The Instrumentation Cable Experts
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- Timothy Wilson
- 10 years ago
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1 1 The Instrumentation Cable Experts
2 Facilities Head office & factory 1300 Industrial Boulevard Mt Pleasant, Texas 75455, USA Stocking Centres USA Mt Pleasant and Houston Singapore (sales office) Saudi Arabia Australia Melbourne and Brisbane New Zealand 2
3 Topics for Discussion 1) Introduction 2) History & Innovation 3) Marmon Group 4) Products 5) Markets & application 6) Focused Operations 7) Quality 8) Project Optimization & Successes 3
4 Dekoron Product Mfg Range Instrument cables Thermocouple extension cables Control cables Field bus cables Fire resistance cables Direct burial cables 4
5 Market we serves Dekoron develops and manufactures cables used in Signal Transmission, as well as Process and Control applications for these industries: Chemical processing Food processing Light Rail Mining and Metal Processing Offshore Oil exploration and production Power Generation Pulp & Paper Refining and petrochemical Waste water treatment 5
6 Dekoron Introduction Instrumentation cables are a critical part of industrial control systems. Clean, reliable signals are essential. Dekoron has 45+ years experience in designing and manufacturing high quality instrumentation cables. Dekoron is the only US manufacturer and quite probably the only one in the world, dedicated to producing instrumentation cable. Part of the Marmon Corp. of Chicago, a privately held $7 billion company. 75,000 sq.ft.(7,500 m²) plant in Mt. Pleasant Texas. Sales office in Singapore. Shortest most reliable lead-times in the industry. 6
7 Dekoron Innovations & Firsts 1962 Electrical signaling transmission technology (low voltage) 1968 Isolated shields for electrical wire 1969 Dekabon Direct Burial Cable 1972 Nuclear rated instrument cable 1983 Plenum Cables non-fluoropolymer 1989 Fire resistant Circuit Integrity Cable 1992 Fieldbus digital instrument cable 7
8 Dekoron Single Pair Instrumentation Outer Jacket Black conductor Shielding tape White conductor Drain or Ground wire 8
9 Dekoron Multi Pair Instrumentation 12 pair 300V # Outer Jacket Overall Shielding tape Individual Shielding tapes White conductors Numbered Black conductors Drain or Ground wires Communication Wire 22awg 9
10 Dekoron Multi Pair Instrumentation Wire Armored Wire armor 12 pair 300V wire armored # Inner Jacket Outer Jacket Overall Shielding tape Black conductors Drain or Ground wires Individual Shielding tapes White conductors Numbered Communication Wire 22awg 10
11 Dekoron Multi Conductor Control Cable 12 conductor 300V # L200S1 Outer Jacket Overall Shielding tape Numbered conductors 11
12 Products & Insulation Instrumentation Cables 300 Volt Thermoplastic PVC, TPE, HDPE Thermoset XLPE, silicone 600 Volt Thermoplastic PVC/Nylon, HDPE, PVC Thermoset XLPE, silicone Thermocouple Extension Cables 300 Volt Thermoplastic PVC Thermoset XLPE 600 Volt Thermoplastic PVC/Nylon, HDPE, PVC Thermoset XLPE Control Cables 600 Volt Thermoplastic PVC/Nylon, HDPE Thermoset XLPE, silicone 12
13 Conductors Copper AWG / mm2 ( 4 mm2 is highest) bare or tinned copper 7 strand as standard 19 strand flexible and solid to special order only Thermocouple Extension AWG/ mm2 EX, JX, KX, TX, SX Extension alloys Solid as standard Stocked raw wire mainly 16 & 20 AWG KX, JX, EX & TX Some 18 AWG KX and JX Metric sizes to special order Stranded thermocouple to special order 13
14 Cable Assembly 2 to100 pair/triad/conductors, all numbered Individual shields/overall shields Aluminum and copper mylar shielding tape Isolated pair shields Maximum core diameter 2.4 / 60mm Increasing to 2.8 / 70mm mid 2008 Very long lengths available (3000M +) Communication wire standard in 300V cables, 22 AWG solid copper with PVC. 14
15 Jacket Options PVC PolyVinylChloride CPE Chlorinated PolyEthylene LDPE Low Density PolyEthylene TPE ThermoPlastic Elastomer TPN ThermoPlastic Non-Halogen HYPALON (CSPE) synthetic rubber NYLON 15
16 Armoring Options Interlock armor, galvanized steel or aluminum Continuous Corrugated Welded Armour Served Wire armor, galvanized steel wires, AWG Dekabon aluminum moisture & chemical barrier, environmentally safe (replacement for lead sheathing) Double armored Dekabon plus served wire armor or interlock armor. Excellent for buried service in hydrocarbon & chemical environments. 16
17 Specialty Products Fieldbus Digital Cable Effectively transmits digital signals in Fieldbus and protocols. Digital systems allow two way communication and can provide lots of information, but sacrifices transmission distances and redundancy. Available in 16 & 18 AWG Often used with SWA armoring 17
18 This image cannot currently be displayed. Specialty Products CIC Circuit Integrity Cable Fire resistant cable that continues to function in the event of a fire. Meets UL1709, IEC 60331, BS 6387 C S W & Z Uses ceramafiable silicone insulation that prevents the conductors from shorting out. ( replacement for Mica tape) Applications include Emergency Communications Motor Control Flame Sensors Sprinkler Activation Temperature monitoring thermocouples Throw some cable on the barbie! 18
19 Cable Standards 300 Volt UL 13 PLTC / ITC 600 Volt UL 1277 TC International Standards CSA # 239 Control and Instrumentation 300 & 600 Volt PVC insulation & jackets with steel and aluminum interlocked armor optional IEC /1000 Volt for PVC & XLPE insulations IEC /750 Volt for PVC insulation BS /500 Volt for PVC & HDPE insulations BS 6346 & /1000 Volt for PVC & XLPE insulations 19
20 Main Markets Dekoron products are used in large scale industrial control systems in industries including: Oil refining Petrochemicals Oil & gas production and processing Power generation Chemicals Paper Steel and metals processing Bio Fuels (ethanol, bio diesel) 20
21 Instruments Instrument cable V Control elements Control cables 600V Pump Low Voltage power 600V Medium Voltage power 2-35KV High Voltage Supply KV Cable in a Refinery Valve Flow Meter Reactor Sub Station Onsite power generation (co-gen plants) common. Central Control Room Power Panel Level Gauge Pressure Transducer Also use some electronic, network and fibre-optics in the control room and for low criticality control, monitoring & communication. 21 Viscosity sensor Heater Flow Meter
22 Key Customers Conoco Phillips Valero ExxonMobil Marathon Chevron Shell/Motiva Dupont Florida Power Kentucky Utilities Cinergy Weyerhaeuser Pemex, Mexico PDVSA, Venezuela Sincor, Venezuela Taiwan Power PTT Thailand Star Petroleum, Thailand Pec-Tech, Indonesia Petronas, Malaysia Saudi Aramco Qatar Petroleum Kuwait Oil Company 22
23 Focused Operations By focusing on instrumentation cable Dekoron achieves the following: Employees make instrumentation cable every day not once or twice a month - improves quality. Equipment is optimized for running instrument cables, for size, speed, controls, material handling & in-process inspection - better deliveries Raw material range & variations are minimized less wastage, optimal pricing Processes and inspection are optimized with regular production of the same items less faults 23
24 Singles Extrusion Bare wire is coated with plastic as it passes through the extruder. The coated wire is cooled & run onto reels holding up to 15,000 ft. Many different types and colors of primary insulation are available. 24
25 Twisting As the pairs of wires are twisted together they are marked, drain wire is added and shielding tape is applied over the wires All the pairs needed for a cable are normally run at one time, changing the numbering as each reel is started. 25
26 Bunching The shielded pairs are laid out on the payoff stands in a specific order to produce the optimum cable. The pairs are pulled through the die plate and twisted together to produce the cable. Protective tapes and binders are applied. 26
27 Bunching The new buncher can produce the longest instrument cable lengths in the USA. Lengths of 16 AWG 50 pair over 5,280ft (1 mile or 1.6km) have been produced. 27 Longer lengths reduce the need for junction boxes on long runs & provide customers more flexibility in their plant design
28 Jacketing Jacket extrusion applies a protective chemical & moisture repellent plastic coating over the cable. 28 Jackets are marked by in line ink jet printers with part #, date and sequential length in feet or meters.
29 Quality Assurance Dekoron is an ISO certified company. UL audits Dekoron on a regular basis with unannounced visits. Electrical testing is performed during manufacturing and on the finished cable. Modern control systems are used to control critical processes such as extrusion. 29
30 Armoring Options The Dekabon process uses a bonded aluminum polymer tape to prevent moisture ingress Served wire armor wraps multiple galvanized wires around the cable to protect it from mechanical damage. 30
31 Finished Inventory & Shipment Dekoron keeps approx.50 items in finished inventory pair 300V PVC 1-36 pair 600V PVC/nylon, 1-24 pair KX thermocouple All reels are heat treated. Cable is wrapped to keep out dirt and handling labels applied. 31
32 2004 Layout Singles Extruder Twist / Respool Bunching Jacket Extruder Armor (optional) QA Offices QA 2 Story Offices Raised Shipping Dock 32
33 Extensive Material Movement Singles Extruder Twist / Respool Bunching Jacket Extruder Armor (optional) QA QA 2 Story Offices Raised Shipping Dock Offices 33
34 2006 Layout QA Singles Extruder Twist / Respool QA Bunching Jacket Extruder Offices Armor (optional) Bank Wire QA QA Finished goods Raw Material Raised Shipping Dock Offices 34
35 Key Metrics On time delivery to customer request date %. Customer returns due to poor quality of in zero These two key metrics are improving while Dekoron enjoys a high growth rate. 35
36 Project Optimization Dekoron is pleased to work with customers to optimize their instrumentation projects. FEED stage Provide technical advice on instrument cable construction, estimated costs and deliveries. Bidding stage Provide timely and accurate bids with comprehensive data sheets etc. Quote alternatives as appropriate Promptly address any questions Manufacturing stage Due to short reliable lead-times Dekoron prefers not to make the cable until the customer is sure of the lengths required. Raw materials and capacity can be reserved with a P.O. and detailed lengths provided later. Priority items are identified and shipped first. Expediting and inspection visits readily accommodated. 36
37 Project Optimization Shipment stage Provide timely and accurate certification, shipping documents. Arrange reliable transportation with companies that can follow jobsite requirements. Stage shipments for complete truck or container loads. Commissioning Provide training on installation techniques as needed. Provide training on field testing as needed. Clean Up Stage Dekoron will take back good condition reels from domestic USA job sites, subject to cost effectiveness. Dekoron will consider the return of un-used standard cables provided lengths are saleable. Dekoron can assist in finding good scrap rates for left over cables and short cuts. 37
38 Field Junction Box Multi pair cable in, many single pair cable out 38
39 Laying of multi pair cable DEKABON direct burial instrument cable under pipe rack 39
40 Laying of multi pair cable DEKABON direct burial multi pair cable in cable trench 40
41 Laying of multi pair cable DEKABON direct burial cable from control room 41
42 42 Dekabon Direct Burial cable going into control room through MCT
43 43 Details of MCT (water and gases barrier) and Dekabon direct burial cable at control room
44 Laying of multi pair cable Securing method of multi pair cable under control room flooring 44
45 Laying of multi pair cable Multi pair cable going into cabinet and terminal block 45
46 46 Comparison of Standards Color code for ANSI, IEC and BS
47 47
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53 53 Questions?
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