1. TraceTek Leak Detection
New Products
and
Applications
February 2011

2. TraceTek System Overview
Sensor Cables and Probes:
Water
Aqueous Chemicals
Fuels
Organic Solvents
Acid
Water Probes / Fast Fuel Sensing Probes
Interface Modules to monitor sensors and produce electrical or data signals
User / System Interface Options
Dedicated Alarm Panels
Windows Supervisory Software
Interface to other BMS and DCS systems
Direct to Web Interface
TraceTek is a system of sensor cables, probes, electronic instruments and software that is used to monitor for leaking liquids. The system is capable of monitoring a large variety of fluids used in commercial buildings, industrial facilities, fuel storage and transportation systems, including pipelines and airports.
There are many different ways that the TraceTek system has been used since it was introduced in the 1980’s. In fact well more than 30,000 systems have been installed throughout the world and the cable concept and locating technology have been copied by a number of competitors
This presentation is an overview of the family of products that make up the TraceTek system. We will talk about some of the applications along the way, but this presentation is focused on the products and how they fit together to form a system

3. TraceTek System Overview
TT1000
TT1100-OHP
Water Sensing Cable
TT3000
Chemical Sensing Cable
TT5000/5001
Fuel/ Solvent
Sensing Cable
TT7000
Acid Sensing Cable
Probes and Floats
Sensors
TTSIM-1
Long Range
TTSIM-1A
TTSIM-2
TTC-1
Relay Only
Flasher
TT-TAR
Mesh Radio (Emerson)
Accutech (Schnieder)
Interface
The TraceTek systems is organized in three layers. Sensors, Interface Units and Display systems.
We’ll start with the sensor layer.
TraceTek currently manufactures 4 varieties of sensor cable and is about to release a 5th cable:
TT1000 for water in commercial buildings
TT3000 for aqueous chemicals including acids, bases, waste water, ground water, leachate, etc.
TT5000 is for liquid fuels such as gasoline, diesel and jet fuel.
TT5001 is used to monitor organic solvents such as TCE Acetone, MEK, etc.
TT7000 is a new cable that is designed specifically for sulfuric and nitric acid applications. It will detect these strong industrial acids but ignore water.
We’ll also mention some of the probes that are available for special situations where a leak can be anticipated in a specific low point or contained area.
Because of the flexibility of the SIM units (which we discuss later) all forms of sensor cable and probes can be interfaced to the system. In fact, the sensor-to-SIM interface units can accept any device that indicates an alarm condition with a closed contact. SO pressure switches, float switches, vacuum switches and some flow detectors are easy to add in when appropriate.
The next series of slides discuss each of the sensor types in more detail.
TTDM-128
Alarm Panel
Custom
Alarm Panels
Supervisor
Software
Modbus to
other BMS or DCS
Web Server
Touch
Screen
Display

4. TT1000 Water Sensing Cable 0.24 in. (6.0 mm) Continuity wire Sensing
TraceTek sensing cable employs a unique construction. Four wires are embedded into a fluoropolymer core. The red and yellow wires are low resistance, copper, insulated wires. The two black wires have a resistance that is carefully controlled in manufacturing. The black material on the sensing wires is a conductive polymer (not insulation) There is no exposed metal to corrode, but - because of the conductive polymer, the black wires act as sensing electrodes.
If water contacts both sensing wires - anywhere along the length of the sensing cable, it completes the circuit and the leak is detected.
The cable is of all fluoropolymer (Kynar) construction. The result is a small but rugged cable that is extremely resistant to corrosion and abrasion.
The unique construction leaves virtually no place to trap moisture, so it dries and clears quickly.
The four-wire TraceTek circuit allows a continual check of the system integrity.
Sensing
wires (2)
Signal wire
© 1996 Raychem Corporation

5. TT1100-OHP Water Sensing Cable

6. TT1100-OHP Water Sensing Cable
Feature
Benefit
Polyester rope over braid
(Black w/Yellow Tracer)
PE core
Pre-terminated or cut to length
Wicking action, dirt protection - but longer drying times
More flexible than fluoropolymer core (TT1000) – polyester rope / polyethylene core are not plenum rated
Easy to trace pipe

8. TraceTek 3000 Aqueous Chemicals
0.24 in.
(6.0 mm)
Continuity wire
TraceTek 3000 is very similar to TraceTek 1000 on the previous slide. The same four wires: two insulated and two jacketed with conductive polymers are used to fabricate the cable, but this version of the cable has excellent chemical resistance. It can be used to monitor acid supply and return lines, caustic systems, process waste streams, contaminated ground water being piped for treatment and similar hazardous fluids.
In order for the cable to detect and locate a leak, the fluid must be conductive. So everything from water to concentrated sulfuric acids are easily detected and located…. But non conductive liquids like gasoline, jet fuel or organic solvents are not detectible. The leaking liquid is a vital part of the detection and location current flow so a liquid that does not conduct electrical current will not be detected by either this cable or the TT1000 cable on the previous slide.
Like the TT1000, this cable is of all fluoropolymer (Teflon-like) construction. TT3000 has excellent resistant to corrosion and chemical attack. It is very tough, abrasion resistant and is suitable for harsh industrial environments.
However, because it will detect any conductive fluid, it is usually used indoors or in double containment pipe because it will detect rain or snow- melt just as readily as it will detect leaking waste water.
Sensing
wires (2)
Signal wire
© 1997 Raychem Corporation

9. TT5000 Series for Nonconductive Liquids
TT5000 for fuels and oils
For liquids (like gasoline and diesel) that are not conductive, Raychem had to take a different approach to detection; the liquid itself would not create the circuit. This slide shows the construction of our hydrocarbon and solvent sensing cables. They have the same four wires as TT1000 or TT3000, but in a braided core construction. A special jacket is extruded over the core. The over jacket is a selective sponge which ignores water, but absorbs hydrocarbons or organic solvents. The jacket swells dramatically (more than 2x if unconstrained), but the tight fluoropolymer braid drives the swelling inward. The jacket touches both sensing wires, and because it is conductive (a second special characteristic), it completes the sensing circuit. The interface module sees it the same way, and locates just as it does for TT1000 or TT3000.
TT5000 is for liquid hydrocarbon oils and fuels (jet fuel, diesel fuel, gasoline, crude oil etc.)
TT5001 for organic solvents (toluene, methylene chloride, n-methyl pyrrolidone, Iso proply alcohol, etc.). The main difference is the jacket material, which is formulated for the type of fluid. TT5001 has a white and black braid to distinguish it from TT5000 which has a red and black outer braid.
Both of these cables take a some amount of time to respond to leaks (it takes some time for the absorption and jacket swelling to occur); the amount of time depends on the fluid and temperature. Once a TT5000 series cable has tripped, that portion of the cable that has been exposed must be replaced. However, replacing some sensing cable is usually a minor cost compared with digging up and repairing buried/double contained pipe.
TT5001 for organic solvents

10. TT5000-HUV Fuel Sensing Cable
Feature
Benefit
Polyester rope over braid
(Black w/ Red Tracer)
Pre-terminated or cut to length
Extra UV Protection
Stronger, easier to handle compared to TT5000
Improved crush resistance makes it easier to strap to pipe
Easy to match pipe system

11. What about TT5001 –HUV and –HS?
Yes they exist
Benefit
TT5001-HS
(White PE over braid w/ purple tracer)
TT5001-HUV
(Black polyester w/ purple tracer)
Limited release
Same as TT5000 series
-HS yields better pull strength and lower friction needed for long slotted conduit pulls
-HUV has enhanced UV protection and is suitable for more rugged handling above ground

12. TraceTek 7000 Sulfuric and Nitric Acid
0.24 in.
(6.0 mm)
Continuity wire
TT7000 is a new cable with a special property that allows it to be installed in outdoor applications where the target fluid is strong industrial acids. This is a cable targeted for the metals and mining industry and fertilizer industry and other industries that consume sulfuric or nitric acid.
What makes this sensor unique is that the electrodes are coated with a water proof material that prevents rain or snow or ground water from triggering an alarm. Under normal circumstances this cable can be safely installed outdoors along pipe racks, under tanks and valves and in situations where TT3000 would react to rain water. But the TT7000 with its specially coated is inert in these situations.
However, when a leak of concentrated sulfuric or nitric acid comes into contact with the cable, the coating on the electrodes is quickly attacked and the normal TraceTek detection and locating technology comes into play.
This is a “one shot” cable. That means that after it detects an acid leak, that portion of the cable must be replaced to restore full operation. TraceTek provides a connector /splice kit for this purpose.
Beta testing of this product is currently underway with full commercial release expected by mid-2005.
Sensing
wires (2)
Signal wire
© 1997 Raychem Corporation

13. TT7000–HUV Feature Benefit
‘Water-proof’ electrodes with acid soluble coating
Black polyester over braid
No Tracer
Sensor can be exposed to rain, snow, salt water spray --- and no false alarms
Electrode coating dissolves when exposed to strong sulfuric or nitric acid and sensor detects and locates point of contact
Enhanced UV protection, rugged handling

14. Probes for low point detection of Water or Fuel
In some applications a float switch or a solid state conductivity probe may be a better fit than a piece of sensor cable. This photo shows several point probes that are compatible with the TraceTek system.
The yellow box-probe on the left is for water. It can be installed in a drip pan or along a base board to detect water in significant quantities. It is quite a bit less sensitive than TT1000 sensor cable so sometimes probes are used in damp areas where “flood” detection is more appropriate than “ leak” detection. But you have to be very careful about where a probe is installed since many small leaks can go undetected if they do not flow to the probe location.
The small black probe is a water/hazardous fluid probe suitable for tight areas, drip pans, low point drains and similar tight spaces. It works just like the yellow box probe and will detect any conductive fluids including acids.
The gray cylindrical probe is a fast acting hydrocarbon detector. It is very fast to react (typically less than a few seconds for gasoline or diesel fuels). It interfaces with the rest of the TraceTek cables and in some circumstances it makes a great combination with the TT5000 or TT5001 cable. The cable covers more area and can detect even very small leaks, the probe can be placed in a sump or drain area to detect and quickly detect larger spills and ruptures before they escape into the environment.
On the right is a float switch which is just one example of any type of sensor device that is normally open in non-alarm conditions, and that will provide a closed contact when a detection, is suitable for interfacing to the TraceTek system. Other examples of contact closure devices are: limit switches, pressure switches, vacuum switches, flow rate detectors, thermostats, etc. They all interface directly to TraceTek systems if desired.

15. TT-FFS Fast Fuel Sensor
Specifically targeted for liquid fuels and petroleum based oils
Very fast reaction time
East to test
Can be reset and re-used many time
This is one of TraceTek’s most recent additions.
It is extremely useful if the user needs leak detection in a confined space like a drip pan, sump, valve or tank vault, utility room, etc.
The advantage is speed. Just a few seconds for most liquid fuels.
Easy testing…a few drops of lighter fluid in a paper cup or squirted through the side will trigger the alarm response, then reset after the lighter fluid evaporates.
Multiple-reuse. IN most circumstances the sensor will reset itself after the fuel evaporates, or can be reset by soaking it in naphtha (lighter fluid, Coleman fuel, etc) then allowing it to dry in the air.

16. TTSIM-1 Maximum range, maximum accuracy.
1500 meters (5000 ft)
20 bit A/D
Precision control of sensitivity
Compatible with all TraceTek cables and probes
Can also interface to other devices which signal an alarm with a closed contact
Serial Data Out:
Modbus RTU/ASCII
N2 Open (JCI)
The SIM-1 is the most precise and accurate interface unit in the family. It can monitor up to 5000 feet or 1500 meters of sensor cable and resolve any leak location to +/- 1 meter.
However, in practice it is rare to install the maximum amount of cable on any one SIM. The SIMs are designed to be inexpensive relative to the total system cost and this means that it is usually good design practice to use an additional SIM whenever it seems like a logical place to subdivide a system. Each SIM and its connected cable is an independent leak detection circuit that is not influenced by surrounding SIMs or sensor cable. Using multiple SIMs makes the overall system quite robust. It is possible to have a leak on one section of cable and still maintain full and complete monitoring on all other SIMs and their cable. If the entire system is concentrated n one SIM, then any leak must be dealt with promptly so that the spill can be cleaned up and the cable restored in order to get the system back to full operation. In many instances getting repairs organized just takes too long, so sub-dividing large systems into smaller, easy to mange segments is just what the SIM is designed to accomplish.

17. TTSIM-1A NEW MICROPROCESSOR
Moderate Range and Accuracy with Relay Output
150 meters (500ft)
Compatible with all TraceTek cables and probes
Can also interface to other devices which signal an alarm with a closed contact
Serial Data Out:
Modbus RTU/ASCII
N2 Open (JCI)
Relay Contact for Local Use
3A Form-C relay for leak alarm and trouble (if desired)
NEW MICROPROCESSOR
The SIM-1A is targeted to the commercial buildings.
It has a limited range compared to the SIM-1 but this amount of cable is usually appropriate to most indoor applications in computer rooms, server facilities, communications rooms, etc.
SIM-1A is often combined with TT1000 water sensing cable in order to monitor for water intrusion in high value building spaces. Many modern building designs use raised floors in office spaces as well as special purpose computer rooms. As a result, piping, valves, fittings and wiring are often concealed below the visible floor surface. Any plumbing problems that cause a leak, are undetected until they find an opening to the floor below and if they remain undetected for a long period of time, the damage can be expensive.
So TTSIM 1A and TT1000 are often combined to monitor in multiple locations around modern commercial buildings. But other high value applications include museums, archive storage, vaults, historic buildings, etc.
Each SIM-1A provides a serial data interface and in addition has a local relay contact. Often the relay contact is used to close a solenoid valve on a water supply line or some similar local control action.

18. TTSIM-2 NEW MICROPROCESSOR Moderate Range, Built In Location Display
150 meters (500 ft)
3 Digit Display for Leak Location
Compatible with all TraceTek cables and probes
Can also interface to other devices which signal an alarm with a closed contact
Serial Data Out:
Modbus RTU/ASCII
N2 Open (JCI)
Relay Contact for Local Use
3A Form-C relay for leak alarm and trouble (if desired)
NEW MICROPROCESSOR
SIM-2 is very similar to SIM1A but it provides an additional local display of leak location. Sometime the local display is very helpful for on-the–scene leak location and clean-up.
This unit provides the same interface to external devices as the SIM -1A but adds the 3 digit display that is very helpful to the maintenance crew dispatched for a clean-up.
With this enhanced user display, the SIM-2 is sometimes used in a complete stand-alone mode. A buzzer or horn can be connected through the relay contacts. And if there is a leak detection , the user can read the leak location of the small display.

19. TTC-1 Limited Length applications Two relays Simple status indication
30m (100 Ft)
Two relays
One for leak detection
One for trouble
Simple status indication
Low input voltage
AC or DC
TTC-1 is a “relay only” device. This unit can monitor a limited length of sensor cable and provides two separate relay signals: one for leak detection and one for trouble.
These units are popular with equipment manufacturers in the semi-conductor business where a small length of cable may be deployed to monitor a drip pan beneath a piece of machinery or a chemical supply dispenser.
They are also used with air conditioning equipment to detect leaks in the chilled water supply and return lines or back-upped pipes in the condensate drain system

20. Battery Powered Flasher
This unit uses high efficiency LED’s that can be easily seen when a leak is detected.
When the sensor is contacted by the fuel or oil, the LED’s will begin to flash at one second interval.
Flashing will continue for at least 30 days (much longer in early years)
5 to 10 year battery life
This is the current “low cost leader”. It is a simple battery powered device with at least one year battery life between changes and many more if more expensive batteries are used.
Tank farm and pipeline operators like this option if they are doing routine visual facility inspections on a daily basis. This option eliminates the cost of wiring through hazardous areas which can often be more than 50% of the construction /equipment budget. But it does offer the uncertainty of operators having to take responsibility
and the possibility of dead batteries.

21. TT-TAR Transducer 2-wire 4-20 mA Output Current (mA) System Status
Damaged wire between control room and transmitter
3.5 < Output < 5
Cable Break in sensor circuit
5 < Output <11
System Normal – No LEAK   No BREAK
Output > 11
One or more FFS has detected a leak

22. Emerson/Rosemount
Type
Transmitters
150 m of TT5000 or TT50001
And/Or
Up to three TT-FFS Probes
Up to 100 transmitters
Output to:
TTDM-128
New Touch Screen (when released)
Direct to DCS software
Also works with TT7000 and TT3000

23. Accutech? Hub and Spoke Type Wireless Lower Cost the Emerson
Focused on production: well heads, gathering lines, field pumps, etc
Looks to be a simple interface
Still in early discussion

24. TTDM-128 Alarm Panel
This is a photo of the TTDM-128 with a SIM 1 and three sensor cables.
The main strength of the TTDM-128 is that it can monitor up to 128 SIM units. And each SIM unit may have many meters of sensor cable, probes or switch device as we have already seen.
The user display for the TTDM is a 4 line by 20 character alpha-numeric display. There are several membrane type buttons that allow the user to access special features, event history and similar detailed information areas. But the main function of the TTDM-128 is to continuously scan all of the connected SIM units and respond to unusual conditions including leak detections.
Often the leak detection system in a building or factory will operate for months with out detecting any problems or any need for human attention. So the TTDM usually operates quietly in the background keeping track of current conditions on all systems.
If a leak is detected, relays in the TTDM can signal other systems or sound a horn, turn on a beacon or operates similar equipment to attract the attention of the operator. Then all of the current and historical information is available through the front panel display and menu system

25. TTDM-128 Features Stand Alone Alarm Panel and User Interface
Local Display of all Leak Detection Parameters: Leak Location, Time of Detection etc.
Capacity to manage up to 128 TTSIM channels
Event History: leaks, trouble alarms, set-up changes, etc.
Summary Relay outputs:
Leak Detected
Service Needed
Trouble
Complete Modbus interface via RS232/RS485 to Host Computer for remote monitoring.
These are the summary features of the TTDM-128.
The local display capability is a 4 rows x 20 character LCD display. The amount of information generated by a single channel can efficiently displayed on a single screen. For systems with multiple channels and , more complex layouts there are a number of set-up enhancements like region labeling , extra programmable relay options and other features. All of the information captured in the TTDM is also made available through a serial communications port to host systems. These can be dedicated PC software custom designed for TraceTek or general purpose Building or factory Automation and control packages.
The limit for a single TTDM is 128 SIM channels. The onboard processor, is responsible for communicating with all TTSIM units; storing and analyzing the reported data; serving the data out to host system when queried and managing the local user interface of buttons alarms and LED/LCD display.
There is a lot of performance squeezed into the TTDM-PLUS but it still retains the “simple-is-best” design philosophy that makes it easy to install, operate and understand.

26. Custom Alarm Panels
This is a typical SIM enclosure for an outdoor installation.
In this case there are 4 SIMs (upper right).
4 lightening arrestors( lower right)
8 sets of zener safety barriers – 2 per circuit (lower left)
An A/C line surge protector and a transformer.
This panel was build for the Madrid Airport and is one of 8 similar panels with two to four SIMs per panel. They are housed underground in equipment vaults. For this project, the telemetry was via RS-485 to a nearby fiber-optic modem then on to the control room and a SCADA pump and valve control system managed by ABB.

27. Dedicated PC Based Monitoring with TT-Supervisor
In many applications the TTDM will be installed in a utility or maintenance area. And sometimes it makes sense to allow access to that information at a remote site.
There are a number of optional methods for exporting TraceTek system status to remote systems.
One of these is to run a dedicated Windows application and use the serial port on the PC to communicate directly with up to 31 TTDM’s in the building.
Each TTDM could be managing a network of SIM s on its own, so for very large systems a PC based central monitoring station is appropriate.

28. TT-Supervisor
These are screen shots from TT Supervisor. This is dedicated Windows software developed by TraceTek for a PC based monitoring station.
In the foreground is the “Display” Screen that shows the current face plate display of a TTDM-PLUS that has been selected by the user. The user can use the PC mouse to point and click on the TTDM buttons and the TTDM will react just as if the buttons are being pushed on the local panel.
Notice the tree type display in the left panel. The entire TTDM-PLUS and SIM network is displayed so that individual units can be selected for display.
In the back ground are the “Graphics” window and the “Event History” window. The graphic window can be used to show any CAD drawing, PDF file, document, etc. all linked to the sensor selected in the left hand pane. This is a good way to store the graphic maps for the various sensor circuit installations and call them to the display when they are needed to help locate a leak.
The event history display and an “Alarm Status” shows tabular data of past events and currently active alarms throughout the system.

29. Direct Connection to PLC’s
TTSIM’s RS485 Modbus
output can be connected
directly to PLCs and Factory
Automation Systems
This photo is a stock photo of typical PLC (Programmable Logic Controller) hardware. This type of data collection equipment is found in factories, large buildings etc. There are many manufacturer’s like Seimens, Allen-Bradley, Group Schneider, General Electric, etc.
All of these companies can provide a modbus driver and a RS485 Comm port for smart sensors. The TTDM and the TTSIM are “smart sensors” compared to most of the typical automation equipment, but because few system integrators have ever worked with TraceTek, there is always a reluctance to make a commitment... So the quotation to integrate a TraceTek system is often too high as the integrator covers his perceived risk.
The exception to this rule is Johnson Controls (JCI). The SIM units are directly compatible with the JCI’s N2 Open protocol. The Open protocol is a feature of the Metasys product family distributed by JCI. Our SIM units are “plug and play” compatible with a JCI Metasys system via the N2 Open protocol. Now additional JCI hardware is required and the system integrator's set-up time is measured just a few minutes for each SIM-1, SIM-1A or SIM If the customer already has JCI equipment, then SIM is an excellent choice for easy addition of leak detection in a building.

30. Integration with BMS or FAS
Using either the N2 protocol with JCI or the more conventional Modbus interface it is possible to use the BMS or Factory Automation Control center as the user interface for TraceTek

31. Remote Site Monitoring via LAN or Web Access
Micro Server monitors up to 8 SIM units
/Pager/Cell Phone notification of any problems
Web Page summary of current systems status, leak locations, etc.
Another approach for “exporting” TraceTek data is via a micro-server. The iServer is the small gray module in the lower left corner of the photo. It has embedded firmware that can scan up to 8 SIMs. The iServer is connected to the LAN for the building or site with a simple RJ-41 type of LAN cable.
The local IT department assigns an IP address. An utility is run to monitor each I Server in the facility (up to 50) and if a leak or trouble condition is detected an is sent to pagers, cell phones or other accounts designated during set-up.
Once alerted a user can then use any browser to check the current situation on the iServer that detected the problem.

32. Web page showing SIM status
This is a screen shot from an active iServer.
You can usually see an active page presentation at

33. TraceTek Applications

34. Water Detection in Buildings
Problem:
Water damage from leaks from drains, hot/cold supply piping, HVAC chilled water systems, etc
Physical damage and business interruption risk
Solutions Provided:
Detect and locate water under floors, behind walls, in drip trays Overhead piping above electronic racks, above false ceilings, etc.
Products: TT1000, TT1100-OHP, TT-Mini-Probes, TT-SIM1A or
TT-SIM2, TTDM-128
Water detection in building remains the highest grossing business segment for TraceTek worldwide.
The main benefit is the detection of water leaks in concealed spaces or at times when the space is unoccupied.
TT1000 is primarily an indoor product looking for water leaking from pipes, roofs, drains, overflowing drip pans etc.
The protected space can be computers facilities, communications equipment, router/server racks, high value offices, archived storage, art galleries, museum storage vaults, etc.
In modern “intelligent building” it is not unusual to sell tens or event hundreds of TTSIM units and short lengths of TT1000 to protect individual spaces. The record for the moment is a building at Canary Wharf in London with 184 SIM/TT1000 systems under one roof.

35. Detecting water leaks in commercial buildings and control rooms

36. Similar project underway in Berlin
TT1100-OHP installed in Madrid Airport Pipe Tunnel
Similar project underway in Berlin
using TT1100-THIN

37. Slotted PVC Conduit beside pipeline
Texas.
Note the two conduits on the left of the pipe.
The white one has 0.020” slots for the oil to seep in and be detected by the TT5000 cable within.
The blue conduit is solid wall Schedule 80- PVC used to protect the power and telemetry cable that was need for this particular installation.

38. Leak Detection for Transmission and Transfer Pipelines
Texas pipeline near Austin on the left.
A typical pull box (Texas) in the center as viewed from the surface looking down into the pull box.
A NATO pipeline in the Czech Republic on the right carrying jet fuel.

39. Installing cable in PVC conduit systems
Another pull port on the left before cable installation Colored tape identifies which direction the rope is running since the horizontal conduit along the pipeline is out of site a few feet below grade level.
On the right the sensor cable and jumper cable is being fed odd the reels and into the conduit as someone out of the frame is pulling on the pull rope (from 780 feet away).

40. TT5000-HUV installed at Port of Townsville Australia
Next large TT5000-HUV project ready to ship to Vopak in Rotterdam in February 2011
~4 km in terminal piping

41. TT7000 Installation in Japan
A reel of TT70000 on the left and an overhead pipeline carrying concentrated Sulfuric acid at a facility in Japan.

42. TT7000 Installation in Japan and Indonesia

43. Containment Piping and Pipes in Trenches
Problem:
Containment piping conceals existence and source of leak
Undetected hazardous fluid spill accumulates in containment space until released
Breached containment permits undetected environmental release
Solutions Provided:
Detect and locate leaking hazardous fluids at their source.
Products: TT3000, TT5000, TT5001, TT7000,
TT-SIM1, TTDM-128, TT-Mini-Probe
Double wall pipe and pipes in trench are primarily an industrial application.
TT3000 will trigger on any water so you have to make sure its installed in an area that is supposed to be dry.
TT5000, TT5001 and TT7000 do not react to water so they can be exposed to weather and still react to the fluid of interest without a false alarm due to rain.
Double containment piping and tanks (sometimes called double wall pipe) is primarily a US market application. It is very expensive compared to single wall piping but does offer additional environmental protection. However in addition to being expensive it is very difficult to install. We run our sensor cable between the inner and outer pipe so that we can detect and locate any problems.

44. Cable in double wall pipe
This is double wall pipe made in Denmark by Logstor.

45. Hazardous Fluid Detection in Process Areas
Problems:
Flanges and Couplings and other equipment can develop leaks
Personnel hazard
Physical damage and process contamination
Solutions Provided:
Monitor drip trays inside process equipment
Detect leakage from valves, couplings, etc within equipment.
Detect leakage from flanges and couplings, in valve boxes etc.
Products: TT3000, TT5001, TT7000, TTSIM-1A, Mini Probes, FFS -Fast Fuel Sensor
This application is similar to that of TT1000 in building. Except that here we are look for leaks of acid, fuels, solvents, wastes, etc.
Never use TT1000 in these applications. TT1000 is reserved for water in buildings. If you need to detect “industrial water” the correct product is TT3000.

46. FFS in drip pan under oil filled equipment
Here are two photos of the same TT-FFS probe installed in a oil drip pan under a piece of equipment in the UK.

47. Fuel Detection Leaks in Fuel Storage and Transportation Systems:
Buried single wall piping can be damaged by corrosion and leak fuel into soil and ground water
Underground storage tanks in vaults cannot be inspected easily
Floor plates in Above Ground Tanks corrode and develop leaks
Buried or concealed pumps and valves can experiences seal failures
Solutions Provided:
Placing sensor cable along side of pipeline, under tanks provides detection of hidden problems
Place probes in vaults or beneath critical equipment
Products: TT5000, TT5000-HS, FFS, TT-SIM1, TTDM-128
Fuel leak detection is the growing market for TraceTek. It is also the largest $/project opportunity.
Pipeline jobs average between $60K and $80K per mile (or more if installation is included)
IN addition to pipelines, TraceTek is used to monitor buried valves, underground storage tanks, above ground storage tanks, pump pads, above ground pipe, fueling racks, sumps, vaults, etc.
The sweet spot for most pipeline projects is in the 1 to 5 mile range. For very long transmission lines, most customers will opt for SCADA based leak detection. For transfer lines, spur lines, batch flow lines, terminal lines, wharf facilities, etc. TraceTek is often the most cost effective solution.
Even on large interstate transmission lines, TraceTek can be installed to protect sensitive areas where a leak too small for SCADA can do a lot of damage if it remains undetected.

48. How it works
Mention that this example is a worst-case: leak begins as far from sensor as possible (at upper right side of pipe).
Point out leak start, sensor and well-screen pipe
[CLICK to start animation]
Note 20 hour time required for first few milliliters of fuel to contact the sensor. THIS IS WHY SENSOR MUST BE HIGH SENSITIVITY. If it were not high sensitivity, it could take many days for sufficient fuel to soak the sensor enough to cause an alarm. 21 20 10 5 3 1
Detection at 21 hours liters spilled < 1 m3 of contamination
Time (hours)
Animation based on 10 liter/hour leak rate (0.001% of flow), 66% solids

49. Pipeline Monitoring with TT5000 in US, Japan, Czech Republic, Spain, Chile
Texas with another view of the conduit and a pull box.
The black corrugate rubber tubing was used to seal out surface water. This design is now obsolete and has been replaced with an inverted bucket that acts as an airlock (Sort of like a diving bell).

50. Leak Detection for Buried Valves with TT 5000 in Canada and US
Buried valve leak detection with TT5000 and a battery powered flasher.
The top two pictures are in Canada. The flasher is hard to see in each photo but it is the small black box on top of the white PVC riser being held vertical by the installer.
The bottom picture is an older version flasher monitoring a buried valve in a tank farm owned by Kinder Morgan in California

51. This is a photo of an early model flasher monitoring an underground valve. Flasher units are also used to monitor beneath storage tank bottoms.

52. A large diameter buried pipeline isolation valve operated by Enbridge Pipelines.
Flasher is at the top of the vertical riser pipe being held by the installer.

53. More buried fittings. In this case these are discharge flanges at an Enbridge pump station in Alberta.
TT5000 was installed under the flanges with several meters of buried PVC conduit leading back to a location within the pump station fence.
A batter powered flasher was used for monitoring.

54. Above Ground Storage Applications
Two frightening photos of what happened with TOTAL overfilled a large above ground storage tank with unleaded gasoline. Total liability is in excess of 1 billion Euros.
Buncefield Tank Farm, UK, December 2005.
Overfill and undetected leak of unleaded gasoline

55. Tank Farm Critical Scenarios Total (France) Study 1997 to 2006
297 Incidents studied – 10 scenarios identified – 5 scenarios would have been managed better with fuel leak detection systems
Tank Overfill (probe solution)
Tank Roof leaks (probe solution)
Mixer, flange, valve or pipe work leak (probe solution)
Roof drain and tank drain failure (probe solution)
Fractured tank (cable solution)
After Buncefield, TOTAL commissioned an internal study of Tank Farm incidents. They have a data base of almost 300 events and sorted them into 10 scenarios, then determined that liquid leak detection would have helped mitigate or prevent the event in 5 of the 10 categories.
The they called in TraceTek to propose solutions.

56. Tank critical scenarios
1. Overfill
2.Floating Roofs
A4 of the five trouble scenarios identified by TOTAL. These are primarily safety related rather than environmental protection.
Thus their interest in the speed with which FFS reacts to liquid fuels.
TT-FFS has a Safety Integrity Level -2 rating which helps TOTAL and others evaluate their overall facility Safety Integrity Levels.
4. Roof drain and tank drain failure
3. Leaks (mixer, flange, valve or pipework)
Large spill => explosion => fire
Protection measures: collecting system and liquid detection on collecting system: TT-FFS

57. Quickly detect a fuel spill in time to activate the emergency response plan
FFS probes installed at low point sump for Total Tank Farm, France
This photo shows one TTFFS in a fixed mounting near the bottom of a sump and a second FFS on a floating platform.
The FFS can detect a thin film of fuel floating on water and the float allows rain water to accumulate, lifting the float while assuring that the FFS always penetrate the water surface to detect any floating fuel.
In a few cases TOTAL has some heavy fuels with SG > 1. Since they won’t float on water, the low point fixed FFS was installed.

58. Tank Overfill Detection

59. 5. Fractured tank fractured bottom plate, => large spill
=> Ground subsidence => bund explosion / fire => tank fire
Prevention measure:
liquid detection systems under the bottom plate or in the service void : sensing cables buried within slotted pipes
This is scenario 5 dealing with tank floor corrosion.
Usually this is an environmental issue, since most frequently the leak is slow and undetected until it contaminates nearby drinking water or surface run-off features. However, TOTAL suffered a massive floor failure when an undetected leak eventually undermined the foundation fill

60. Early detection of fuel leaks and spills
The black lake is crude oil after a catastrophic tank floor failure.
This incident took place at Callo, Belgium in 2006.
Pictures from the VRT internet website.

61. Tank bottom monitoring
Buried under the tanks with horizontal drilling machines
Installed into slotted PVC pipe
This is the TraceTek design for tank floor monitoring.
We have about 250 large tanks being monitored with his technique in the US and Europe.
This biggest user is Kinder Morgan.
High Sensitivity sensor cable

62. AST Applications Typical plan view
More on the tank floor application including the pattern of sensors.
These can be installed under existing tanks using specialize horizontal drilling rigs. The rig drills from one side to the other , then pulls in a slotted PVC conduit ant TT5000 is then inserted into the conduit.
The photo shows Kinder Morgan tanks at Concord California with flasher sat the ends of each leg. Another approach used in Spain is to tie all the sensor legs to a single \circuit monitored by a control room alarm panel
Typical plan view

63. Tank Bottom Monitoring with TT5000 and TT-Flasher In US, France, Spain, Belgium and UAE

64. Small Tanks, Portable Equipment
This is a really low cost approach used for small above ground tanks at a fuel distributor in San Jose.
Each small tank has a single conduit and sensor cable drilled into place at about a 45 degree angle from the perimeter. The sensor stays in place and once every two or three days a worker carries a hand held flasher to see if the sensor has detected any underground fuel.
Several leaks have been detected at this facility.

65. Range of Options for Tank Farms
Manual Inspection
Hand Held: TT-FFS Test Instrument, PTB
TT-FLASHER-BE
Low Cost – still manual but easy to detect
Two wire
4 – 20 ma useful for retro fit if two wire circuits are available
Emerson Mesh
Greatly reduce wiring cost compared to traditional 4 wire
New TTDM software upgrade available for Emerson Gateway
Standard TraceTek 4-wire
Best overall for longer lengths
Only method that reports leak location automatically

66. Fuel Detection for Safety
Products: TT-FFS
Customer Need:
Tank overfill or component failure can lead to hazardous situation
Solutions Provided:
FFS (Fast Fuel Sensor) Detects volatile fuels in 5 seconds
Safe for installation in hazardous areas up to Zone 0 (with barriers)
Provide input to emergency shut-down systems

67. Hard wires or wireless Wireless Emerson /Rosemount Type 702-61
TT5000 and TTFFS sensors
Also TT5001, TT3000, TT7000
Back end is either DCS software or TTDM
New 2-wire option for retrofit
Can make use of existing 2 wire cable pairs that may have been installed for other systems
New approach using older TraceTek product
TT-TAR (first developed in 1980’s but rarely used)

68. More photos of the TT-FFS including the float assembly for dike enclosed areas or sumps that can fill with water.

69. Special Problems for Biodiesel
B100 can cause seal and gasket failure when stored and transferred in equipment designed for petroleum diesel
Solutions Provided:
FFS (Fast Fuel Sensor) Detects B100 in 45 seconds
B85 and other bio/petroleum blends are detected faster
Products: TT-FFS, TTSIM-1A

70. This is a photo of a leak caused by storing and moving 100% bio diesel in a system previously used for petroleum diesel.
Bio-diesel eats through the gaskets and seals normally used in petroleum fuel systems.
Both TT5000and TT-FFS detect bio-diesel leaks

71. Acid Pipe and Fitting Monitoring
Problem:
Sulfuric Acid storage and transfer used in refineries and mining
Tanks, transfer piping, valves and fittings corrode and leak
Solutions Provided:
TT7000 detects concentrated H2SO4 and HNO3
Will not react to water
Provide safety monitoring capability for acid systems in mining, alkyation units, water treatment, etc. - anywhere strong sulfuric and nitric acid is used
Products: TT7000, TT7000-HUV, modified TT-SIM1

72. Summary Sensors TT1000 – Water
Flat Probes, Mini-Probes, Float Switches
TT1100-OHP Water (Overhead Pipe)
TT3000 – Aqueous Chemicals
TT5000 – Liquid Hydrocarbon Fuels
TT5001 – Organic Solvents
TT7000 – Strong H2SO4 and HNO3
FFS – Liquid Fuels – Fast Point Detection

73. Summary Sensor Interface TTSIM-1- Long lines, special situations
TTSIM-1A – Shorter lengths, relay contact
TTSIM-2 – Shorter lengths, relay contact, local 3-digit display
TTC-1 – Short cables and probes, relay logic
Flasher – Battery powered, visual indication only
2-Wire 4-20 mA (retro fit in older facilities)
Wireless: Emerson Mesh

74. Summary Monitoring Options TTDM-128 – Alarm and Display, Event History
TT-Supervisor – PC based, updated software
PLC, DCS – Direct input to 3rd party systems
iServer – SIM-to-Web interface
Direct to DCS and Plant Automation Software
Coming soon: Touch Screen

75. TraceTek System Overview
TT1000
TT1100-OHP
Water Sensing Cable
TT3000
Chemical Sensing Cable
TT5000/5001
Fuel/ Solvent
Sensing Cable
TT7000
Acid Sensing Cable
Probes and Floats
Sensors
TTSIM-1
Long Range
TTSIM-1A
TTSIM-2
TTC-1
Relay Only
Flasher
TT-TAR
Mesh Radio (Emerson)
Accutech (Schnieder)
Interface
The TraceTek systems is organized in three layers. Sensors, Interface Units and Display systems.
We’ll start with the sensor layer.
TraceTek currently manufactures 4 varieties of sensor cable and is about to release a 5th cable:
TT1000 for water in commercial buildings
TT3000 for aqueous chemicals including acids, bases, waste water, ground water, leachate, etc.
TT5000 is for liquid fuels such as gasoline, diesel and jet fuel.
TT5001 is used to monitor organic solvents such as TCE Acetone, MEK, etc.
TT7000 is a new cable that is designed specifically for sulfuric and nitric acid applications. It will detect these strong industrial acids but ignore water.
We’ll also mention some of the probes that are available for special situations where a leak can be anticipated in a specific low point or contained area.
Because of the flexibility of the SIM units (which we discuss later) all forms of sensor cable and probes can be interfaced to the system. In fact, the sensor-to-SIM interface units can accept any device that indicates an alarm condition with a closed contact. SO pressure switches, float switches, vacuum switches and some flow detectors are easy to add in when appropriate.
The next series of slides discuss each of the sensor types in more detail.
TTDM-128
Alarm Panel
Custom
Alarm Panels
Supervisor
Software
Modbus to
other BMS or DCS
Web Server
Touch
Screen
Display

76. TT- FFS Fast Fuel Sensor – Drip Pan Installation in UK