Voltage Shore Connection (LVSC) Systems – General
requirements”.

5.3. Drum
The drum is used to store the cables. The internal diameter of the drum is selected to meet the minimum bend
radius requirements of the cable and to ensure an optimal relationship between reeling torque and cable tension.
The external diameter of the drum is selected to ensure that the full cable length can be accommodated.
The compartment width of the drum depends on the cable diameter and the type of lay selected (eg. monospiral,
3-2-3, random).

5.4. Cable guide

The guide acts to provide a relatively frictionless path for the cables between the drum and the side of the ship. It consist s
of several rollers arranged in a way that cable path radius is greater than the minimum allowable bending radius of the cable.

Cable guide configuration:

• Hydraulic – may be extended and retracted,

via hydraulic pistons, by:

- a hydraulic hand pump.

5.5. Roof
The PowerRun will be covered by a roof to limit weather impact on it.

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Technical Specification PowerRun |

5.6. Plugs
Cable(s) will be terminated on ship with following type of plugs:

Cavotec Type PC5 push-pull - inverted

• Manufacturer: Cavotec;
• Housing material: Cast aluminium;
• Max Voltage: 1 KV
• Max current phase: 420 A;
• Configuration:
- 3 poles + earth;
- 4 pilots.

Figure 2: PC5 push-pull type plug - inverted

Plugs are compliant with following standards:

• IEC PAS 80005-3 “Utility connections in port – Part 3: Low Voltage Shore Connection (LVSC) Systems – General
requirements”.

5.7. Collectors

Figure 3: collector example

The collectors, embedded within drum structure, facilitate the transmission of power and data between the
rotating reeling cable and the fixed machine cables.
Two different versions available:

Low Voltage (LV) collector

The low voltage (LV) collector consists of rotating brass sliprings against which a number of fixed carbon brush
tips located.
Insulation distance between different phase rings is increased as per the same suitable for high voltage
application, with the aim of achieving as well a best installation condition for cables within slipring structure.
Pilot signals are transferred via a dedicated LV slipring assembly embedded within same housing.

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Technical Specification PowerRun |

5.8. Hydrodynamic drive

The Hydrodynamic drive is a specially designed reduction gearbox, suitable for providing a constant torque to the
output shaft, that incorporates an oil-immersed torque-regulating clutch.
Torque is produced by shearing oil between bronze/steel friction interface of two rotating metallic disks.
The faces of the clutch are specially machined, so that the static torque is no more than 3% – 10% higher than the
normal dynamic operating torque.
The amount of pressure acting at the interface, and therefore the torque output, can be easily adjusted over a
wide range.
The drive is powered by a standard motor which runs at a constant speed; any variation in reel speed is taken up
as slip in the clutch.
The optimum torque output of the drive is just enough to recover and pay out cable in all operating conditions
without applying undesirable stress to the cables.
The drive unit permits the reel out of cable even in case of motor failure.

5.9. Reel control centre

The Reel Control Centre (RCC) is an IP56 enclosure that incorporates the electrical switchgear (Auxiliary AC LV
power demand: 9 kW) required to control cable reel operation.
Installation condition:

• fixed on the side of PowerRun frame;

The lid of the enclosure is equipped with:

• Pushbuttons and selector switches suitable for several functions such as: Emergency stop, Manual/Auto,
Reel-in, Reel-out.

WARNING
Pull-out E-button on RCC lid is wired to the ship feedback signal: once activated, it transmits a control
signal to shore side suitable for immediately disconnect the shore connection.

• Pilot lights for providing a visual feedback of PowerRun operating status (e.g.: Power ON, Reel Ready,
Motor Overload…etc).

A pendant acts as alternative operator interface for controlling PowerRun operating activity.

5.10. Geared rotary limit switches

PowerRun incorporates two geared rotary limit switches suitable for checking the limit conditions for cable turns
presence on drum.
Each one of the two Geared Rotary Limit Switch (GRLS) incorporates 7 cam operated switches, (14 switches totally
available), which are used for checks here below:

Second last turn NO contact - indicates two last turns of cable remain on the drum.
This signal should be transferred on a permanent supervised room with the
aim of activating a procedure for visually checking the PowerRun status, so to
restore normal condition or manually shutdown power and disconnect ship in
case of abnormal condition.

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Technical Specification PowerRun |

Last turn / Reel NC contact - indicates only last turn of cable still remain on the drum.
emergency This signal trip the pilot circuit (opening of pilot circuit must trip LV circuit
breakers on shore/ship) and can be used on supervising system for backup trip.
Due to unexpected condition the cable on drum is close to its ending edge;
operator shall check the reason, restore normal condition or fastly disconnect
ship to avoid damage on reel.
It indicates that PowerRun emergency button on pendant (or on Reel Control
Centre) has been pressed, NO contact (note that this signal will be open also in
case AMP has no power).
This signal must activate procedure to visually check the AMP reel and find out
the reasons why the E-button has been pressed.

Reel ready NO contact - indicates PowerRun is ready to operate.

(optional) When signal is open, a procedure shall be activated for visually checking the
system status.

The three remaining cam operated switches are available for other functions as required.

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Technical Specification PowerRun |

6. Datasheet
System type PowerRun
Proposal identifying code
Machine type
Drawing
Main preliminary dimensions Width [mm] 3700
Height [mm] 3400
Length [mm] 4200 (with cable guide fully extended)
Weight [kg] 7000 (approximately)

Ambient condition Ambient temperature -10°C - +40°C

Environment close to the sea with salt and high humidity

Main system data Transfer power 1 MVA (@ Vin=460 VAC @ Tamb=+45°C)

Rated Voltage 460 V ac
Insulation Voltage 1.1 kV ac
Required current @1 MVA – 1255A (314A through each cable)
Short circuit current 16 kA 1 sec
Auxiliary supply 230 V

Power cables on drum Type Cavoflex

Voltage rating Up to (1,2) kV
Composition 3x185+2G95/2+(4x2,5)C
Dimensions 61.2 mm, 7,93 kg/m
Active length 30 m for each coil (+ 2 dead turns)
Cable ampacity 369 A at 30° each cable

Main reel configuration System type PowerRun - Previously known as AMP REEL Shore
Gearbox type "Model 300 - Gear reduction: 1:237 - Max Torque:
2700 Nm"
Induction motor poles quantity 4P
Chain ratio 4
Number of cables 4
Drum type Monospiral
Drum size Inner ring diameter 1050 [mm] - Outer ring diameter
2100 [mm]
Drum compartment width 074 mm

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Technical Specification PowerRun |

Drum material Galvanized

Drum surface treatment No treatment
Slipring typology 2 x 7240 - Seven rings nominal rating 2400A each
Slipring diameter Suitable for LV applications
Slipring insulation voltage (MAX) 1100 V -
Pilots number 8
Fiber optics No Fibers
Limit switches 2
Heater Included
Cable guide configuration Hydraulic
Cable guide type
Number of rollers 52

Options AMP Reel Foundation Foundation twistlock

AMP Reel Movimentation Standard movimentation (forklift)
AMP Reel incoming cable Pigtail fix side 5 m
AMP Reel skid Skid mounted
AMP Reel Roof Included
AMP Reel - Plug rotating with drum No

Accessories Accessories 1 Pendant remote controller – AMP remote controller Commentato [FA1]: Dobbiamo inserire in questa sezione
connected to Reel Control Centre anche il pendant remote controller?
Accessories 2 Roof -
Accessories 3 No accessories -

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Technical Specification PowerRun |

7. Limits of supply
Any equipment or services not explicitly mentioned in this technical specification is not included in Cavotec scope of
supply, such as:

• Trasformers;
• Multimeter;
• Vt TV;
• Heavy duty circuit breaker;
• Hazardous location compliance;
• Installation activities;
• Selectivity study;
• Civil works;
• Upstream protections;
• Auxiliary circuit and supply devices to handle cable pilots;
• Protection relay;
• Commissioning;
• Spare parts;
• Training;
• Service activities;
• Withstand F.A.T (to be discussed if required).

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Technical Specification PowerRun |

8. Annex
8.1. Cable datasheet

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Technical Specification PowerRun |

8.2. Preliminary drawing

The drawings are for information only showing a PowerRun with 4 cables dimensions.

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