technology day japan 2013 - eaton
TRANSCRIPT
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© 2012 Eaton Corporation. All rights reserved.
Cable Support Solutions
B-Line by Eaton
Technology Day Japan 2013
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© 2012 Eaton Corporation. All rights reserved.
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© 2012 Eaton Corporation. All rights reserved.
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4 © 2013 Eaton, All Rights Reserved.
Manufacturing Facilities
Global Cable Tray Capabilities M
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5 © 2013 Eaton, All Rights Reserved.
Cable Ladder
Strut Accessories
Cable Tray
Strut Systems Trefoil and Single
Product Portfolio
Cable Ladder Fittings Cable Tray Fittings
Cable Cleats
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6 © 2013 Eaton, All Rights Reserved.
Cooper Specifier Center - CoSPEC
CAD
PDMS
BIM Graphics
Web-based specifier destination featuring a 3D-powered catalog
Select, view and download content for CBL products
Content in nearly 100 formats including: Proprietary and standard 2D & 3D CAD
Aveva Plant PDMS
Intergraph® SmartPlant® 3D
Autodesk® Revit®
Product information and submittals
Graphic files
Leading scope, depth and breadth of outputs
World Class Design Tool
Industry Leading Resource for Design Content
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7 © 2013 Eaton, All Rights Reserved.
Finding CoSPEC
• Home page → Resources tab
→ CoSPEC Specifier Center
• http://www.cooperbline.com/
CoSPEC
Connect to CoSPEC via main page or URL
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8 © 2013 Eaton, All Rights Reserved.
View Selected Products in 2D and 3D
• Click 3D Preview tab to
generate 3D view (requires
Active X control install)
• Full-featured viewer move,
zoom in/out, snap to views,
move around, etc.
• Stereoscopic 3D feature
works with 3D glasses to
float in the screen
Three Dimensional View – Also With 3D Glasses
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9 © 2013 Eaton, All Rights Reserved.
Download Design Content
• Click ‘CAD Download’ tab to begin download
• Select any one of nearly 100 output formats including:
• 2D or 3D standard, non-proprietary
• 2D or 3D proprietary, native files
• Graphics
• Aveva Plant PDMS Equipment Spec
• Intergraph SP3D
• PDF cut sheets / submittals
Download in Any One of Nearly 100 Formats
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10 © 2013 Eaton, All Rights Reserved.
Design Tools - PDMS & SP3D Models
• AVEVA PDMS Library available
• With and without UDA’s
• Spec content also in Excel
• Intergraph SP3D Library available
• With and without UDA’s
• Spec content also in Excel
• Design usage and import instructions located within .zip file
Download via CoSPEC website
Direct Link: B-Line PDMS
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© 2012 Eaton Corporation. All rights reserved.
Cable Tray Basics: Materials and applications
I-Beam construction
Fitting construction
Standard and specialty splicing
High performance cover clamps
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Hot Dip Galvanized After Fabrication (HDGAF) Steel Cable Tray
Application - Hot-Dip Galvanized Steel
Indoor 260°C / 500°F Max. Temperature
Outdoor - Non-Saline -29°C / -20°F Min. Temperature
Outdoor - Saline Strength to Weight Ratio
Acids/Chlorines Electrical Conductivity
Steel Hot Dip Galvanized Finish to ASTM A123 Salt Spray Test Results
24 hours exposure 96 hours exposure 240 hours exposure 504 hours exposure
Conclusion – Not Acceptable for Saline Environments
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13 © 2013 Eaton, All Rights Reserved.
Aluminum Cable Tray
Application - Aluminum
Indoor 93°C / 200°F Max. Temperature
Outdoor - Non-Saline -129°C / -200°F Min. Temperature
Outdoor - Saline Strength to Weight Ratio
Acids/Chlorines Electrical Conductivity
Aluminum 6063-T6 Salt Spray Test Results
96 hours exposure 240 hours exposure 504 hours exposure 1032 hours exposure
Conclusion – No Degradation of Strength; Rate of Weight Loss Decreases
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14 © 2013 Eaton, All Rights Reserved.
Fiberglass Cable Tray
Application – Fiberglass (Polyester, Vinyl-Ester, Low Smoke/Dis-stat)
Indoor 93°C / 200°F Max. Temperature
Outdoor - Non-Saline -129°C / -200°F Min. Temperature
Outdoor - Saline Strength to Weight Ratio
Acids/Chlorines Electrical Conductivity
(FA Series)
Vinyl Ester Salt Spray Test Results
96 hours exposure 240 hours exposure 504 hours exposure 1032 hours exposure
Conclusion – Acceptable for any Environment
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15 © 2013 Eaton, All Rights Reserved.
Stainless Steel Cable Tray
Application - Stainless Steel
Indoor 426°C / 800°F Max. Temperature
Outdoor - Non-Saline -184°C / -300°F Min. Temperature
Outdoor - Saline Strength to Weight Ratio
Acids/Chlorines Electrical Conductivity
Stainless Steel AISI 316 Salt Spray Test Results
96 hours exposure 240 hours exposure 504 hours exposure 1032 hours exposure
Conclusion – Acceptable for any Environment
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16 © 2013 Eaton, All Rights Reserved.
I-Beam Side Rail Profile - Steel
• I-Beam profile is the most efficient structural shape
• Features
1. Roll formed for extra strength
2. Enlarged top flange for stiffness
3. Structural grade, traceable steel
4. Rung top lock and weld bead
5. Positive rung support
6. Marked every 450mm with company name, part number, material, and heat trace
Engineered Side Rail Design Provides High Strength
1
2
3
4
5
6
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17 © 2013 Eaton, All Rights Reserved.
I-Beam Side Rail Profile - Aluminum
• I-Beam profile is the most efficient structural shape
• Features
1. I-beam side rail maximizes strength to weight ratio
2. Thick top flange for stiffness
3. Rung top lock and weld bead
4. Positive rung support
5. Thick outside flanges for accessory attachment
1
2
3
4
5
6 1
2
3
4
5
6
Engineered Side Rail Design Provides High Strength
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18 © 2013 Eaton, All Rights Reserved.
Common side rail
designs:
C-shape without weld
bead.
C-shape curved flange.
C-shape with weld bead.
Offset C-shape
I-Beam Engineering Outperforms all Other C-Shapes
Common Side Rail Shapes
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19 © 2013 Eaton, All Rights Reserved.
I-Beam vs. C-Shaped Rails
19
C-shape side rail profile: - 150mm high x 1.5mm thick (16 gauge) side rail
- 184kg/m on a 3.0m span
- Based on simple beam destructive load test to NEMA VE-1
I-beam side rail profile: - 150mm high x 1.5mm thick (16 gauge) side rail
- 446kg/m on a 3.0m span
- Based on simple beam load test to NEMA VE-1
I-Beam Profile Carries 2.3X Greater Load than C-Shape Profile
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20 © 2013 Eaton, All Rights Reserved.
Fitting Design
Fitting Designs Help Maximize System Strength
Features:
• 300mm, 600mm, 900mm & 1200mm Standard Radius
• Smooth radius for cable protection
• Positive rung support
• Requires fewer supports to carry design load that NEMA VE-2 diagrams
• 75mm and 100mm Tangent
• Maximizes Splice Plate Contact
• Improves Electrical Continuity
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21 © 2013 Eaton, All Rights Reserved.
Splices & Specialty Splices
• AL ‘Wedge-lock’
• Structurally integral
• Self-Supporting
• Fast, simple, and safe installation
• Steel Splice
• Maximizes rail to splice engagement
• Unique hole pattern
• Heavy Duty Expansion
• Minimize structural supports
• Minimize deflection
• Increase system flexibility
Splice Plates Enhance Structural Integrity
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22 © 2013 Eaton, All Rights Reserved.
High Performance Cover Clamps
Recommended for any application – indoor and outdoor
• Available in stainless steel 316 and mechanical zinc
• Works with B-Line HPL, SDL, and HDL Series
• Reduces cover sagging and warping
Cyclonic Wind Rated
• Withstands 76m/s (170mph) Standard
Two Styles to Select From
• Standard – flush with top of ladder
• Raised (35mm) - for ventilation
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23 © 2013 Eaton, All Rights Reserved.
Why B-Line Cable Ladder ????
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24 © 2013 Eaton, All Rights Reserved.
B-Line Cable Ladder Construction =
*** Strongest in the Industry ***
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25 © 2013 Eaton, All Rights Reserved.
If Not B-Line Ladder ????
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26 © 2013 Eaton, All Rights Reserved.
Car Crash!!!!
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© 2012 Eaton Corporation. All rights reserved.
Structural Steel Savings:
Reduce Procurement Cost and Engineering Complexity
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28 © 2013 Eaton, All Rights Reserved.
Opportunity: Cable Tray Supports
Trapeze Support
$75 - $250 / support Engineered Pipe Racks
$1,500 - $15,000 / support
Supports for Cable Ladder can Exceed the Price of Cable Ladder
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29 © 2013 Eaton, All Rights Reserved.
Current State – Fitting Supports
Horizontal Bend – 8 Supports
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30 © 2013 Eaton, All Rights Reserved.
Why the current state?
• NEMA VE 2, BEAMA, and Manufacturers supply recommendations for the installation
of cable tray including support locations for fittings
That’s the way we’ve always done it…
Horizontal Bend Vertical Bend
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31 © 2013 Eaton, All Rights Reserved.
How Can B-Line Help You?
Minimize Required Steel for Fittings
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B-Line Recommendations – Horizontal Bend
Added Flexibility for Horizontal Fittings
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B-Line Recommendations – Vertical Bend
Added Flexibility for ALL Fittings
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Implementation…
Use Manufacturers Recommended Support Locations
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The Math…
• 90° Horizontal Bend Fitting:
• Steel weighs approx. 52 kg/m
• Opportunity to reduce approx. 12 linear meters of steel for 1 x horizontal bend.
• Results in ~ 624 kg of steel removed.
• Therefore:
• 1 x example of a horizontal bend saves 624kg & $546 of steel
• 200mm x 100mm Steel I-beam = Yen 76,000 ($875) / 1000kg (Japan Metal Bulletin)
• Question:
• How many horizontal bends on your current project?
• How much steel weight and $$$ can be saved?
What if the Competition Gives Their Tray Away for Free?
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Straight Sections
3m Support Spacing – Only for the Competition
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Straight Sections – Removing Supports
6m Support Spacing – Removes 50% of the Supports from a 3m Span
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Straight Sections – Up to 12m!
Removes 50% of the Supports Of a 6m Span
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39 © 2013 Eaton, All Rights Reserved.
Success Story:
Situation:
• TOTAL completing a refinery expansion in Louisiana. Supports for cable ladder run to a flare 213m from existing structures cost $30,000/support due to soil conditions
• 6m support span = 35 supports x $30k = $1.05M
Solution:
• Substitute 6m straight section cable ladder with 12m straight section cable ladder
• 12m support span = 18 supports x $30k = $0.54M
Results:
• Reduced the number of supports required for the 213m run by 50%, reducing the support cost from $1.05M to $0.54M
• Saved $510,000
Longer Spans Save Significant Time and Money
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40 © 2013 Eaton, All Rights Reserved.
Estimated Project Savings:
Save: $3,233,413 support spans + $2,023,125 fitting supports + $1,128,974 expansion splice supports
TOTAL SAVING $6,385,512.00
Instructions: Make changes in yellow shaded areas for specified project.
Select choice from blue drop down menus.
Quantity ***
Units of Measurement (PLEASE SELECT) Metric Support Install
Time (minutes)**
Splice Install Time
(minutes)****
Horizontal Bends 545
Labor Rate ($/hr) $50.00 Horizontal Tees 780
Cable Tray Straight Run Length (m) 19,932 Horizontal Crosses 90
Individual Support Structure Weight (kg) 500 30 10 Vertical Bends 310
Cable Tray Material Steel
Temperature Differential (⁰C) 55.6 Fitting/Intermediate Support Cost $300
Maximum Expansion Splice Interval Spacing (m) 39.0
Support Span Savings Tray Price
per Meter* Support Span (m)
Individual Support Cost
**
Number of Supports Required
Labor Per Support Location
Labor Per Splice Location
Cable Tray & Support Cost
Cable Tray and Support Savings
EXCLUDING SUPPORTS REQUIRED FOR EXPANSION
JOINTS
$ 10.00 3 $ 1,000.00 6,644 $ 25.00 $ 8.33 = $ 7,064,786.67 $ 3,233,413.33
$ 20.00 6 $ 1,000.00 3,322 $ 25.00 $ 8.33 = $ 3,831,373.33
Expansion
Splice Price Support Span (m)
Cost of each Support **
Number of Supports Required
Labor Per Support Location
Labor Per Splice Location
Expansion Splice and/or
Additional Support Cost
Additional Support Savings
Expansion Splice Locations
Standard Expansion Splice $ 15.00 (Each Pair) 6 $ 1,000.00 1,106 $ 25.00 $ 8.33 = $ 1,150,329.68 $ 1,128,973.97
Heavy Duty Expansion Splice $ 45.00 (Each Pair) 6 $ 1,000.00 0 $ 25.00 $ 8.33 = $ 21,355.71
Steel HDG Cable Ladder MTO Value = $1.5 million
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Combine all Features = Total System Solution
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Questions