Raychem TRACETEK TT5000-HS, TRACETEK TT5001-HS Installation Instructions Manual

GENERAL NOTES: DO’S AND DON’TS:

TOOLS REQUIRED

nVent RAYCHEM TraceTek
TT-PTB-1000
(part # 486437-000)

Ohmmeter
(>20 M ohm)

nVent RAYCHEM TraceTek
TT-MAPPING CAP-MC
(part # P000000871)

Extran Vent RAYCHEM
TraceTek TT-MLC-MC-BLK
(part # 133332-000)

Extra TT-MET-MC
(part # 571293-000)

nVent RAYCHEM TraceTek
TT-Kellems-Grip-Large
(part # P000001291)

nVent RAYCHEM TraceTek
TT-ULTRA-TORCH
(part # 390067-000)

TT5000-HS (for fuel leaks) TT5001-HS (for solvent leaks)

TraceTek Sensing Cable for Underground Leak Detection
Installation Instructions

DESCRIPTION

These instructions explain the proper procedures for installing and testing
nVent RAYCHEM TraceTek TT500X-HS sensing cables. (TT500X-HS refers
to either TT5000-HS or TT5001-HS). TT500X-HS sensing cables are primarily
intended for use in underground (fuel or solvent) pipeline applications. TT500X­HS sensing cables ignore water but will detect and locate (fuel or solvent) spills
and leaks. (See the data sheet for specific performance characteristics.)

Important Notes

When used to monitor underground fuel pipelines, TT500X-HS sensing cables
are typically installed within slotted conduit that is routed alongside the main
pipeline. TT500X-HS sensing cable is designed for use within slotted PVC
conduit and is constructed with an outer layer of polyethylene fibers to provide
extra pulling strength and low friction during the installation process. The
sensor cable core is standard TT5000 (for fuel) or TT5001 (for solvent) with
well documented response times, numerous third party qualifications and years
of successful applications.

• TT5000-HS sensing cable is identified by the all white color of the outer jacket.

• TT5001-HS sensing cable is identified by a purple TRACER in the white
outer jacket.

Portable Test Box, battery powered instrument
specifically designed for testing and trouble
shooting TraceTek systems

Can be used as an alternative and supplement to
the PTB 1000

Used to simulate leaks at connector points during
commissioning and mapping process

Leader cable. Used with the ohmmeter to make
connections to the sensor cable for resistance
measurements

End termination. Used during installation or trouble
shooting to temporarily isolate a sub-section of
sensor cable for resistance measurements.

Large Kellems Grip used in cable pulling when rope
overbraid loop not available.

Flameless heating tool (Ultratorch 200) or suitable
heat gun with concentrator tip

REQUIRED MATERIALS

Conduit cleaning tool Used in proofing installed sections of conduit.

Conduit end caps Used to cover exposed conduit end to maintain

Heat shrink tubing
segments

conduit cleanliness.

Used as environmental seal over all mated male/
female (pin/socket) connections

OPTIONAL MATERIALS

nVent RAYCHEM TraceTek
TT-MBC-MC-TW
(part # P000001206)

nVent RAYCHEM TraceTek
TT-MJC-XX-MC-BLK

nVent RAYCHEM TraceTek
TT5000–HUV–CK–
MC–M/F
(part # P000001207)

Branch connector designed for rugged outdoor
applications used to connect and branch "T" lines

Jumper cable is available in various pre-cut and
terminated lengths

Connector kit used during field connection of
TT500X-HS bulk cable

DO:

• Store the cable in its original container in a clean, dry area until ready to install.

• Schedule the sensor cable installation as late as possible in the construction
schedule to avoid risk of damage or contamination by other contractors or
construction tasks.

• Remove cable from the pipe if any thread cutting, welding, soldering or similar pipe
fitting work will be performed.

DON’T:

• Drag the cable through water, paint, solvents, oil or other contaminants.

• Install damaged or contaminated sensing cable.

• Exceed the maximum pulling force of 100 kg (220 lb).

• Use the cable as a rope for lifting or securing any object.

• Allow tools or heavy objects to fall on cable.

• Exceed 3300 ft (1000 m) of individual sensor cable circuit length when using a SIM
alarm module.

• Testthecablewithfuel. • Usetiewraporwiretosecurethecable.

Installation

1

2A

Prepare the conduit and pull rope.

• Verify that major construction is complete.

• Verify conduit and pull rope has been installed
properly. Reference TraceTek document
H58175 for general information.

Note that conduit dimensions and related parts can vary
between projects.

Conduit Cleaning:

• Even if the conduit was proofed with a conduit cleaning
tool during the conduit installation process, it is
recommended to clean and check clearance of the
conduit immediately before installing cable in order to
avoid damaging the cable.

• Attach a rope section with a rag tied to the eye splice in
advance of the sizing tool.

2B

• Verify that the pull rope is free of knots and splices
and that there is 6 feet of extra rope at both ends of
each section.

• Two people are needed to manage the pull rope. One
person is on each end of the end pull rope, and each
person must be able to communicate with the other in
case of problems during the pull.

• The person feeding the pull rope into conduit needs to
maintain slack at all times.

• Pull the sizing tool from one end of the conduit
section to the other.

• Verify that the sizing tool pulls freely through
each section of conduit. Pull with a slow steady
motion. Do not use excessive force on the pull
rope, as this could damage the conduit.

• As you pull, coil the pull rope by hand and keep the
pull rope out of the dirt by placing it on cardboard or
plastic sheeting.

• If the pull rope becomes stuck, do not increase
pull force-instead pull the rope in opposite
direction for a short distance, then try repulling
in original direction with normal force.

• Shake the rag attached to the sizing tool free of excess
debris. Remove the rope section containing the rag
from the sizing tool. Replace the rag with a clean rag if
necessary, and then attach the rope section with the rag to
the eye splice in advance of the sizing tool.

• Reverse the pulling direction to bring the sizing tool
through the conduit in the opposite direction, and return the
original pull rope back into the conduit. Remove the sizing
tool and rope section with rag from the pull rope.

• Verify conduit ends are marked for example, with different
color conduit endcaps or tape to indicate direction
(towards or away) relative to TraceTek alarm module.

• Arrange excess pull rope by coiling around the riser pipe
and taping in place.

• Cover conduit ends to maintain cleanliness within conduit.
Use a plastic bag taped in place, or stuff a clean rag into
conduit end.

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3A

3B

Install sensing cable in accordance with the leak detection
layout plan.

Planning the cable pull:

• Verify that each end is terminated in a rope overbraid
loop. Identify which end of the cable (Pin or Socket) is
on the outside of the reel by examining the label near the
overbraid loop.

• Attach the pull rope to the rope overbraid loop only
after planning the direction of the cable pull based
on which cable end is on the outside of the reel.

Note the PIN connector end of cable is always
oriented towards the TraceTek alarm module.

• If PIN connector end is on the outside of reel, pull cable
into conduit towards the TraceTek alarm module.

• If SOCKET connector end is on the outside of reel, pull cable
into conduit away from the TraceTek alarm module.

Common mistakes include pulling the cable into the wrong
conduit, and pulling the wrong end of cable into the conduit.

Before pulling the cable into any conduit, verify that correct
conduit is being used. Good conduit installations will use a
strategy to mark conduits. Check with project supervisors
if any doubt exists as to how the conduit is labeled. Errors
in conduit identification and cable orientation can result in
compromised cable quality.

Attach the Kellems grip (if necessary):

• For TT500X-HS bulk cable, you may need to use a
Kellems grip to perform the cable pull when the rope
overbraid loop is not available.

• Make sure the end of the sensing cable has been
properly prepared.

• The end of TT500X-HS sensing cable should be sealed
with heat shrink tubing, and the end of the rope braid
should be taped to form a tapered end.

3C

• Insert the end of the rope braid as far as possible into
the cage end of the Kellems grip.

3D

• Tightly wrap electrical tape over last 1 inch of the
Kellems grip cage, and also over 1 inch of the rope
braid. Make a smooth transition with the tape. The tape
is necessary to prevent the Kellems grip cage from
releasing the cable in the event of a backwards pull.

2 in

(50 mm)

Tape over here.

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