HISTORY

Founded in 1981, McRae Electric Ltd is a leading provider of marine electrical and electronic integration solutions across North America. With offices in Burnaby and Victoria, British Columbia, McRae specializes in delivering custom automation, control, and power systems for vessels, terminals, and port electrification projects.

PROJECT SUMMARY & CHALLENGE

McRae Electric Ltd developed and commissioned a Shore Control System (SCS) to support Seaspan Ferries’ hybrid ferry vessels at multiple British Columbia terminals. This high-power, fully automated system enables safe, efficient, and rapid shoreto- ship energy transfer, ensuring maximum battery charging time and reducing emissions by minimizing generator use.

Project at a Glance:
Customer: Seaspan Ferries Corp.
System: Shore Control System (SCS)
Terminals: Tilbury, Duke Point, and Swartz Bay
Peak Charging Power: 2.5 MW
Commissioning: First terminal August 2025; others to follow

As high-power shore charging remains a developing technology in the marine industry, McRae Electric faced the challenge of designing a fully integrated control solution from the ground up. The objective was to coordinate the vessel’s hybrid power system, the Zinus automated charging arm, and the electrical
utility supply, safely and efficiently. Environmental constraints — including non-standard 740 VAC operation and full outdoor exposure — required a robust, weatherproof enclosure with anti-condensation measures.

“Horner’s OCS and remote I/O solutions have been instrumental in our marine projects. The integrated controller and HMI design delivers the compact footprint we need onboard and at the terminal — critical where space and reliability are at a premium.”
~ Chris Warren, Senior Technologist / Project Manager, McRae Electric Ltd.

SOLUTION

To meet these requirements, McRae implemented the SCS using Horner’s X7R PLC with HMI, paired with a variety of OCS I/O modules (CNX116, DIM610, ADU100, DQM502). The system utilizes digital and analog I/O with Cscan internal communication. Hardwired interlocks and permissives manage the vessel connection process, while the integrated HMI provides operators with live system status, alarms, and voltage monitoring. An internal UPS ensures operational continuity during power interruptions, and custom sequencing logic governs safe connection and disconnection procedures with the Zinus automated charging arm and locking connector.

The system was certified by CSA/ETL and designed for long-term reliability in marine terminal environments. Although the initial implementation does not include remote monitoring or SCADA integration, the SCS architecture was designed with scalability in mind, allowing for future connectivity upgrades.

RESULTS & BENEFITS

Upon docking, the ferry’s automated charging sequence begins immediately, maximizing available charging time and ensuring consistent, safe power transfer. This hands-free connection minimizes manual intervention and enhances operational efficiency. By leveraging the available charge window, Seaspan Ferries can extend battery operation and reduce generator runtime, resulting in lower fuel costs and emissions.

Customer feedback has been highly positive, noting the speed, reliability, and simplicity of the automated process. The successful deployment at multiple terminals establishes a foundation for future electrified ferry initiatives across the region and beyond.

CONCLUSION / TESTIMONIAL

McRae Electric Ltd developed and commissioned a Shore Control System (SCS) to support Seaspan Ferries’ hybrid ferry vessels at multiple British Columbia terminals. This high-power, fully automated system enables safe, efficient, and rapid shoreto- ship energy transfer, ensuring maximum battery charging time and reducing emissions by minimizing generator use.

Project at a Glance:
McRae Electric selected Horner’s All-in-One controller and remote I/O solutions for their rugged design, integrated PLC + HMI architecture, and compact footprint — key factors for space constrained marine environments. Horner’s fast lead times and support made the SCS project both efficient and reliable to implement.

“Horner’s OCS and remote I/O solutions have been instrumental in our marine projects. The integrated controller and HMI design delivers the compact footprint we need onboard and at the terminal — critical where space and reliability are at a premium.”
~ Chris Warren, Senior Technologist / Project Manager, McRae Electric Ltd.