HEAT TRACING SYSTEM

1. Veeral Additives Private Limited – Mahad
Operations Overview
HEAT TRACING PPT

2. WHAT IS HEAT TRACING METHOD
Electric Heat tracing cables are used for freeze protection or
temperature maintenance of piping, tanks, Valves and instrumentation.
Heat Tracing used for heating and temperature maintaining purposes.
The pipe and other application are usually covered with thermal
insulation to retain heat losses .
Electric Heat generated by the element then maintains the required
temperature of the pipe.
Heat Tracer element run in physical contact with pipe outer surface .
Heat Tracing Method Mostly Used for Industrial applications for
Surface Heating and temperature maintaining Purposes .

3. PURPOSE OF HEAT TRACING
Heat trace is an electrical system used to maintain or raise the
temperature of pipes and vessels. The electric heating is
achieved by utilizing a resistant element that is run alongside
the piping or vessel
Current heat trace technology utilizes a self-regulating polymer
that controls the wattage of the element. When the ambient
temperature drops, the polymer creates conductive pathways
that allow current to flow and heat to be produced.
When the ambient temperature drops, the polymer creates
conductive pathways that allow current to flow and heat to
be produced. When the ambient temperature increases, the
conductive pathways begin to separate, allowing less
current to pass.

4. WHEN DO WE NEED HEAT TRACING ?

5. MODES OF HEAT TRANSFER
THREE MODES OF HEAT TRANSFER :-
1. CONDUCTION
2. CONVECTION
3. RADIATION.
CONDUCTION :- Heat Transfer when bodies are in contact .
CONVECTION :- Heat Transfer by movement of gases .
RADIATION :- Heat Transfer through electromagnetic waves.

6. HEAT TRACING CIRCUIT

7. HEAT TRACING CKT
1
2 3
4
5
1. Power distribution panel.
2. Distribution JB .
3. ON/OFF switch .
4. Thermostat .
5. Heat Tracer .

8. WHAT IS THERMOSTAT
Thermostat is very important part of Heat tracing system .
A Thermostat is a component which senses the temperature of
a Physical system and performs actions so that the system's
temperature is maintained near a desired set point .
Thermostat used device to cut off the Heat tracing circuit after
maintain set point temperature . It works automatically on system
temperature variation .
1
2
3
4
5
1. Thermostat JB .
2. Heat Tracing Pipe .
3. Thermostat Sensor.
4. Thermostat Range Selector .
5. Circuit connection .

9. HEAT TRACER TEMPURATURE

10. HEAT TRACING CONDUCTOR

11. TYPES OF HEAT TRACING CABLE
TYPES OF HEATING
CABLE
SELF REGULATING
HEATING CABLE
POWER LIMITING
HEATING CABLE
PARALLEL CONSTANT
WATT HEATING CABLE
SERIES CONSTANT
WATT HEATING CABLE
1. BSX
2. RSX
3. TSX
4. HTSX
5. KSX
6. VSX
1. HPT 1. FP 1. TES
2. TESH
3. MIK

12. SELF REGULATING HEATING CABLES
SELF REGULATING
CABLE
BSX RSX TSX KSX VSXHTSX
Nickel-plated copper
bus wires (16 AWG)
Radiation cross-linked
semiconductive heating
Matrix
Watt densities…. (10,16,26
33 w/m @ 10°C
Max. maintenance
temperature..65°C
Max. continuous exposure
temperature Power-off.
85°C
Nickel-plated copper
bus wires (2.1 mm2)
Radiation cross-linked
semiconductive heating
Matrix
Max. maintenance
temperature..65°C
Max. continuous exposure
temperature Power-off.
85°C
Watt densities…
48 W/m at 10°C
Nickel-Plated Copper
Bus Wires (1.3 mm2)
Semiconductive heating
Matrix
Max. maintenance
temperature..121°C
Max. continuous exposure
temperature Power-off.
190°C
Watt densities… 9, 18, 27
, 37 W/m at 10°C
Nickel-Plated Copper
Bus Wires (1.3 mm2)
Semiconductive heating
Matrix and Fluoropolymer
Dielectric Insulation
Max. maintenance
temperature..121°C
Max. continuous exposure
temperature Power-off.
191°C
Watt densities… 48 ,64
W/m at 10°C
Nickel-Plated Copper
Bus Wires (1.3 mm2)
Max. maintenance
temperature..121°C
Max. continuous exposure
temperature Power-off.
200°C
Semiconductive heating
Matrixand Fluoropolymer
Dielectric Insulation
Watt densities… 48 ,64
W/m at 10°C
Watt densities ..
15, 32, 48, 64
W/m at 10°C
Max. maintenance
temperature..149°C
Max. continuous
exposure temperature
Power-off. 204°C

13. SELF REGULATING TRACER CONSTRUCTION
At low temperatures, there are many conductive paths, allowing current
to flow between the bus wires.
At high temperatures, the polymer expands, reducing the number of the
conductive paths, and thus reducing current flow.
ADVANTAGES :-
1. Output power changes with temperature.
2. Will not overheat and damage.
3. Overlapping cable is possible.
4. Parallel conducting paths.
5. Can be cut to length and terminated on site.
6. According to need can use two-way or three-way connection.
7. Corrosion resistant jacket.
8. Can be used at 120 volts, 208-277 volts.
9. Highest maintain temperature up to 150 degC.
10. Maximum exposure temperature up to 250 degC.
11. Approved for use in non-hazardous and hazardous areas.

14. POWER LIMITING HEATING CABLE ( HPT)
HPT TRACER :-
High performance HPT power-limiting heating cables are designed specifically for process temperature
maintenance or freeze protection where high maintain temperatures or high temperature exposure is
required. HPT withstands the temperature exposures associated with steam purging .
A coiled resistor alloy heating element (patent pending) provides the power-limiting feature of HPT.
This PTC (Positive Temperature Coefficient) characteristic decreases the cable’s power output as
the heat-traced product temperature increases and allows the cable to be overlapped
during installation.
CONSTRUCTION :-
1 Nickel-Plated Copper Bus Wires (3.3 mm2)
2 Composite Metal Alloy/ Fiber.
3 Heater Bus Connection (not shown)
4 Fiberglass Braid (not shown)
5 Fluoropolymer Dielectric Insulation
6 Nickel-Plated Copper Braid.
1. Available Watt densities . 14, 28, 42, 57 W/m at 10°C
2. Maximum maintenance temperature ..... 149°C
3. Maximum continuous exposure temperature
Power-off ... 260°C

15. MINERAL INSULATED HEATING CABLE (MIK)
MIK TRACER :-
MIK high performance mineral insulated heating cables are used extensively for high temperature
maintenance, high temperature exposure and/or high Watt density applications which exceed the
limitations of thermoplastic insulated cables.
MIK mineral insulated cables are available in three outer sheath materials to meet the temperature
and exposure requirements of the application.
CONSTRUCTION :-
1 Solid Alloy or Copper Conductor
2 Compacted Magnesium Oxide Insulation
3 Metallic Sheath
1. Available Watt densities . 200 W/m at 10°C
2. Maximum maintenance temperature ..... 600°C
3. Maximum continuous exposure temperature
Power-off ... 650°C

16. SERIES CONSTANT WATT HEATING CABLE (TESH)
TESH TRACER :-
Long Line Temperature Maintenance or Freeze Protection TESH series resistance constant Watt heating
cables are used where circuit lengths exceed the limitations of parallel resistance heating cables. TESH
withstands the temperature exposures associated with steam purging.
The series circuitry of TESH provides consistent Watt-per meter power output along the entire
length of the cable with no voltage drop. A glass ceramic tape layer adds additional
protection to the heating cable and a fluoropolymer over jacket provides chemical resistance while
maintaining maximum flexibility.
CONSTRUCTION :-
1 Heating Conductor
2 Fluoropolymer Dielectric Insulation
3 Glass ceramic Tape
4 Nickel-Plated Copper Braid (BN)
5 Fluoropolymer Over jacket
1. Available Watt densities . 25 W/m at 10°C
2. Maximum maintenance temperature ..... 200°C
3. Maximum continuous exposure temperature
Power-off ... 260°C

17. HEAT TRACING CONDUCTOR

18. TRACER

19. ADVANTAGES OF ELECTRICAL HEAT TRACING SYSTEM
ADVANTAGES OF HEAT TRACING SYSTEM :-
1. ONE TIME INSTALLATION .
2. EASY TEMPURATURE CONTROL .
3. EASY MONITORING FOR ANY ALARM AND FEEDBACK .
4. SAFE AND RELIABLE SYSTEM .
5. LONG LIFE SYSTEM .
6. LOW OPERATIONAL COST AS COMPARE TO OTHER HEATING
SYSTEM .
7. SIMPLE CONTROLABE SYSTEM .

20. TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSE REMEDY
No heat/no current
A. Loss of power (voltage)
B. Controller set point too low
C. High temperature limit switch
activated
D. “Open” series heating circuit
E. Controller failure
A. Restore power to tracing circuit (check circuit
breaker and electrical connections). Poorly made
terminations can cause EPD-type breakers to trip
unexpectedly
B. Adjust set point
C. May require manual reset to re-enable heat
tracing circuit
D. Repair or replace circuit1
E. Repair sensor or controller2

21. TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSE REMEDY
Low system temperature
A. Controller set point too low
B. Temperature sensor located too
close to heating cable or other heat
source; may be accompanied by
excessive cycling of control relays/
contacts
C. Insulation material and/or thickness
different than designed
D. Ambient temperature lower than
designed
E. Low voltage (check at power
connection point)
A. Adjust set point
B. Relocate sensor
C. Replace insulation; increase
insulation thickness (if dry);
consider increasing voltage for
higher cable output3
D. Install higher output heating cable;
increase insulation thickness; raise
voltage3
E. Adjust voltage to meet design
Requirements.

22. TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSE REMEDY
Low temperature in
sections
A. Wet, damaged or missing insulation
B. Parallel heating cable; open element
or damaged matrix
C. Heat sinks (valves, pumps, pipe
supports, etc.)
D. Significant changes in elevation
along length of the heat-traced pipe
A. Repair or replace insulation and
jacket
B. Repair or replace; splice kits are
available from cable manufacturer
C. Insulate heat sinks or increase
amount of tracing on heat sinks
D. Consider dividing heating circuit
into separate, independently
controlled segments .

23. TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSE REMEDY
High system temperature
A. Controller “on” continuously
B. Controller failed with contacts
closed
C. Sensor located on uninsulated pipe
or too close to heat sink
D. Backup heating circuit controller
“on” continuously
A. Adjust set point or replace sensor2
B. Replace sensor or controller2
C. Relocate sensor to an area representative
of conditions along entire
pipe length
D. Adjust set point or replace backup
controller

24. TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSE REMEDY
Excessive cycling
A. Temperature sensor located too
close to heating cable or other heat
source; may be accompanied by
Low system temperature
B. Ambient temperature near controller
set point
C. Connected voltage too high
D. Heating cable output too high
(overdesign)
E. Controller differential too narrow
A. Relocate sensor
B. Temporarily alter controller set point
C. Lower voltage
D. Install lower output heating cable or
lower voltage
E. Widen differential or replace controller
to avoid premature contact
failure

25. TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSE REMEDY
Temperature variations
from set point along
Pipeline .
A. Unanticipated flow patterns or
process operating temperatures
B. Inconsistent cable installation along
pipeline
C. Inconsistent cable performance
A. Redistribute heating circuits to accommodate
existing flow patterns; confirm process conditions
B. Check method of cable installation,
especially at heat sinks
C. Compare calculated watts/foot
[(volts x amps) ÷ length] for the measured pipe
temperature with designed cable output for the
same temperature; regional damage to parallel
cable can cause partial failure.

26. Thank you
DEEPAK SINGH
9634844138