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Beauty and Performance Mark Tank Insulation System for World’s Largest TES Tank
Key Challenges

Beauty-Performance-TES-tank.jpgChicago Bridge and Iron (CB&I) constructed the tallest thermal energy storage (TES) tank in the world for The Texas Medical Center Central Heating and Cooling Services Corporation (TECO).  The tank is 100 feet in diameter and an impressive 150 feet tall, and used to provide water for numerous buildings in the Houston, TX downtown medical district. The key challenge was to insulate the tank so that it enhanced the appearance of the surrounding location rather than having this massive tank create an eye sore for the area.

Solution

The customer took advantage of our Heat Management System approach. Pentair Thermal Management fabricated and constructed the Tracer Trac-Loc standing seam tank insulation panel system with a unique pattern that blended the tank with its surroundings.

Products & Services

Our Tracer Services team, per the customer’s architectural design, successfully fabricated and constructed a Trac-Loc standing seam tank insulation system with the unique pattern that blended the tank with its surroundings. The team also coordinated the detailed planning, shipments, and scheduling for the project; and successfully installed the various colored panels spanning the tank sidewall, creating the unique appearance of the tank.

Benefits

The end result was a superior tank insulation system that also enhanced the appearance of the surrounding location.  No scaffolding was needed which resulted in a lower installation cost and reduced the overall schedule.

Beijing Airport Automated People Mover (APM) System
Key Challenges

Shuttle.jpgIn cold weather climates, Automated People Mover (APM) system running surfaces, such as guideways, power and signal rails, switches, and turntables, require de-icing for safe operation.

Beijing Capital International Airport needed to keep snow and ice from forming on the guideway and associated running surfaces of a new APM system for the Beijing Capital International Airport. This APM system was part of the airport’s extensive expansion program in preparation for the 2008 Olympics being held in Beijing, China.

Solution

Pentair Thermal Management can engineer heat-tracing systems to accommodate the most unique aspects of de-icing applications, including embedded guideways and tight clearance and configuration areas as seen in rails, switches and turntables.

Bombardier Transportation, acting as the prime contractor for the Beijing Capital International Airport Authority, contracted Pentair Thermal Management to provide all engineering, design and products for an integrated heat trace system for a new APM. The system was designed and based on predicted heat requirements and thermal profiling of the guideway running surface.

Pentair Thermal Management performed a Finite Element Analysis (FEA) to predict the heat requirements and snow melting characteristics under varying conditions. A total of eleven case studies were submitted using data on Beijing’s snowfall and temperature averages over the past 100 years. This information was used to establish and implement operating philosophies for the customer that allow for the most suitable and energy efficient heating system solution.

There are specific challenges inherent to this type of project including:

  • Extremely long running surfaces associated with the guideways    
  • Tight clearances    
  • Unique configurations typically associated with power rails, switch points and turntables

Pentair Thermal Management provided a final system design that incorporated various heat‐tracing technologies to address these issues.

Products

The largest engineering challenge for the new APM at Beijing Airport lay in the design of the Skin‐effect heat tracing system for the concrete guideways. By developing and utilizing specialized component assemblies, Pentair Thermal Management was able to design a system with long continuous circuits averaging over 1000 meters in length. Other unique components and assemblies were designed specifically for this project to be compatible with the power rails, switch points and turntable layouts.

Benefits

By doing a thorough analysis and design for the deicing system, Pentair Thermal Management created an overall solution that was cost effective and very reliable.  The de-icing system used the best heat tracing technology and customized components and assemblies for this application.

CEPSA Phenol and Acetone Project
PROJECT DETAILS

Client:CEPSA (Compa ía Espa ola de Petróleos, S.A.U.)
Location:CaoJing SCIP, Shanghai
Completion Date:June, 2014
Contract Scope:Engineering Design, Material Supply, Installation Supervision and Commissioning for the Electrical Heat-Tracing System
Applications:Temperature Maintenance and Pipe Freeze Protection for Chemical Pipes and Vessels
Technology:Raychem Self-Regulating and Mineral Insulated Heat-Tracing Systems, and NGC-30 Control and Monitoring System

Key Challenges

The CEPSA Phenol and Acetone Project Team required a Heat Management System provider to implement a more comprehensive solution to meet the strict mix of Process Maintain and Freeze Protection requirements, as well as the extreme exposure temperature conditions at the Shanghai SCIP job site. With a 60 km complex piping route, over 80 km of heat tracing cable and 75 control and power distribution panels were required to create a heat-tracing system that provided tighter control, limiting downtime repairs and providing the ability to withstand high temperature exposure conditions in excess of 600°C.

Solution

Pentair Thermal Management’s overall solution included the use of NGC-30 controllers that employ a centralized multi-circuit control and monitoring system to configure/control the distributed heat-tracing circuits respective of process maintain or freeze protection requirements. Key data such as temperature, ground-fault current, operating current, and voltage are monitored through panel-mounted touch screens. NGC-30 controllers provide immediate access to key process maintain and freeze protection data. Additionally, field maintenance engineers are able to check the circuit on/off status via a lighted end seal kit above the insulation, or conveniently browse information remotely from a workstation with pre-configured supervisory control and monitoring software.

The bulk of the technology for the CEPSA Phenol and Acetone Project utilized the Raychem Self- egulating Heat Trace technology. The Pentair design team also utilized mineral insulated (MI) heating technology, which met the need for specific exposure temperature conditions and paired well with the NGC-30 control methodology.

Products

To meet the needs of this challenging application, Pentair Thermal Management offered a Heat Management System which included:

  • Self-Regulating Heating Cables
  • Mineral Insulated Heating Cables
  • Above-Insulation Connection Kits
  • NGC-30 Control and Power Distribution Panels

Benefits

  • Raychem Self-Regulating Heating Cable technology, paired with the NGC-30 controllers, substantially reduced the energy consumption with accurate power output to minimize the heat loss of the pipes and vessels.
  • Centralized control and monitoring system provided information on the status of heat-tracing circuits, failure alarms, minimum/maximum values of temperature etc. Better reporting enabled predictive maintenance which reduced the TOC of the plant and improved its performance.
  • The broad range of PTM technologies afforded CEPSA the opportunity to utilize heat-tracing technology that met the requirements of their high-temp exposure conditions.

With decades of experience in designing, manufacturing and installing heat management systems, PTM was able to provide a comprehensive solution to CEPSA’s unique needs. The use of multiple heat tracing technologies, a unique controller platform that allows for better energy utilization, and a more reliable heat-tracing system substantially reduced operations and maintenance requirements.

Pentair Thermal Management provides unique solutions for various applications and offers a full suite of optimization strategies customized for a given application resulting in reduced CAPEX/OPEX for the project.

Charters Ascot Luxury Private Residences
The Project

Charters Ascot, UK, is a development of luxury private residences in the grounds of a mansion house. The requirement was to supply underfloor, secondary heating to the living areas to supplement the main warm/cold air-conditioning, and fully integrate it with the building management system. There was also a requirement to provide heating to bathroom areas.

Key Challenges

Finding an energy efficient, easy to install solution, which would keep the floor height to a minimum. A solution for wet areas, and for all areas, systems which could be integrated with the building management system.

Solution

T2Red heating cables and T2Reflecta insulation boards provided the right combination of comfort - even heat distribution across the entire floor surface - flexibility for further room decoration and reduced installation time. The floor heating system was integrated with the BMS, meaning no individual controllers were required. With the ease of use that comes with the T2Reflecta underfloor heating product this meant a great reduction in installation time and a reduction in onsite costs for the contractors.

Products

2000 m T2Red self regulating cable and T2Reflecta insulation boards
326 T2QuickNet mats (90W/m² and 160W/m²)

Downhole Heating Application for Heavy/Extra Heavy Oil
Key Challenges

 Heavy-Oil-Venezuela.jpgOne of the world's largest accumulations of natural bitumen and heavy oil is the Orinoco Heavy Oil Belt in Venezuela. It has been estimated that there are about 270 billion barrels of recoverable oil in place. These reservoirs hold a heavy to extra heavy oil with API range of 16 to 8 API with high viscosities that inhibit the mobility of the crude. The use of diluents has become standard practice to move this oil, resulting in an expensive maintenance process, not only to procure but to treat (separate). In 2008, Pentair Thermal Management supplied and installed a PetroTrace Downhole Heating System for use in the Orinoco Heavy Oil Belt to assist the oil recovery.

Solution

Pentair Thermal Management engineered a PetroTrace Mineral Insulated (MI) Downhole heating system for this deep onshore, horizontal well to deliver bottom-hole type heat to reduce the viscosity of the extra-heavy oil in this producing well.

The PetroTrace Downhole heating system supplied produced 65 kW along the 3,000 ft (914 m) of the 7-in slotted liner. The heater was designed so that more power was delivered towards the end of the liner where heat is needed the most. The heater was configured by three heating sections with a lower power density in the sections closest to the Progressive Cavity Pump (PCP). The heater was deployed inside the horizontal section of the slotted liner by attaching it to the outside of a 2-3/8 in supporting pipe.

The supplied system included a control panel for ease of operation and monitoring of temperature and current.

Products

The products utilized for this flow assurance project include Pyrotenax Mineral Insulated (MI) heating cable for bottom-hole heat and Raychem control panels.

Benefits

The heating system significantly lowered the viscosity of the oil by increasing the temperature in the liner approximately 50°F (10°C) in less than 24 hours. As a result, oil production increased 65% from 340 BOPD to 560 BOPD.

Downhole Heating System Increases Production in CA Stripper Wells
Key Challenges

Petro-Trace-Bakersfield.jpgSome of the largest heavy oil reserves in the continental United States are located in California's Central Valley oilfields north of Los Angeles. The reservoirs in this area are estimated to be a 40-billion-barrel resource, primarily of heavy crude approximating 13 to 9 API located in shallow reservoirs not deeper than 2,300 ft (701 m) in depth. Pentair Thermal Management has been supplying PetroTrace Heating Systems to oil companies in this region since 2005.

Solution

Pentair Thermal Management engineered a PetroTrace Mineral Insulated (MI) Downhole Heating System for these onshore low-flow, shallow wells to deliver bottom-hole type heat to improve the mobility of oil in the near wellbore area and allow for an increase in production.

The PetroTrace Downhole heating system supplied produced 27 kW of energy in the pay zone at 600 V. The Downhole heaters were secured to a stinger pipe below the pump that contained several passes of MI cable, producing a power density of 300 W/ft.

The supplied system included a control panel for ease of operation and the monitoring of temperature and current. To allow the client to confirm target temperatures along the length of the heated section, multiple sensing thermocouples were installed to provide temperature measurement.

Products

The products utilized for this flow assurance  project include Pyrotenax Mineral Insulated (MI) Heating Cable for bottom-hole heat, and Raychem Bottom-Hole Heating (BHH) Control Panels.

Benefits

Production increased from 3 BOPD to over 20 BOPD, resulting in a payback of less than four months.

Expertise in Heat Tracing Systems for Crude Oil Transfer Ensures Flow at CA Refinery
Key Challenges

The Tesoro Refinery in Martinez, CA needed to heat trace its Amorco Wharf pump station and transfer lines to ensure crude oil flow from its off-load wharf to a series of storage tanks. Detailed engineering drawings for the heat tracing did not exist and the project proved to be complicated due to the intricate valve piping at the pump station. The client had a tight deadline and so they contacted Pentair Thermal Management.

Solution

Due of the variety of pipe sizes, high number of large and small valve assemblies and the tight temperature maintenance requirements, the heat trace design required creative solutions and flexibility to best meet the customer’s needs. Pentair Thermal Management engineers visited the refinery and completed a field design by taking pipe measurements and designing the heat tracing system on site. They worked with the local refinery personnel to define the necessary power distribution systems, power-point locations, necessary control and monitoring solutions and heat trace cable recommendations.

Products

Our experience with crude oil transfer and marine applications allowed us to develop a timely and cost effective solution for the Tesoro Refinery. Raychem XTV self-regulating heat trace cable was specified for all of the piping in order to minimize the installation costs as well as to ensure the temperature maintenance requirements. Raychem 920 Control & Monitoring panels were combined with transformers and a power distribution system in a self-contained skid to reduce on-site installation time and expense.

Benefits

The installation was completed in accordance with Tracer safety standards resulting in a 100% safety record on the project. Along with the quality installation of the heat tracing system by experienced craftsmen, Tesoro received a Warm Pipe Warranty as a guarantee of the quality of the installation. Experience, creativity and flexibility were key in completing this project for Tesoro Refinery. Put these traits and capabilities to work for you on your next job.

Fuel Leak Detection for Crude Oil Storage Tanks at French Refinery
Key Challenges

A refinery in France sought a system capable of quickly detecting hidden leaks beneath its four crude oil tanks. Undetected leaks beneath oil storage tanks pose a major threat to operational safety at oil storage facilities and have the potential for disaster.

Solution

The refinery needed a specialist sensing cable to quickly detect the presence of liquid hydrocarbon fuels at any point along its length, without reacting to the presence of water.

Products

Pentair Thermal Management installed its TraceTek TT5000 Oil and Fuel Sensing Cable at the refinery. Each of the four crude oil storage tanks at the Notre Dame de Gravenchon refinery now has TraceTek TT5000 cable buried beneath its perimeter. The cables are attached to the TraceTek Sensor Interface Module to continuously detect and pinpoint any oil leak.

Benefits

Pentair Thermal Management’ TraceTek system is constantly ready to alert the operators to any fuel leakage. This allows the refinery to detect leaks early, giving the response team enough time to react before the situation becomes critical. The system protects the operational safety at the oil storage facility and shields from potential disaster.

Leak-Sensing Cable Helps Protect the Cabinet War Rooms Museum, London
Key Challenges

The Cabinet War Rooms are situated in the basement of the Treasury building in the Parliament Square in London, where Winston Churchill directed the war effort. It is now a museum containing irreplaceable artifacts and exhibits from that time. As part of the recent refurbishment of the Treasury, facilities management noticed undetected water leak could damage or destroy many of the historic contents.

Solution

Pentair Thermal Management advised that the Cabinet War Rooms required a system that is capable of quickly detecting, locating and alerting the facilities manager to water ingress.

Products

Pentair Thermal Management installed a TraceTek leak detection system with over 2.3 kilometers of TraceTek TT1000 sensing cable to detect water along with Sensor Interface Modules and Master Modules, each of which can monitor up to 500 feet (150 meters) of sensing cable. The modules are connected to a building management system via a RS-485 network. When water is detected, the TraceTek Sensor Interface Modules provide an alarm and leak location display.

Benefits

Pentair Thermal Management’ TraceTek monitoring system allows the museum to quickly take remedial action to protect the exhibits. The leak detection network has been designed to be versatile enough to enable the system to be extended to other areas in planned phased expansions.

Optimized Heat Management System Ensures Safe Sulfur Transport at Large LNG Plant
Key Challenges

Qatargas Sulfur Transfer Line’s heat management system challenges included:

  • A tight range of allowable temperature from 125°C to 145°C for molten sulfur, with a set point of 135°C along the entire length of pipeline.
  • A large outdoor pipeline with significant weight, multiple flow paths, and vertical expansion loops at every 150m.
The customer also required the capability to re-melt and re-heat solidified sulfur without causing overheating or over-expansion. Additionally they needed a redundant heating system that would cover 100 percent of the pipeline.

Solution

Pentair Thermal Management’ ability to engineer and integrate multiple technologies with its expertise in construction and commissioning heat management systems resulted in a world-class, safe, reliable and efficient electrically traced sulfur pipeline.

Products

To meet the needs of this application, Pentair Thermal Management employed a heat management system that included the following:

  • An inherently safe Raychem Skin-effect Tracing System, which has high exposure temperatures and efficient heat transfer to the pipe
  • A state-of the-art Raychem control and monitoring system with vacuum contactors.
  • Finite element analysis to determine the temperature profile of sulfur across the cross-section of the pipe.
  • Fiber-optic based distributed temperature sensing system that provides a dynamic pipeline temperature profile at each meter within 1°C accuracy for the entire length.
  • A multi-power heat delivery mechanism with 7 percent of installed power for normal operating conditions and 100 percent of installed power for heat-up/re-melt conditions.
  • A multi-later thermal insulation system with high temperature expanded inner layer, load bearing closed call foam out layer and UV resistant jacket.
  • Full service procurement of materials, project management, construction and commissioning of the pipeline.

Benefits

A Pentair Thermal Management Heat Management System provided Qatargas Sulfur Transfer Line with the following benefits:

  • The Raychem STS Skin-effect Tracing System minimized the number of circuits and also resulted in better heat transfer and a low temperature differential between the pipe and cable sheath, thus leading to a safer design.
  • The finite element analysis and Raychem control and monitoring solution ensured that the sulfur temperatures did not go outside the tight control temperature range under normal operating conditions.
  • The fiber-optic distributed temperature sensing system provided continuous monitoring of the temperature along the entire length of the pipe. This helped to locate hotspots along the length of pipe during the re-melting process and in turn avoided excessive pressure generated by melting sulfur.
  • Multi-power heat delivery mechanism and multi-layer insulation systems not only optimized the total operating costs of the system but also contributed to a shorter re-melt duration.
  • By assuming total responsibility of the heat management system, Pentair Thermal Management ensured that the project was completed on time, and to the satisfaction of the customer.

Optimized Heat Management System Reduces Costs at Ethanol Production Facility
Key Challenges

BP-Ethanol.jpgBridgeport Ethanol is a green-field 40-million gallons/year ethanol production facility in Nebraska. Their heat-tracing application needed to be modified to include pipe freeze protection for water lines, tank heating and process temperature maintenance of syrup, silage and caustic lines. They brought in Pentair Thermal Management’ Tracer Turnkey Solutions team in May 2008 for the project.

Solution

The Tracer Turnkey Solutions team completely engineered, procured and installed the necessary heat management systems (HMS) at Bridgeport Ethanol. The team leveraged a complex and diverse range of Raychem control and monitoring solutions to reduce the number of necessary circuits to 35. And in doing so, the team was able to reduce the total cost of the heat management system at Bridgeport Ethanol.

Products

Products used included the Raychem 200NG with proportional ambient sensing control (PASC) for the pipe freeze protection and broad temperature maintenance applications. In PASC, the power to the heat tracing is proportioned based upon on the ambient temperature.

The Tracer Turnkey Solutions team also selected a combination of the Raychem 920 and HTPG local control system to control and monitor remote circuits for tank heating as well as pipe freeze protection of the water lines. These areas were respectively 800 feet and 450 feet away from the centralized control panels and would have required 2/0 power wires due to the voltage drop.

Additionally, the team chose the Raychem 200NI with line sensing control for the critical temperature maintenance applications. To reduce the RTD wiring costs, we used the Raychem power line interface technology (PLI) and Smart End Seals (SES) to transmit temperature and continuity data over the heating cable conductors.

Benefits

The project was successfully completed in November 2008. With the use of PASC algorithm, the Tracer Turnkey Solutions team was able to reduce Bridgeport Ethanol’s operating costs by 75 percent from that of the standard ambient sensing controller. The conduit and wiring costs were also greatly reduced by using a local control system, and the use of Raychem power line interface (PLI) technology eliminated the estimated $40,000 of RTD wiring costs.

Pentair Thermal Management Installs Electric Heating Solution for Offshore Flow Assurance Application at Maari Field
Key Challenges

Maari.jpgIn March 2006, Pentair Thermal Management was brought in to install an electric heat-tracing system into an offshore oil production facility located in the Maari Field off the coast of New Zealand. The customer was having trouble with wax buildup in the production tubes of five separate wells, which was interfering with oil flow from the reservoir to the platform.
The Pentair team faced tight installation constraints between production tube and casing, thereby necessitating a unique solution of system deployment through the production tube. Minimizing the platform footprint relative to the power supply and associated system controls was also a challenge the team faced.

Solution

For similar wax mitigation applications, Pentair Thermal Management normally employs heaters externally strapped onto the production tube, such as the PetroTrace DHSX™ or PetroTrace MI product lines. However, the project-specific restrictions and constraints at Maari Field made those technology applications difficult to use. To overcome this, the Pentair team developed a unique solution utilizing the STS technology, resulting in the first-ever application of Skin-effect Tracing System to downhole heating. The team combined the systems to a common power and control scheme, thereby minimizing the need for several large pieces of topside equipment.

Products

The PetroTrace STSi Skin-effect Tracing Systems at Maari Field utilized an STS™ wire that was inserted into coiled tubing filled with dielectric fluid. It was then installed inside of an offshore production tube to deliver heat along the length of the entire production wellbore maintaining the flow rates necessary to prevent wax buildup.
The PetroTrace STSi heaters installed on the wells provide power outputs up to 150 W/m for a total of up to 315 kW per well. To maximize heat transfer, the team installed the heaters within the production tube. The successful development of this field was largely due to the efficient heat transfer of the STS system, preventing the crude from reaching the wax formation temperature even with only a 3°C variation between the reservoir and wax appearance temperatures.

Benefits

The new PetroTrace STSi Skin-effect Tracing Systems at Maari Field were successfully completed in July 2009. The project-specific solution proved to be reliable and provide realistic returns on investment as it mitigated wax buildup in the well’s production tube and maintained consistent oil flow from reservoir to topside.

Pentair Thermal Management Installs Electric Heat-Tracing System at Tesoro Golden Eagle Refinery
Key Challenges

Tesoro.jpgThe Tesoro Refinery in Martinez, Calif., needed its Amorco Wharf pump station and transfer lines heat traced to ensure crude oil flow from its off-load wharf to a series of storage tanks. Detailed engineering drawings for the heat tracing did not exist and the intricate valve piping at the pump station proved to be a challenge. The client had a tight deadline, so they contacted the Tracer Turnkey Services Team at Pentair Thermal Management.

Solution

Due of the variety of pipe sizes, high number of large and small valve assemblies and the tight maintain temperature requirements, the heat-tracing design required creative solutions and flexibility to best meet the customer’s needs. Pentair Thermal Management engineers visited the refinery and completed a field design by taking pipe measurements and designing the heat-tracing system on site. They worked with the local refinery personnel to define the necessary power distribution needs, power-point locations, necessary control and monitoring solutions and heat-tracing cable recommendations.

Products

Pentair Thermal Management’ long history of experience with crude oil transfer and marine applications allowed the team to develop a timely and cost-effective solution for the Tesoro Refinery. The team installed 7,000 ft. of self-regulating heating cable and 40 control circuits. The Raychem XTV self-regulating cable was specified for all of the piping in order to minimize the installation costs as well as to ensure specified maintain temperatures were met.
In addition, Raychem 920 control and monitoring panels were combined with transformers and power distribution panels in a self-contained skid to reduce on-site installation time and expense.

Benefits

The installation was completed in October 2007 in accordance with strict safety practices resulting in a 100 percent safety record on the project. The successful installation of the new heat-tracing system allows Tesoro Refinery to seamlessly pump crude oil from its Amorco Wharf pump station to the storage tanks. Tesoro also received Pentair Thermal Management’ Warm Pipe Warranty as a guarantee of the quality of the installation.

Pentair Thermal Management Installs Floor Heating at Syon Park Waldorf Astoria
Key Challenges

The newly constructed Syon Park Waldorf Astoria Hotel, on the outskirts of London, called on Pentair Thermal Management to provide floor heating solutions for its 5-star, 13,000 square meter complex. The hotel is on the grounds of the Duke of Northumberland’s mansion and had been a home to the duke’s family for more than 400 years.

Solution

TTC went into the hotel to install Raychem Quicknet-160 floor heating mats to provide warmth under the luxurious marble and limestone floor covering. TTC also installed the Raychem floor heating systems in the hotel’s luxury spa.

Products

The Raychem systems are controlled centrally via the hotel’s building management system, which switches on the floor heating when the room is occupied. Of the 151 guest bathrooms, 124 have had this technology installed.

Benefits

The main spa area includes 350 square meters of T2QuickNet heating mats, which are insulated using Raychem Isolecta insulation boards to reduce heat loss and increase energy efficiency by about 20 percent. 

The project was completed in October 2010 and guests were welcomed to the hotel in early 2011.

Pentair Thermal Management Installs Heating Solutions at London Rolex Building
Key Challenges

Pentair Thermal Management was brought in to employ a variety of its heating solutions at the new Rolex Building in London, England. Rolex was looking to convert its heating to a simpler, lower cost single pipe system that required less maintenance.

Solution

Pentair Thermal Management provided hot water services using the Raychem HWAT single pipe hot water temperature maintenance system.

Products

Pentair Thermal Management installed more than 400 meters of cable to provide hot water all the way to the point of use, 600 meters of WinterGard pipe frost protection cables, and RayClic connection devices to safeguard the chilled water supply lines from freezing.

In addition, a beautifully tiled floor at the entrance foyer now welcomes visitors with the ambient warmth of Raychem floor heating systems, with the installation of nearly 50 square meters of T2QuickNet.

Benefits

The reduction of pipework left more space for the single pipe and insulation so that thicker insulation over the system could be used to increase its efficiency. The total estimated energy savings for this project will be approximately 50-60 percent. Even with the higher unit cost of electricity, the actual customer savings are expected to be 5-15 percent.

The design, supply, and installation of the Raychem systems were undertaken by Jointing Technologies, a Pentair Thermal Management distributor partner headquartered in South East England. The project was completed in October 2010.

Pentair Thermal Management Installs Tank Insulation System for Disneyland Resort
Key Challenges

Trac-Loc.jpgPentair Thermal Management was hired to install its Trac-Loc tank insulation system on a thermal energy storage (TES) tank built by Chicago Bridge & Iron at Disneyland Resort in Anaheim, Calif. Vital to the park’s operations, the tank had to have advanced thermal functionality as well as an aesthetically pleasing design since it’s located by the park and private hotels.

Solution

Working in a very tight space, Pentair Thermal Management ensured park operations weren’t interrupted and that guests weren’t bothered while insulating the 58 foot tall tank with an approximate surface area of 18,500 square feet. They also paid close attention and adhered to stringent safety standards due to the close proximity of numerous guests through the project’s five week duration.

Products

Complete with the new insulation system, the neutral-colored Disneyland TES tank blends with its surroundings and chills close to two million gallons of water during off-peak hours. The chilled water is then used during the day by surrounding Disneyland Resort buildings for the HVAC systems.

Benefits

The installation of the Trac-Loc System helped ensure that the tank's service to the surrounding area is done effectively and in a more economical manner. Additionally the tank is protected from heat, resulting in an energy savings of approximately 3.3 million kWh per year.

"The Walt Disney Imagineering team really challenged us to be cognizant of the details from project award through onsite completion. This tank will be an essential part of the day to day activities of Disneyland. We're confident we met the challenges of this project with the highest safety standards, detailed scheduling, and quality assurance of the installation." - Blake Heger, Project Manager

Pentair Thermal Management Provides Single Source Heat Management System for Biodiesel Terminal in Canada
Key Challenges

Biodiesal-Canada-tank.jpgA Large Global Gas & Oil company decided to expand their biodiesel terminal in Winnipeg, Manitoba, in order to store B100, a pure biodiesel product. As biodiesel has a higher gel point than regular diesel, it requires a more precise temperature.

Solution

Pentair Thermal Management provided a complete turnkey heat management system (HMS) for the piping as well as the heat tracing and insulation of the tank. The project was managed out of the Kitchener Services office in Canada and they utilized resources and talent from service centers in Houston and Edmonton to complete the project on schedule.

Products

The project entailed a detailed heat tracing design in combination with insulation on the B100 tank. Raychem XTV heating cable was used for its design flexibility to maintain an accurate temperature; Tracer Trac-Loc, a vertical lock-seam tank insulation system, was used to insulate the tank.

Solution

The comprehensive design was easily integrated within the customer’s timeframe and provided the accuracy required.

Pipelines Traversing Beaches on Mayotte Island, Tanzania and on the Coast of Chile
Key Challenges

When tankers unload their cargo of crude oil or refined fuels into small oil ports and pipe systems, there’s risk to the sensitive beach and dune zones they pass through. In locations like these from Mayotte Island to Tanzania to the coast of Chile, SCADA-based leak detection systems may be ineffective since the pipes are small and the flow is inconsistent.

Solution

Environmentally sensitive areas required a more advanced product that can detect and pinpoint the location of a leak instantly.

Products

The TraceTek TT5000 pipeline monitoring system uses specialist hydrocarbon leak detection cable that is buried inside slotted conduit and located in the same trench as the pipework. The system is installed with one kilometer circuits to monitor the entire pipeline and pinpoint leaks within one kilometer in either direction.

Benefits

Each circuit on the system has its own Sensor Interface Module (SIM) and up to 128 SIMs can be networked back to the alarm and user interface panel. This system can be installed along with single wall steel pipes to provide a long-term monitoring and leak alert capability.

Raychem Pioneers Combined Temperature and Moisture Sensor
Key Challenges

In the summer of 1986, 300m of gutter snow melting cable was installed at CKW Ruopigen (Switzerland). As well as guaranteeing roof snow melt, the client’s objective was to accurately determine the operating cost of the system.

Solution

The installation was divided in two systems, each with a different control method. One system operated with temperature sensing only; the other with temperature and moisture sensing. Temperatures and power consumption were measured during four months.

Products

GM-2X snow melting cable

Benefits

Electricity consumption dropped by 78% when the system was operated using temperature and moisture sensing, compared to temperature sensing only.

Taking Energy Expertise Underground
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TO SAFETY TRANSFER CRUDE OIL OVER A RECORD-BREAKING 700km, PENTAIR ASSISTED CAIRN IN DEVELOPING THE WORLD'S LONGEST HEATED AND INSULATED PIPELINE

In 2004, Cairn India Ltd. uncovered India’s largest onshore oil discovery in 25 years. More than 4 billion barrels were discovered 1.5 Kilometers below ground in the Thar Desert. In this remote, undeveloped area, the oil needed to be transported to refineries 700 km away, without roads or rail.

In all, the transfer solution had to cross a variety of urban and rural landscapes, as well as 34 major rivers. The highly viscous composition of the oil only complicated matters, as it solidified to a hard wax as soon as it reached the ground surface. In order for the oil to flow, it had to be heated to and maintained at a temperature of 65° C (150° F).

pentair_story_mangala_inline_03.jpg

To be as safe, reliable, and economical as possible, the best transfer option was determined to be, an underground pipeline employing a sophisticated engineering system known as the “Skin-Effect Heat Management System” (SEHMS).

Cairn tapped Pentair Thermal Management to help implement the Mangala Development Pipeline Project, leaning on the company’s technical expertise and localized presence in India. Pentair held a strong track record with similar projects, making it uniquely qualified to execute the complex engineered system.

THE HEAT MANAGEMENT SOLUTION

Pentair Thermal Management designed and engineered a custom implementation of its Raychem STS proprietary heat management system. As the backbone of the underground pipeline, it maintains the flow of the crude oil at an elevated temperature, irrespective of changes in environmental conditions.

pentair_story_mangala_inline_02.jpg

The Mangala pipeline consists of a 24” pipeline buried 1 meter below the ground and thermally protected with three different insulation layers. The insulation minimizes heat loss, prevents corrosion, and reduces any potential physical damage to the pipeline.

AN INTEGRATED EFFORT

Pentair teams in Mumbai, India and Houston, Texas, US worked daily with the engineering teams at Cairn to design and implement the important and challenging application. The collaboration was vital to progress on a project that would take over five years to complete.

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RESPONSIBLE IMPACT

Throughout the development, Cairn took great care with regard to the regions social and environmental impact. While the shortest available route for the pipeline was sought, a direct line would have run through the Gulf of Kutch, home to a fragile marine ecosystem. Cairn engineers extended the pipeline route by 75 km in order to avoid the area, ensuring its conservation.

From an engineering standpoint, the ability to bury and submerge the pipeline while not adversely affecting the performance of the HMS enabled Cairn to minimize the chances of a potential leak or spill due to interference.

Economically, the Mangala Pipeline Development has been a major boon to India. The resulting domestic oil production reduces India’s import bill by more than $6 billion USD each year. Besides affording the country energy self-sufficiency, the crude oil has enabled India to enter the market as an exporter.

“Technology like Pentair’s “Skin-Effect” Heat Management System will be increasingly vital as the search for energy resources requires going to areas that are remote and undeveloped.”

- Franco Chakkalakal – Global Director, STS, Pentair Thermal Management

TraceTek Detection System Gives Early Alert of Water Leaks
Key Challenges

Large museums will often display only a fraction of their exhibits at any given time, with the remainder held in archives. At the National Museum of Korea they are stored in 20 basement vaults that are protected from fire and theft. The biggest potential danger is water ingress and this can ruin the priceless treasures, dating back over 1500 years, in the storage area. Water can originate from the leaks in the plumbing systems or enter through the structural walls and foundation seepage.

Solution

The museum need a device that would detect water leaks quickly so operators could take remedial action before irreparable damage was done to the valuable contents.

Products

Pentair Thermal Management installed its TraceTek water leak detection system. At the heart of this system is the TT1000 water sensing cable which will quickly react to the presence of water and trigger an alarm. This is supported with Sensor Interface Modules and a remote control panel that alerts building management staff in the security office and central control room.

Benefits

The TraceTek system allows building management staff to continuously monitor all 20 of the archive vaults individually for the presence of water in sensitive areas. A leak can be quickly detected and remedied before it’s too late.

TraceTek Detects the 'Weeps' and 'Seeps' that SCADA Systems can Miss
Key Challenges

Regulatory pressure and environmental concerns have led operators to take more precautions in high risk areas to detect large leaks. Small leaks may still go undetected since conventionally used SCADA-based CPM systems are unable to detect a leak less than 0.5% of the flow rate. This can be very dangerous since small leaks often grow into larger issues.

Solution

A leak detection system can be installed on pipelines spanning many kilometers to detect and closely pinpoint the leak within one meter in both directions.

Products

Pentair Thermal Management offers a TraceTek TT5000 Oil and Fuel Sensing Cable, which detects liquid hydrocarbon fuels without reacting to water.

Benefits

TraceTek TT5000 is located inside the PVC conduit and is buried in the same trench as the pipework, keeping it protected and secure. The system prevents even the smallest leak from causing damage in the pipeline and surrounding area by quickly detecting and alerting operators to its location.

TraceTek Fast Fuel Sensors Alert Emergency Response Teams Quickly
Key Challenges

A refinery in France sought an effective hydrocarbon leak detection system for its fuel storage tank that would immediately alert operators and trigger an emergency response in the event of a leak. Hydrocarbon leaks pose an extreme danger if they’re not quickly detected.

Solution

Pentair Thermal Management determined that the refinery needed a fast acting, hyper sensitive device that could detect hydrocarbon fuel spills and not react to water. Oil is often on the surface of rainwater. Sensors that can quickly detect leak detection allow drain valves to close before fuel escapes into storm drains or surface channels

Products

Pentair Thermal Management recommended its TraceTek FFS (Fast Fuel Sensors): fast acting probes for detecting hydrocarbon fuel spills as small as one milometer.

Benefits

The device’s sensors will trigger an alarm within a few seconds of initial contact. The probes will reset once removed from contact with the oil and fuel residue is easy to clean off, making it easy to reuse them.

TraceTek Sensing Cables will Detect and Precisely Locate Leaks in Hydrant Fuelling Systems.
Key Challenges

More and more airports are adopting hydrant fuelling systems with underground fuel lines. The fuel lines pass beneath the thick concrete surface of airport runways, taxiways and aircraft aprons. These systems can have considerable environmental, safety and repair-cost implications if the leak is not precisely located and fixed in a timely manner.

Solution

Pentair Thermal Management determined that the airport needed a cost-effective leak detection and monitoring system to accurately monitor and detect fuel leaks.

Products

Pentair Thermal Management installed a TraceTek leak detection monitoring system and its TT5000 sensing cable, which contains a hydrocarbon scavenging material. It’s designed for installation in PVC conduit within the backfill when the fuel pipes are laid down.

Benefits

If a hydrocarbon leak occurs, the liquid fuel is detected by the cable and drawn into the conduit by capillary action. This triggers an alert via the TraceTek monitoring system, which will pinpoint the location of the leak to within one meter in either direction. Pull boxes (access holes) and connectors allow the system to be inspected in small sections. The TraceTek system quickly detects leaks and alerts engineers of the precise location of the leak, preventing time - intensive excavations of the line.

TraceTek System Will Quickly Detect a Fuel Leak and Alert Operators to Its Location
Key Challenges

Oslo-Airport.jpgOslo Airport realized that a leak in the underground pipe of its hydrant fuel system could result in significant environmental, safety and cost implications since it’s very time intensive to reach the source of the leak underneath the concrete.

Solution

Oslo Airport fuel system designers sought a solution that would mitigate safety and environmental risks and offer a more complete leak monitoring solution than periodic hydrostatic pressure checks. The designers needed a system that would immediately detect and pinpoint a leak for operators, enabling them to quickly reduce the implications of the oil leak.

Products

Pentair Thermal Management’ cable-based TraceTek system continuously monitors a pipe to alert operators if a leak is detected within one meter of the location in either direction.  The system has TT5000 sensing cable with a hydrocarbon scavenging material that is installed in the backfill of a 42 millimeter slotted PVC conduit when the fuel pipes are laid down.

Benefit

The TraceTek system quickly reacts to a hydrocarbon leak. The liquid fuel is detected by the cable and is pushed to the conduit by capillary action, triggering an alert via the TraceTek monitoring system.

TraceTek Systems Provide Early Warning of Oil Leaks Into Soil
Key Challenges

Coast Oil Co., one of the USA's largest distributors of gasoline, diesel fuel and lubricants, wanted to prevent ground water pollution at its San Jose tank farm and exceed the standards set forth by the Regional Water Quality Control Board.

Solution

The facility, consisting of 12 closely grouped small diameter tanks, needed an effective leak detection system to monitor the soil beneath the tanks without interrupting commercial operations. The solution was a complete monitoring solution to detect and signal an alarm. Working within space limitations, engineers used a small, customizable drilling machine.

Products

Pentair Thermal Management recommended its TraceTek leak detection system using TT5000 sensing cable, which contains a hydrocarbon scavenging material.

Benefits

Installed within PVC conduit in the soil, beneath the fuel tanks, this system quickly detects and signals an alarm if the fuel leaks. Any spillage is drawn into the conduit by capillary action and is absorbed by the cable jacket.

Inspired Solutions for a Changing World