400 Hensel DK Cable Junction Boxes For Major Scottish Water Project

By Chris Dodds on 7th August, 2012

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Hazardous Area Equipment

Hensel DK Cable Junction Boxes

 

Electrical engineers working on a flagship project for Scottish Water have installed over 400 electrical enclosures and junction boxes from Hensel.

Glencorse Water Treatment Works is a greenfield development and will soon be on-line supplying 70% of Edinburgh’s drinking water. It will replace two existing plants, Alnwickhill and Fairmilehead, both of which are of Victorian origin and despite having served Edinburgh well, are now ready for replacement.

Pictured: Glencorse Water Treatment Works

The overall objective is to provide clearer, fresher drinking water to around half a million people in Scotland’s capital and support the continue economic growth of the city where possible.

“This is a very important project for Scottish Water. Edinburgh has a population of 500,000 and could grow by 20% in the foreseeable future,” said Garry Hall, engineering manager of Field Systems Designs Ltd – an electrical engineering company, which is installing the lighting and cabling the process drives and instrumentation at Glencorse, as well as fire and intruder alarms.

“Being the second most visited tourist destination in the UK, a lot of people will depend on the reliability of Glencorse,” noted Hall. “It was essential that we installed only the best equipment and worked to the highest standards so that we can be sure of long-term reliability.”

To this end, Hall and his team reassessed many of the items of equipment they would normally use in light of the long life expectancy of the plant. It was clear that many different sizes of junction box would be needed, yet it would be advantageous to procure them all from a single range if possible, in order to keep costs as low as possible.

Pictured: Hensel DK Cable Junction Box

To rationalise the project requirements Katherine Beddard, FSDL project engineer for Glencorse, classified the junction boxes by both size and configuration.

“We were also concerned with the IP rating and impact resistance as some installation points were outside and in harsh environments. At this point we began to see potential suppliers,” said Beddard. Delivery is always an issue on big projects, so we focussed on companies that had engineering capacity in the UK.”

Hensel DK Cable Junction Box Applications

In rooms with dry climate In damp and wet environments Protected outdoors (refer to technical details) On flameable parts of buildings In buildings with mainly inflammable materials In areas with a high risk of fire Cable trunking installation Intrinsic fire resistance "Waterproof" for encapsulating “Weatherproof”, for outdoor installation (harsh environment and/or outdoor) Improved behaviour in cases of fire “flame-resistant” and “halogen-free” Offshore applications Security lighting circuits Equipotential bonding UL Approval DNV Approval Germanisch Lloyd Russian Maritime Register of Shipping

Hensel’s DK range of junction box was identified as being wide enough to meet the needs of the job and seemed to have all the quality issues addressed - a meeting was arranged with Graham Fox of CeeNorm – Hensel’s UK distributor.
 
“I realised that ease of installation - and subsequent maintenance and reconfiguration - would be key considerations,” said Fox. “It was also clear that steel wire armoured glands would be used extensively on-site. FSDL’s experienced electricians often complain of the lack of glanding space with the off-the-shelf boxes normally supplied as the spacing between glands increases resulting in a number of the cable entry knockouts unusable.

“I suggested we went with the Hensel DK range of junction boxes and used a larger than normal spacing for the knockouts into which the cable glands would be mounted.”

Dave Harding, the electrical supervisor for FSDL at Glencorse said: “the junction boxes supplied were perfect for the harsh environment they were exposed to and the terminals and cable terminating space inside the junction boxes made the install and future maintenance much easier”.

CeeNorm performed the special knockout machining at its engineering base in Telford.

Pictured: Hensel Weatherproof DK Junction Boxes For Outdoor Installation

The Hensel DK cable junction boxes are to a solid, modern and user friendly design. Junction boxes are halogen- and silicone-free, meeting stringent environmental specifications, while their stainless steel quick fastening screws meet installation and longevity needs. The vibration tolerant terminals were suitable for a site under continual operation.

Hensel makes its DK range so that they can comply with IP54, IP55 or IP65 ratings, are VDE tested conform to the new international standard 60670-22. Critically for a large project they can take a range of cable entry options including most grommets and glands types and can be drilled or adapted on-site.

Hensel Weatherproof Junction Boxes Operating & Ambient Conditions

Application Area	Suitable for for outdoor installation (harsh environment and/or outdoor) To reduce the formation and accumulation of condensed water see technical information
Resistant To Occasional Cleaning Procedures (direct jet)	Resistant to occasional cleaning procedures (direct jet) with high- pressure cleaner without additives' Water pressure: max. 100 bar, Water temperature: max. 80° C, Distance => 0,15 m, in accordance with the requirements IP 69K, enclosure and cable glands at least IP 65
Ambient Temperature	Average value over 24 hours + 55 °C Maximum value + 70 °C Minimum value - 25 °C
Fire Protection In The Event Of Internal Faults	Demands placed on electrical devices from standards and laws Minimum requirements - Glow wire test in accordance with IEC 60 695-2-11: - 650°C for boxes and cable glands  - 850°C for parts of insulating material necessary to retain current carrying parts in position
Burning Behaviour	Glow wire test IEC 60 695-2-11: 960 °C UL Subject 94: V-0 Flame-retardant Self-extinguishing
Degree Of Protection Against Mechanical Load	IK09 (10 Joule)
Toxic Behaviour	Halogen-free Silicone-free "Halogen-free" in accordance with the examination of the cables and insulated wires - corrosiveness of fumes - as per IEC 60 754-2

FSDL has supported many water industry projects around the UK from its head office in Dorking, Surrey. Beddard, based in the Warrington office, worked closely with Black & Veatch engineers to optimise the lighting systems design to meet the Scottish Water specification and the needs of their operatives.

The majority of the individual lighting circuits cover a large area therefore the Hensel DK junction boxes were utilised to split circuits thus reducing circuit lengths offering a more cost effective installation.

“We wanted a sound environmental design that did not waste power, yet provided suitable lighting for all areas of plant both internal and external,” she explains. “So we have many of the lights switchable locally. A master off switches ensures the lights are not left on overnight,” said Beddard. “The design hours far exceeded the normal requirements for a lighting scheme on a Water Treatment Works but the extra work is worth it when you consider the long term reduction in running costs.”

In order to achieve the best possible sustainability Scottish Water has installed a hydroelectric turbine to generate about 35% of Glencorse’s power needs. Grass roofs and sensitive building design means the whole site blends into the landscape.

The use of counter current dissolved air flotation & filtration (CoCoDAFF) as the treatment process has significantly reduced the size and impact of the treatment works. Rather than the traditional separate process units of dissolved air flotation (DAF) and rapid gravity filters (RGF) the two processes are combined into one.

Videos: Hensel DK-Assembly Videos

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