Equipment Protection Case Studies
Piping Freeze Protection for Cooling Tower
Water Detection System Protects Datacenter
Rugged Snow-Melting Solution for Truck Ramp
Piping Freeze Protection for Cooling Tower
This downtown NYC financial district building requires year-round cooling tower operation. A sophisticated powerline-based monitor and control system was selected by the consulting engineer to be the most cost-effective method to protect the piping from freezing and to monitor the pipe temperatures. Forty-five remote temperature transmitters are located at every pipe location that could contain standing (non-circulating) water, based on valve positions or pump operation. All monitoring is performed without any wiring, other than power to the heater cables.
Mission critical 24/7 cooling in this financial district building requires operating cooling towers and external water piping as large as 24" in the winter. Any pipe or valve freeze-up (and burst) would be catastrophic, so a fully-supervised system of monitoring and controlling heat tracing was specified.
Distributed pipe temperature sensing was determined to be the most accurate method of verification that pipes were not in danger of freezing. A patented powerline-based heat trace monitor and control system was determined the most cost effective method of providing distributed pipe temperature monitoring. Sensors were placed in the worst-case locations, namely between each isolation valve and the corresponding pipe connections to the cooling towers. Based on valve position and pump operation, these remote locations could contain non-circulating water, which is most likely to freeze.
Remote temperature sensors (the black junction boxes) are fully addressable, self-diagnostic, and “ruggedized” for industrial, transit, and low temperature/high vibrtion installations.
A modular control and monitor panel is provided to monitor the 5000 feet of heater cable and 45 temperature sensors. The spread-spectrum powerline communication technology utilized does not require filters or isolation transmitters, making it ideal for existing and retrofit applications. The only wiring required for this system is the power feed to the heater cables. All monitoring occurs over these wires.
Water Detection System Protects Datacenter
Real-world conditions, even in "clean" datacenters require rugged sensor cables, built from 100% non-corroding materials, and equipped with low profile connectors for ease of maintenance. Leak detection systems are often operating for years before a leak occurs. There is only one chance for early detection and location. After 20 years of development and improvements, the Patented Tracetek system is still the most accurate and reliable leak detecting and locating system.
This typical under raised floor sensor cable installation illustrates why only the most durable sensor cable (orange wire by stanchion running below datacom wiring) should be used. Conduits, copper grounding wires, and telecom wiring bundles cross over the sensor cables in many locations. The Tracetek sensor cable is insensitive to pressure and kinking, and can be provided with low profile connectors for ease of future removal for cleaning.
This example of the contamination present in a "clean" datacenter illustrates why only non-metallic, non-corroding materials must be utilized in the sensor cable. Only Tracetek uses conductive polymeric construction and insulation, exposing no metal to the environment to corrode.
Rugged Snow-Melting Solution for Truck Ramp
The most rugged, flexible, cut-to-length heater cables were selected for this industrial facility truck ramp. The ability to withstand vibration from commercial trucks, salt and other corrosive chemicals, and thermal expansion of the ramp assures heater cable life that will exceed that of the concrete ramp.
Cables are easily attached directly to rebar. A 2-stage pour is not required. Cable reels of 1000 feet each are provided and cut to length in the field. Field conditions often require modifications in cable lengths and layout from the original engineering design.
Heater cable power connections and terminations are above grade in accessible junction boxes. Only the rugged polyolefin jacket of the cable is in the slab. Rakes, shovels, and stone will not damage the heater cable. There are no buried splices that can fail due to poor manufacturing, handling, or galvanic corrosion.
Buddhist Temple Maintains Comfort with Floorwarming System
This Buddhist temple utilized over 11,000 feet of floorwarming cable to maintain carpet surface temperatures of 80 degrees for the comfort of its members. Finite element heat transfer models were generated by Raychem to design the floorwarming system with as little heater cable as possible. First floor heater cables were imbedded in the floor slab, second floor heater cables were located on the underside of the second floor slab.
Cables are installed prior to topping concrete pour. Cable reels of 1000 feet each are provided and cut to length in the field. Field conditions often require modifications in cable lengths and layout from engineering design.
Heater cable power connections and terminations are above grade in accessible junction boxes. Only the rugged polyolefin jacket of the cable is in the slab. There are no buried splices that can fail due to poor manufacturing, handling, or galvanic corrosion.
Custom made floor temperature sensing thermostats provide an additional level of control for comfort and energy savings. Capillary tubing of up to 50 foot lengths allow temperatures to be monitored in the center of the room(s). Installation in thermally conductive fluid-filled conduit provides rapid response and the ability for removal for future service.
Equipment Protection Tracetek in NYCTA Rail Control Center
The NYCTA's recently completed Rail Control Center, located in midtown Manhattan, is the central nervous system for the entire NYCTA rail system.
Miles of Raychem Tracetek water detection cables are located throughout the facilities raised floors. In the event of water leaks from piping, foundations, or other sources, the networked Tracetek alarm modules instantly report the presence of water, and the location, accurate to 1 foot, along the length of the cable.
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