Roxtec has specialised in the delivery of sealing solutions for panel building and system integration for more than two decades. UK managing director Clive Sharp says the firm’s seals are used within the most demanding environments on land and at sea all over the globe. He details a number of recent projects completed within wastewater treatment, food manufacturing, power generation and data centre sectors which highlight the importance of flexible and reliable sealing solutions.
Effective protection of equipment
Roxtec has developed an international reputation for sealing cables and pipes entering structures and its products are now increasingly being used to protect equipment. There are multiple hazards to consider with cable entries including lightning, gas, fire, dust, flood, humidity, rodents, electro-magnetic disturbances and the risk of explosion. However, traditional sealing systems only tend to protect against one particular hazard. The effective protection of electrical equipment in manufacturing, power, industrial and hazardous environments has become a major engineering challenge. In addition, industry is calling out for cable transit devices which can significantly reduce the quantity, size and weight of cable sealing systems.
Withstanding high water pressure and preventing ingress
A recent project within the wastewater sector saw Roxtec involved in a £220m water treatment upgrade project in London. This involved the supply of multi-cable transit seals to Thames Water for its Crossness Sewage Treatment Works – the second largest in Europe. Roxtec’s seals were used throughout the site to help protect one of Greater London’s last remaining grazing marsh lands. The major project enabled the site east of the capital to treat 44pc more sewage than its previous capacity. The upgrade also significantly reduced the amount of storm sewage that overflows into the River Thames when the site becomes overloaded due to rainfall. Renewable energy sources on site include a wind turbine and thermal hydrolysis plant (THP). The THP works as an industrial-scale ‘pressure cooker’ to heat sludge, the leftover solids from wastewater treatment, to around 160 °C. It produces up to 50pc more biogas which is then burnt to create heat to generate renewable energy. Roxtec’s seals were selected because of their durability and flexibility – they can withstand extremely high water pressure and prevent water ingress which is vital in a project of this nature. They are used specifically to seal power and control cables in the water works, the THP and the wind turbine. The gas tight seals also help to protect local wildlife by preventing sewage from entering the River Thames while guarding against fumes. The IP67 rated seals further aid Thames Water in protecting its assets against other hazards such as fire and vermin.
Effective sealing for multiple cables and pipes – Project Q Data Centre, Queretaro, Mexico
When building the Project Q Data Centre in Queretaro, Mexico, the owner representative Santander Global Facilities México faced a real challenge sealing cable and pipe penetrations. The project required multiple cables and pipes to be routed through a 45-centimetre thick wall while maintaining integrity. Construction coordinator DIINESA specified Roxtec cable entry solutions. Due to the sensitive equipment within the data centre, the construction project required all perimeter walls to be completely watertight and weather resistant. The walls were also to be fire resistant and capable of keeping out rodents and insects. It was obvious that the traditional cable sealing method, which consisted of a portion of pipe cast into the wall with intumescent mastics, would not work. However, Roxtec’s seals are area efficient and easy to adapt to cables and pipes of different sizes. The installers from Lebanc handled cables ranging from 13mm to 34mm in diameter and pipes from 29mm to 305mm. The seals can be opened to provide spare capacity. Due to the high safety demands special concrete mixtures and last generation waterproofing were used to ensure the wall surface was impermeable. Naturally, the cable and pipe transits had to meet the same strict requirements. However, the huge perimeter wall was made of high strength concrete making it difficult to open a passage for additional installations in the future. That is why the goal was to leave transit preparations for easy upgrades. It was crucial to find a way of holding together many pairs of sleeves with a sealing system at a distance of 45cm. DIINESA and Roxtec managed to solve the problem – with custom made steel structures that were cast between the sophisticated grillage foundation allowing only small tolerances between walls. The steel structures hold together seals and frames through a pair of sleeves connected with paper casting moulds.
Quick and easy cable replacement – Haas-Meincke, Denmark
When designing the spreaders, extruders and ovens for the global baking industry, Haas-Meincke A/S was keen to incorporate a cable sealing solution which could keep dust out and prevent water from entering and damaging equipment during high pressure hosing. Haas-Meincke A/S developed the machines to ensure high reliability in production and a high level of hygiene. However, its former cable sealing solution, using cable glands, often gave rise to problems due to the accumulation of debris. Roxtec seals now ensure that cable failures are less frequent, which helps avoid unnecessary machine downtime. If a cable should fail, replacement is quick and easy even if the cables are of different sizes and pre-terminated at both ends. Haas-Meincke A/S now consciously designs its products to incorporate Roxtec seals right from the start. A key advantage is that Roxtec can offer a 100pc integrated solution for those machines with stringent requirements for water-tightness and ease of cleaning.
Customised bulkhead and deck seals – Dudgeon Offshore Windfarm
Another area Roxtec is driving innovation is the offshore windfarm sector. Roxtec was recently involved in a project in the North Sea. The firm delivered cable transit systems – which are a key safety component to safeguard workers, structures and equipment. The systems are located on a substation platform created as part of the Dudgeon Offshore Windfarm, sitting 20 miles offshore near the seaside town of Cromer in North Norfolk. It involved the delivery of customised bulkhead and deck seals designed to be flexible with easy maintenance access and spare capacity for upgrades. They are both easy to install and inspect. The cable sealing systems are further designed to meet the long-term lifecycle of the 402MW wind farm whose turbines will provide power to 410,000 UK homes and is set to be commissioned during 2017. Roxtec delivered A0/A60 bespoke seals for HV and MV applications on the substation platform. They also seal array cables to MV switchgear and cables from MV switchgear to transformer input. Additional products have been used on the platform’s cables linking its transformer to its Gas Insulated Switchgear (GIS) and on export-to-shore cables. Roxtec has now been involved in cable sealing projects across more than 40 offshore wind farms in Europe. Seals are used for different applications in windfarm projects, from control cabinets to generators and converters. They offer protection against fire, gas, water pressure and corrosion and provide cable retention.
Passing on knowledge
Due to the specialist knowledge acquired over many years Roxtec has devised a programme of accredited technical CPD seminars covering the importance of sealing cables and pipes in a variety of industries. These are based upon industry standards and our own practical experience.
For further information visit the website www.roxtec.com or contact info@uk.roxtec.com Tel: 0161 761 5280.