Traditionally, cables have been sealed using cable glands or compounds; however, Roxtec - a next-generation, certified, well-proven, modular-based sealing system offers substantial cost savings and flexibility compared to the old cable glands.

1. Hydrocarbon Processing | NOVEMBER 2018 49
Special Focus Instrumentation and Automation
M. A. RØE, Industrial Journalist, Oslo, Norway
New cable sealing system offers cost and
maintenance savings for processing plants
Miles of cables of various diameters
are routed into new process plants, indus-
trial plants, petrochemical plants, refiner-
ies and other industrial applications. The
list of cable types is long—high-voltage
cables; low-voltage cables; cables for au-
tomation and process control systems;
cables for communication, fire and safety;
computer backup systems, etc.
All cables and pipes must be transited
through walls or into cabinets, in and out
of explosion-proof areas throughout the
facilities. Traditionally, cables have been
sealed using cable glands or compounds;
however, a next-generation, certified,
well-proven, modular-based sealing sys-
tem is available for multiple cables. This
system demonstrates substantial cost sav-
ings compared to the old cable glands.
Next-generation sealing system.
Cable glands have limited flexibility, as
the cable diameter fits a specific size of
gland, so an array of different sizes may be
needed during the construction and in-
stallation period. The contrast is huge to
the modular-based sealing system, which
is made from a rubber material that is wa-
tertight, dust-tight and corrosion-proof,
and which offers electromagnetic inter-
ference/electromagnetic pulse (EMI/
EMP) protection. In addition, the system
saves approximately half the weight of a
traditional gland system, half the physical
size, half the installation time and half the
costs, as it guarantees operational reliabil-
ity. FIG. 1 shows cables sealed by glands,
while FIG. 2 shows entry solutions with
one opening for all cables.
Flexibility is a key word for the system.
The correct opening for the cable through
the multi-cable system is so flexible that
when designing a cable array, the exact
diameter of the cable does not need to be
known, nor does the total number of ca-
bles going into the cabinet. Looking at the
multi-cablesystem,themaincharacteristic
is that the layers of the seal can be peeled
off, like an onion—but in the opposite di-
rection, as one must start at the core and
then peel off as many layers as needed to
make room for the cable (FIG. 3).
The cabinet’s exact size (i.e., number of
cablesgoingin)doesnotneedtobeknown
during the design phase, which will save
time and money by reducing the need for
multiple knockouts in cabinets or cutouts
in walls and floors in buildings and e-hous-
es. Due to the built-in spare capacity, there
is no need to make additional holes onsite:
• Cut costs instead of holes
• No more cutting off pre-terminated
connectors
• Simplicity for installation and
maintenance teams
• Installation is up to 50% faster
than with conventional cable
glands, at 50% of the physical
space with 50% of the weight
• Watertight
• Dust-tight
• Corrosion resistant
• EMI/EMP protection.
The system can be installed according
to both simple and demanding require-
ments, including harsh and hazardous
environments.
FIG. 1. Cables sealed by glands.
FIG. 2. Entry solutions with one opening
for all cables.
FIG. 3. Seal layers can be peeled off to make
room for cables in the multi-cable system.

2. 50 NOVEMBER 2018 | HydrocarbonProcessing.com
Instrumentation and Automation
Sealing system for many applica-
tions. The sealing system has been widely
used within the maritime and offshore
businesses, whereas land-based industries
have been more traditional and slower to
adopt solutions for cable and pipe entries
using mostly cable glands. The solution is
ideal for upstream, midstream and down-
stream processing projects, as well as en-
tire mega-projects. This non-traditional
methodcoverspotentialrisksinbuildings,
stations and enclosures protecting life and
assets in hazardous locations, as well as in
the harshest operating environments.
The simplicity of the system provides
substantialsavingsthroughoutthelifecycle
of any plant—from the design and plan-
ning processes to the finished plant, as well
as throughout the entire operational life:
• One cut-out for dozens of pre-
terminated cables
• Flexibility for cables and pipes of
different sizes
• Time savings in design, installation
and maintenance
• Built-in spare capacity for bonding,
grounding and electrical safety
• Solutions for hazardous locations
and armored cable.
System components. The system is
based on rubber modules with removable
layers (FIG. 3). It allows for perfect sealing,
regardless of the outside dimension of
the cable or pipe. This simplifies design,
speeds up installation and reduces the
needs for stock, material and logistics. It
also provides spare capacity for future up-
grades. The modular solution is an inno-
vation for flexibility based on removable
layers. It makes the mechanical system
adaptable to cables and pipes of different
sizes. With only a few parts, the result is
a strong, reliable barrier securing opera-
tional performance.
The seals, certified by independent
classification societies, protect life and as-
sets against risks caused by fire, gas, water,
dust, pests and blast load. With the line’s
RM modules (FIG. 4), modules and round
seals are based on a 60-mm (2.362-in.)
standard depth, whereas the RS seals may
present a wider range of depth. Typical
areas of use are penetration sealing of ca-
bles and metal and plastic pipes in walls,
floors, bulkheads and decks.
In CM frames (FIG. 5), modules and
round seals are based on standard depth of
15mm–40mm(0.591in.–1.575in.).Typ-
ical areas of use are entry sealing of cables
and smaller hoses through cabinets and
enclosures. Both the RM and CM groups
are available in the electromagnetic com-
patibility (EMC) application area, as well
as in the explosion-proof application area.
Exploring the efficiency of modular-
based sealing solutions. Challenging
the traditional glands and compounds,
multi-cable sealing solutions combine
high cable density with high performance
demands. Both characteristics fit when
building a new processing plant or other
industrial unit.
Versions are available for metal-clad/
armored cable and use in potentially ex-
plosive atmospheres. With this method,
only one hole is required for cables to
pass into the cabinet. As a result, it leaves
a smaller footprint, which means that the
user may use a smaller cabinet than the
size traditionally prescribed for metal
glands. It also facilitates the routing and
sealing of pre-terminated cables without
cutting connectors. This saves installation
time and reduces the risk of human error.
The system may also be opened again, so
that a new cable(s) can be added in one of
the spare modules.
FIG. 4. RM modules are typically used in
penetration sealing of cables and metal
and plastic pipes in walls, floors, bulkheads
and decks.
FIG. 5. CM modules are typically used in
entry sealing of cables and smaller hoses
through cabinets and enclosures.
FIG. 6. High cable density must be managed in the enclosures and junction/terminal boxes.

3. Hydrocarbon Processing | NOVEMBER 2018 51
Instrumentation and Automation
Use of the traditional method of cable
glands would, in this connection, require
the drilling of another hole(s), which
could compromise the equipment. In ad-
dition, many of the existing cables may
need to be removed before fitting the new
cables and then reinstalling the old ones.
This is both time-consuming and increas-
es the risk of errors.
Efficiency for owners and a tool for
designers. When designing a new plant,
there are many key success factors for the
owners of the plant. The most important
element is the overall safety of a plant. Per-
sonnel safety means having a safe and pre-
dictable operating environment. Next on
the list is operational reliability, with little
unscheduled downtime, as this may delay
deliveries. Multi-cable transits are not the
onlysolutiontoperformance,buttheywill
give owners peace of mind as the fire- and
blast-resistant, non-corrosive transits can
be mostly ignored for years after installa-
tion. They will not loosen up, unscrew or
in any other way compromise the safety
and operational reliability of a plant.
When designing a plant, a time-sav-
ing engineering tool, known as a transit
designer, is available. This tool receives
straightforward input from the end user
of the plant on cable/pipe input schedule
and estimates, sealing and certification
requirements, installation requirements
and preferences, and materials quality
selection. From these inputs, the system
will automatically generate 2D drawings
in DXF and PDF and 3D STEP. The bill
of materials is generated in Excel, includ-
ing installation instructions and all needed
documentation and certificates. The tool
is used by tens of thousands in more than
100 countries. Onsite advice and inspec-
tionsareprovidedduringtheconstruction
period, as well as personnel training.
Feedback from electricians that have
not previously used multi-cable transits
has been positive. This feedback reveals
the flexibility of the system—if a cable
needs to be added, this is easily done as
space is set aside for additional cables.
Reduced footprint compared to glands is
another element of the system’s flexibility.
For example, a transit may be designed
for 32 cables, but if the space has been de-
signed for 40 cables, adding more requires
very little work and tools. The multi-cable
transits are also maintenance-free, and any
retrofit projects will be easy to implement.
A closer look at the solutions.Highca-
ble density must be managed in the enclo-
suresandjunction/terminalboxes(FIG. 6).
FIG. 7. Multiple cables may be sealed in
one opening.
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4. 52 NOVEMBER 2018 | HydrocarbonProcessing.com
Instrumentation and Automation
This includes facilitation for armored ca-
ble types to ensure bonding, grounding
and protection against electromagnetic
interference. This is a lightweight, direct
replacement for cable glands. The design
is that of a single, cut-out solution for up to
32 cables, providing quick and easy instal-
lation of pre-terminated cables.
Multiple cables may be sealed in one
opening (FIG. 7). The transits are avail-
able in different materials for any kind of
structure. The transits can provide sepa-
ration of cable categories and be fire, gas,
water and blast resistant. No spare parts
are needed for upgrades.
A site may be protected against water
pressure, humidity and risk of partial dis-
charge (FIG. 8). The entries are easy to
install, even in running water conditions,
and provide excellent cable retention ca-
pabilities.
Pipe penetration seals prevent fire, gas,
and water from spreading (FIG. 9). The
transits can be used both for new pipes or
for retrofit around existing pipes. The so-
lution provides fast single-side installation
andcablesandpipesfordifferentsizesmay
be sealed in one opening. Perfect for retro-
fit and for reducing the need for welding.
Global mega-projects. End customers
of the multi-transit solutions are often
large, global companies in the hydrocar-
bon processing industries. Constructing
their sites are equally global engineering,
procurement and construction (EPC)
firms. Time is of the essence when provid-
ing solutions for new or retrofitted plants.
Onsite support includes visual in-
spection to confirm that cable and pipe
entry systems meet safety requirements
and official regulations. To enhance risk
management, installation training ses-
sions and corrective action recommen-
dations are available, if needed. Finally,
support is offered for future upgrades
and retrofit solutions.
MAGNE A. RØE has worked with business-to-business
communications as a Vice President in charge of
market communications for DNV GL Maritime, as well
as offshore and energy segments in Oslo, Norway.
He has an electrical engineering background with
ABB, including Vice President in charge of media
relations at ABB’s corporate headquarters in Zürich,
Switzerland. He has also worked for Norsk Hydro,
managing the company’s customer magazine.
Mr. Røe holds a MA degree in mass communications
and journalism from the University of Minnesota
and a BA degree in political science.
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FIG. 8. The entries are easy to install, even
in running water conditions, and provide
excellent cable retention capabilities.
FIG. 9. Pipe penetration seals prevent fire,
gas, and water from spreading.