0419-38002 Hg Umbilical Installation Guide GUIDELINES FOR THE INSTALLATION OF DEKORON UNITHERM MERCURY ANALYZER BUNDLES This bulletin provides the Field Engineer and Crafts with tips and techniques to help them complete a successful installation of Dekoron Unitherm Mercury Analyzer bundles. This information was provided by tradesmen and companies that work with these bundles, and is a record of techniques that have worked in the past. However, it is not a complete list. This bulletin must not be considered a condition of warranty. The installer has the sole responsibility for insuring that his methods and techniques are correct for the type of bundle and location. This bulletin provides a general discussion on: Product Properties and Characteristics, Handling and Storage, De-reeling, Bundle Installation, Methods of Bending and Straightening, Hanging and Support, Termination and Commissioning Bundles, Illustrations are included to help in planning and installation. A condensed version of this document is available as drawing 0419-17000, which is included with each reel of product shipped. PRODUCT PROPERTIES AND CHARACTERISTICS Mercury Analyzers bundles are different than the NOx and SOx bundles most installers are familiar with. These bundles: 1. are almost twice the weight of a typical NOx/SOx bundle; 2. can contain up to 7 sample and support tubes; 3. can contain multiple sensor, communication and control wires, fiber optic cables, and can have as many as five separately controlled heating zones, 4. run hotter than most NOx/SOx bundles, 5. can be up to 1000 feet long, 6. are more easily damaged during installation. Dekoron Unitherm can provide a Product Characterization drawing for each bundle that details the construction and operating characteristics of the bundle to assist the installer. A test sheet is also available for each bundle detailing the electrical specifications found during final inspection. This gives the installer a baseline value to determine operating condition after installation. These documents are keyed to the part number and lot number printed on the outer jacket of the bundle, and are available from Dekoron Unitherm Customer Support. Hg-INST 11/13/13 1
HANDLING AND STORAGE Dekoron Unitherm Mercury Analyzer Bundles are shipped on non-returnable wooden bridge reels. The standard reel has a 54" flange, is 36" wide, with a 40" drum, weighing 160 pounds. Larger reels are used when required because of the length of the bundle. Installers must take the weight and size of the reel in account when planning the installation. Each length is sealed at the ends to prevent entry of moisture or foreign material. However, if reels are to be stored out of doors at the jobsite, a weatherproof covering (e.g., polyethylene film, canvas, etc.) should be used. Short bundles and flexible heated hose bundles may be shipped in cardboard cartons. Care must be take to insure that these cartons are not exposed to the weather. These products should only be stored indoors. PLANNING AND PREPARATION Planning and preparation are essential to proper installation of Mercury Analyzer Bundles. Preliminary planning should include: determination of bundle run lengths position and angle of probe connections accessible routing of the bundle existing support structures, the type of support and location entry into the analyzer structure location of heat sources that could affect bundle performance enclosed runs and transitions placement of equipment and scaffolding needed to raise the bundle into position. The installer should review the section on hanging and supports while planning the run to make the best use of existing supports. LENGTH DETERMINATION Bundle length is determined by the routing distance between probe box and the analyzer, plus any additional length required for servicing the equipment. Most Mercury Analyzer Bundles are finished at both ends, but can be trimmed in the field if necessary. Any excess bundle must be properly supported and separated to prevent overheating. Coiling excess bundle on top of the analyzer shelter or at the probe connection can lead to overheating and is not recommended. ROUTING The initial consideration in establishing the best route is to install instruments and adjacent supports which will allow the analyzer bundle to run straight for at least 12" before being connected to the probe and analyzer. This will simplify the job of connecting the tubes after the bundle is secured. 12 minimum to clamp Probe Box Analyzer Bundle Hg-INST 11/13/13 2
Probe Bundle routing takes advantage of existing catwalks, stairs and support structures. Analyzer Shelter All bends must have a radius equal or greater than the minimum bend radius listed on the Product Characterization sheet. Support the bundle from 12 to 18 inches (5 to 7 cm) either side of the bend with wide bearing clamps or ties. Do not clamp the bundle within the bend. Do not route the bundle near a boiler, or against a hot chimney wall where the ambient temperature will reach above 130 F (54 C); unless the bundle is designed specifically for high ambient temperatures. Routing should be chosen to take advantage of existing cable trays, beams, columns, etc. The shortest distance between two points may be a straight line, but this may not be the easiest route for the bundle. Use of existing structures when routing may reduce or eliminate the need for costly scaffolding or cranes. When planning a route: Provide long radius sweeping bends when ever possible. Long radius bends allow the bundle to work at its maximum efficiency and also provide a place where the bundle can expand and contract due to ambient and tube temperature changes. For tighter bends use a mandrel or bending tool as explained in later sections. 1/2 Wide Metal Straps Analyzer Bundle Existing Pipe Run When using existing piping for support, insure that the piping is sturdy and is not heated. Attaching analyzer bundles to insulated steam pipes can lead to overheating and failure of the analyzer bundle. The ambient temperature around the control sensor cannot vary more than 35 C (63 F) from the ambient temperature of any point within the section of umbilical it is controlling. Check installations where part of the bundle is routed outside, in a closed tray or conduit and the balance is inside or in the open to insure that the maximum temperature variation is not exceeded. Horizontal runs should be sloped to assist drainage of any condensate or particulate matter that may collect in the tube. Users have reported success with slopes as small as 1/4 per foot of horizontal run, 1/2 to 3/4 per foot is more common. The slope required will vary with the flow rate, and the moisture and particulate content of sample. Analyzer Bundle 10 ft (3 0.2 ft (2.5cm) minimum Hg-INST 11/13/13 3
Adequate Space Around Bundles in Tray Multiple bundle assemblies, where more than one bundle are run in parallel, should allow at least 1/2" space between bundles for bundles operating at 250 F (121 C) to 400 F (204 C). Bundles operating at higher temperatures will require additional spacing. Bundles may be stacked if insulating spacers, no less than 1" thick, are used. Bundle routing must take into account the location of temperature sensors and heater power connections (if any). Temperature sensors (indicated by a label on the outside of the bundle) must be in the same ambient conditions as the section of bundle they control. Improper location of these sensors can lead to overheat failures in the bundle or to loss of sample. Bundles must not be clamped or tied within 12 of a sensor of power splice. TECHNIQUES OF INSTALLATION UNCOILING METHODS A free-wheeling payoff stand should always be used when uncoiling analyzer bundles. Back tension should only be enough to keep the reel from overrunning the pull. Tension should always be minimal. METHODS OF BENDING This method can be used to remove the set in bundles with stainless steel tubes. Do not pull the bundle off the side of the reel. This will lead to kinks in the product and may damage the heating cable. Bending the Dekoron Unitherm traced products can be accomplished by various means, depending upon the product type and size. In any case, no bend should be tighter than the minimum bend radius.. Hg-INST 11/13/13 4
Exceeding the bend radius can result in damage to the bundle jacket, core tubes, and heater. Since most analyzer bundles contain fluoropolymer tubing, they can be bent by hand. If metal tubes or a number of messenger wires are in the core, other methods may be needed. A thin wall conduit or MCM cable bender can be used with the smaller O.D. tube bundles. Other types of benders can also be used for all products if care is taken to prevent flattening of the tube(s) or damaging the heating element. A small amount of wrinkling in the jacket is normal and does not indicate bundle failure or loss of bundle properties. A severe kink in the outer jacket 0K means the insulation is compressed so bundle properties are compromised. A stationary mandrel may also be used for bending. The mandrel, such as a cable reel flange, should have a diameter of twice the minimum bend radius of the particular product. If the mandrel is smaller than twice the minimum bend radius, the complete bend cannot be made in one operation. Several large curvature bends must be made throughout the entire bend area so as not to exceed the minimum bend radius. The installer should also use this procedure when hand bending HANGING AND SUPPORTS Dekoron Unitherm traced products should be supported securely according to the support center dimensions shown on the Product Characterization sheet. In addition to these dimensions, the product should be securely supported within 18 to 24 inches of any connection kit. Suggested support methods are listed below. 1. ANGLE IRON Angle Iron, sized larger than the nominal bundle O.D., can be used effectively to support long vertical or horizontal single bundle runs. The bundle is secured to the angle iron with metal strap ties. As always, strap ties should have wide bearing area and should not be so tight that they deform the jacket of the analyzer bundle more than 1/8 inch. Horizontal runs should have the angle iron over the Dekoron Unitherm traced product to prevent containment of water, ice and snow. 2. CHANNEL IRON Channel Iron can be used in the same manner as angle iron, but can accept multiple bundles if sizing is made to allow bundle separation. Strap ties may also be used here. Hg-INST 11/13/13 5
3. CABLE TRAY Anchoring Industrial grade cable trays are becoming common for analyzer installations when multiple bundles are installed. The product should be anchored to the tray to maintain clearance between the bundles. Product can be anchored with clamps or cable ties. The distance between anchor points is noted in the table below. Note: Anchoring distance for Freeze Protection and Probe Support can be the same as for Mercury Analyzer Bundles. The wider anchor length simply reduces installation cost. Spacing Product Max Operating Air Gap Spacing Between Anchors Type Temp ( F) (Inches) Horizontal Vertical Mercury Analyzer 400 F 0.50 8 rungs 3 rungs Freeze Protection 185 F 0 14 rungs 7 rungs Probe Support 140 0 14 rungs 7 rungs 1/2 Spacing around Sides, Top and Bottom of Mercury Analyzer Bundle No Spacing required between Probe Support and Freeze Protect Bundles Mercury Analyzer Bundle Probe Support Bundles Freeze Protection Bundle The clearance between bundles will vary based on the type of bundle, the operating temperature, and the ambient conditions. Mercury Bundles must have at least 1/2 air gap on all sides to prevent overheating. Probe Support and Freeze Protection Bundles can be in contact with each other and the wall of the cable tray, but must be at least 1/2 from the Mercury Bundle. Bundles of any type should never be tied or clamped together in a tray. Bundles should be secured to the cable tray with clamps or ties that have a wide bearing surface. Tie wire should never be used to secure bundles to any support, except as a temporary measure during installation. See Section 4 for more detail on recommended clamps. Bend Area Clamp Bends Secure each bundle to the tray 12" to 18" (2 to 3 rungs) of either side of a bend. This allows the bundle to expand and contract in the bend. Allow extra distance between the bundles in the bend on high temperature bundles. Double the listed Hg-INST 11/13/13 6
separation distance if using covered trays as higher temperatures under the cover will result in greater thermal expansion. Cable tray bends should be sized to the next standard size above the minimum bending radius of the bundle. Cable Tray Covers Many installations require the use of covers on cable trays. These covers are used to protect the bundles from such things as fly ash, ice, and dropped tools. The drawing below shows some of the covers typically seen in Mercury Analyzer installations. Vented Perforated Cable Tray Covers Open Solid Expanded Metal The installer must consider the effects of these covers during installation. A solid cable tray cover can cause the temperature of the air around the bundle to be over 50 F (28 ) higher than the ambient. This can lead to overheating on bundles operating at 350 (175 C) or 4. PIPE OR TUBE SUPPORTS Dekoron Unitherm recommends using individual supporting hardware that has large supporting surface areas and cannot be over tightened to the point where the support can crush the product and damage the core tube or heating element. One of the most common methods used for attaching bundles to existing support structures is channel strut and strut clamps. Strut clamps are sized according to the bundle diameter and the location of the clamp. Clamps used on horizontal runs are sized to the nearest standard size greater than the bundle diameter. This allows the bundle to expand and contract through the clamp. Clamps used on vertical runs are sized to the nearest standard size less than the bundle diameter. This provides a secure anchor for the vertical run. Do not use wire ties to tie bundles together or to attach bundles to hangers. These deform the jacket and insulation, and can cause overheating, reducing bundle efficiency and life. Channel Strut and Strut Clamps are an effective way to support bundles. YES NO Hg-INST 11/13/13 7
Other types of hangers and supports can also be used effectively when routing Dekoron Unitherm traced bundles. The table below lists the common types of hangers, clamps and supports and shows how they can be used. Dekoron Unitherm cushion clamps can provide a solid anchor for bundles on vertical runs without deforming the jacket. These clamps are sized for the bundle supplied and can be used with any channel strut system. SUGGESTED HANGER TYPES ARE: TYPES OF USE Cushion clamp Support and anchor Strut Clamp Support and anchor Split Steel Hanger (Split Pipe Clamp) Support and anchor Short Clip Hanger Sliding Guide Support w/ clamps Double Bolt Hangers Band Hangers Clevis Hanger J Hanger Swivel Ring Hanger Type 11 Ring and Bolt Hanger J Hook Strap Hangers Pipe Rollers and Roller Supports U Bolt Clamps Saddle Clamp Support and anchor Support and anchor Support and anchor Support Support Support Support Support Not Recommended Not Recommended Not Recommended Not Recommended Not Recommended The Product Characterization Drawing included with the Mercury Bundle O&M Manual has the proper spacing for clamps and hanger used in vertical and horizontal runs. Contact Dekoron Unitherm Customer Service if the O&M Manual is not available. Cable Ties Installers have successfully used cable ties for years when installing NOx/SOx bundles. The weight and operating temperature of mercury analyzer bundles make selection and used of cable ties more difficult. Installers have reported that thermal expansion of Mercury Analyzer Bundles has caused ties to snap, releasing the bundle. Any cable ties used for Mercury Analyzer Bundles should have the following properties: 0.30 wide or greater Self-Locking Weather Resistant UV Stable Rated for the ambient temperatures of location Resistant to chemicals found at location Ties should be installed in a cross or X pattern over the bundle at the spacing stated earlier in this guide. Installers may wish to purchase an installation tool with a tension setting to improve the consistency of ties. Hg-INST 11/13/13 8
5. Pulling Bundles into Position Many times existing structures and routing require the installer to pull the Mercury Analyzer Bundle into position. Care must be take on any vertical or horizontal pull. The Dekoron Unitherm Analyzer Bundles cannot be treated like power cables. The maximum pulling tension on most Dekoron Unitherm analyzer bundles is less than 50 pounds, so they cannot be simply attached to a draw cable and pulled into place. Steps for pulling analyzer bundles: Position the reel so that the bundle can be pulled straight. Use a draw cable that is rated for the weight of the bundle. Attach the cable to the bundle at intervals so the weight of the bundle is carried by the draw cable. Support the entire length of bundle being pulled into place. Split pulling grips are an effective way to attach the bundle. These grips are attached to the bundle at intervals of 20 feet or less. The cable and bundle are then pulled up to the level of the probe. The grips can then be removed and reused. Other methods can be used to secure the bundle to the draw cable. Whatever method the installer chooses to use: The bundle must be securely attached to the draw cable. Any slippage during the pull can damage the bundle. The should be some slack in the bundle between attachment Secure bundle at intervals to prevent damage during pull. Slight bow in bundle during pull shows that the weight is being take up by the draw cable and not by the bundle. points. This insures the weight of the bundle is born by the cable. The bundle must be lowered and re-secured if any slippage is noted during the pull. NOTE: these methods are not use for securing the bundle to the stack. Methods shown earlier must be employed. If the vertical run is offset around the stack from the probe location, the installer should pull sufficient bundle up the stack to make the offset. The bundle is secured on the vertical run before routing the bundle around the stack. Do not attach pulling blocks at the top of the vertical run and pull the bundle from the probe location. The force applied at the pulling block is sufficient to damage the internal components even though there may be no apparent Any sheaves used for pulling or changing bundle direction must be greater than the minimum bending radius for the bundle. Do not kink or twist the bundle during installation. Lay bundles into place if possible. Horizontal pulls in pipe chases or cable trays should be handled the same as a vertical pull up a stack. Hg-INST 11/13/13 9
THERMAL EXPANSION The cabled construction of the Dekoron Unitherm analyzer bundle inherently allows for movement caused by thermal expansion and contraction. At Hg Analyzer operating temperatures, the bundle will expand noticeably, especially on vertical runs where clamps must be tight to provide support. On horizontal runs, clamps can typically be adjusted to allow movement of the bundle. In this case, a smooth bend above the minimum bending radius is generally large enough to absorb tube movement due to thermal expansion. In long runs on bundles with a single metal process tube product, some method should be used to take up the movement. An expansion loop or bellows connector could be used. Thermal contraction is not a problem even at arctic temperatures, But care should be taken if bundles are serviced during extremely cold weather. Thermal contraction could cause tubing to snap back and make it impossible to reconnect the bundle until it is powered up an allowed to warm and expand. Cold temperature installations require only minor variations in procedures. Care should be taken to make all bends slowly over a mandrel and above the minimum bend radius to prevent damage to the bundle components. TERMINATING AND SEALING BUNDLES Many analyzer bundles are factory sealed and terminated. If not, the installer must follow recommended procedures to insure the bundle is not damaged by water or contaminants during or following installation. Dekoron Unitherm End Sealant, Boot Kits, and Seal Patch Kits can all be used to provide weather-tight seals to analyzer bundles. Instructions for installing these items are supplied with the kits or available on our web site. Contact Dekoron Unitherm Customer Service for more information. ELECTRICAL CONNECTIONS Dekoron Unitherm Mercury Analyzer Bundles are built to the specifications of the analyzer integrator or equipment manufacturer. The installer should refer to their installation instructions for proper connection practices and procedures. COMMISSIONING TEST A commissioning test sheet is included with this manual that details tests that should be performed on the bundle prior to it being placed in service. These tests were performed at the factory prior to shipment. A copy of the test record is provided with the bundle or can be obtained from Dekoron Unitherm Customer Service. The purpose of these tests is to insure that the bundle was not damaged during shipment or installation. The commissioning test sheet can also provide a benchmark for analysis and troubleshooting bundle operation in the future. Hg-INST 11/13/13 10
INITIAL START-UP OF HG ANALYZER BUNDLES Dekoron Unitherm recommends a staged start-up procedure when Hg Analyzer bundles are powered up from a cold start. The large component count and the relatively high operating temperature can cause problems if the bundle is not given time to stabilize as it comes up to temperature. Problems could include: Overheat failures due to the response time of the temperature controller; Loss of support clamps due to rapid thermal expansion of the bundle; Spark faults due to movement of components. We recommend bundles be warmed to a temperature about 1/3rd the final operating temperature and allowed to stabilize at this temperature one hour. After this soak, the bundle temperature is raised to 2/3rd the final operating temperature and allowed to soak. After a 1 hour soak at this temperature, raise the bundle to the final operating temperature. For example: A Integrity Series Hg Analyzer Bundle is designed to operate at 365 F (185 C). The bundle would be initially heated to a temperature around 140 F (60 C) and allowed to soak for one hour once it reaches that temperature. Then the bundle control temperature would be raised to around 250 F (121 C) and allowed to soak for one hour at this temperature. After this soak, the bundle would be raised to full operating temperature. The operator or technician should monitor the bundle temperature as it climbs. A severe overshoot may indicate a control problem that could damage the components in the bundle. 1531 Commerce Creek Blvd Cape Coral, FL 33909 USA Toll Free: 800.633.5015 Phone: 239.995.8111 Fax: 239.995.8027 For additional information visit our website: www.unithermcc.com This document contains empirical and theoretical information provided by Dekoron Unitherm Engineering and does not alter or supersede the Standard Warranty as stated in the Conditions of Sale. All values represent typical performance for the conditions given. Variations in local conditions and materials may alter product performance. This information is proprietary to Dekoron Unitherm and is furnished upon the express condition that the information contained herein will not be used for second source procurement, or directly or indirectly in any way detrimental to the interests of Dekoron Unitherm LLC. 2013 Dekoron Unitherm LLC All Rights Reserved Hg-INST 11/13/13 11