Basics of heat-tracing Industrial het-tracing solutions Product details Design basics & controls Source: Patrick Bloemen, Kevin Chantillon (Pentair) http://www.ie-net.be/reg

1. INDUSTRIAL HEAT TRACING SOLUTIONS
Overview
Patrick Bloemen, Kevin Chantillon
Antwerpen, 14 september 2017 ie-net
INDUSTRIALHEAT TRACINGSOLUTIONS - ie-net 14 september 2017PENTAIR

2. PENTAIR
AGENDA
• BASICS OF HEAT-TRACING
• INDUSTRIAL HEAT-TRACING SOLUTIONS
• PRODUCT DETAILS
• DESIGN BASICS & CONTROLS
INDUSTRIALHEAT TRACINGSOLUTIONS - ie-net 14 september 2017

3. PENTAIR
3 modes of heat transfer
Conduction
• Transfer when bodies are in contact
Convection
• Transfer by movement of gases or liquids
Radiation
• Transfer through electromagnetic waves

4. PENTAIR
What is heat tracing?
Providing heat to maintain temperature of fluids, by replacing the heat lost
through thermal insulation on pipes, vessels & associated equipment
TAmbient
TFluid
Insulation material
Cladding
Pipe
Fluid
Heat tracing
Pin ≥ P out

5. PENTAIR
Heat tracing always in combination with insulation
Fluid
Temperature
Time (hrs)
Insulated + not traced
Insulated + traced
Fluid
Temperature
Un-insulated + traced
Time (hrs)
Time (hrs)
Fluid
Temperature
ONLY THIS OPTION
IS ACCEPTABLE

6. PENTAIR
When do we need Heat-tracing ?
Freeze protection
– Maintain T > 0°C
– Snow & ice melting
Process heating
– Increase T(process)
– Reduce viscosity
– Flow assurance
Temperature
maintenance
– Maintain T (product)
– Control viscosity for
flow assurance
– Avoid phase changes
– Avoid condensation

7. PENTAIR
Factors that influence heat loss
• Temperature difference (Tfluid – Tambient)
• Pipe diameter
• Type of insulation material
• Insulation thickness
• Pipe location: indoor/outdoor, wind/no wind
• Others Q = A x dT
R

8. PENTAIR
AGENDA
• BASICS OF HEAT-TRACING
• INDUSTRIAL HEAT-TRACING SOLUTIONS
• ELECTRICAL HEAT-TRACING PRODUCTS
• DESIGN BASICS & CONTROLS

9. PENTAIR
Typical thermal fluid system
9
…
1 Burner
2 Heater
3 Temperature Controller
5 Expansion Tank
6 Level Gauge
7 Pressure Gauge
8 Oil-Gas Separator
10 Gate Valve
9 Pump
4 Stop Valve
11 Drain
12 Strainer
13 Drain Tank
1
3
56
2
3
4
4
7
3
8
9 4
10
11 13 13

10. PENTAIR
Typical steam tracing system
4 Distribution Manifold
5 Valves
6 Pre Insulated Tubing
8 Connection
9 Heating Tube
10 Fastening Material
11 Steam Trap
10
…
4
5
6
7
8
9
10
12
11
13 Condensate Collection Piping
12 Collection Manifold
7 Cable Tray
6
7
8
8
8
13
1 Boiler
2 Pressure Control Station
3 Steam Distribution Piping
1
2
3
14 Condensate Vessel / Flash Tank
15
Feed Tank / Feed pump / Make Up
Water
16 Insulation
16 13
16
14
15

11. PENTAIR
Typical electric tracing system
3
4
11
…
1 Transformer
2 Heat Tracing Panel
3 Power Distribution
5 Power Connection
6 Heating Cable
7 Lighted End Seal
8 RTD Temperature Measurement
10 Insulation
9 Remote Configuration and Monitoring
4 Cable Tray
2
1
7
10
8
5
6
8
Steam, Thermal Fluids or ElectricTracing? – System Overview

12. PENTAIR
Advantages of thermal fluid tracing
• Variety of fluids
• Water
• Silicone-Based
• Hydrocarbons (Mineral Oils & Aromatics)
• Close Temperature Control
• Safe
12Steam, Thermal Fluids or ElectricTracing? – System Pros & Cons

13. PENTAIR
Disadvantages of thermal fluid tracing
• Engineering : Infrastructure
• Low heat capacity
• Limitted tracing length
• Jacketed Piping – double wall tank
• leaks : environment & health , cross contamination
• Fluid cost & maintenance
• Fluid selection
13

14. PENTAIR
Advantages of steam tracing
• High Efficiency
• High energy content
• Heat transfer
• Heat up & Melt up
• Perceived to be free
• by product ( condensation or exothermic reaction )
• Re-use of condensate
• Safe
• Not hazardous
• Intrinsically safe : Div1 (zone 0) areas
• Self Limiting
14

15. PENTAIR
Disadvantages of steam tracing
• Cost of installation
• Heating circuit length
• Infrastrucure & Labor
• Cost of operation ( Maintenance )
• Corrosion & Erosion
• Wet insulation
• Energy consumption
• Always ON
• Heat losses
• Technical Limitation
• Application ( Temperature )
• Control & monitoring
15

16. PENTAIR
Advantages of electrical heat tracing
• Technology :
• Type of cable
• Circuit length
• Non-metallic & lined piping , impuls lines , instrumentation , tubing bundles
• Temperature Control
• Monitoring
• Alarms
• System feedback
• Safe & Reliable
• Unconditional T-rating
• Long life
• Simple & low maintenance Cost
16

17. PENTAIR
Disadvantages of electrical heat tracing
• Temperature maintenance
• slow heat up & melt up
• ATEX
• Ex Proof components
• some applications with limiter
• Cable Exposure Temperature
• Slightly higher investment
• Engineered system
• Qualified personnel
17

18. PENTAIR
Electrical Heat Tracing
(EHT)
Typical application range
Steam and Thermal Fluids have a Clear Limitations Compared to EHT
Technologies
300
150
200
100
50
MaintainTemperature(ºC)
0 50 150 250 400 500 700 1000 1500 2000
Maximum Circuit Length (m/km)
25 kms3000
18
Thermal
Fluids
Steam
HP
SteamLP
600

19. PENTAIR
“Why is the use of electric heat tracing increasing for industrial applications ?”
• Ecological footprint
• Self-Regulating heating cables deliver safety and reliability
• Heating cable reduces power output as the temperature rises
• The cables can’t overheat itself and burn out
• Self regulation is an inherently safety feature with assigned T-ratings
• Class 1 Division 1 applications are possible
• 100% electrically insulated (safe to touch the cables)
• 10 year product warranty
• Lower installed cost
• Reduced construction time
• Lower maintenance and operating costs
Trends
It’s the SMART choice for the future
19

20. PENTAIR
Trends
“Why is the use of electric heat tracing increasing for industrial applications ?”
• Best fit for the application
• Exact amount of heat
• Easy temperature control & Monitoring
• Straightforward and cost effective
• Expert assistance from supplier
• Raychem invented and pioneered self regulating technology
• Solid track record with 40 years+ experience
• Proprietary Engineering tools and Software
• Worldwide network of support
• Electric/Steam Evaluation
It’s the SMART choice for the future
20

21. PENTAIR
AGENDA
• BASICS OF HEAT-TRACING
• INDUSTRIAL HEAT-TRACING SOLUTIONS
• ELECTRICAL HEAT-TRACING PRODUCTS
– Cables
– Connection kits & accessories
• DESIGN BASICS & CONTROLS

22. PENTAIR
Electrical Heat Tracing Products
Heating cables
Lighted end seals
Junction
boxes
Probes & Thermostats
One of the largest product bags available in the market
Self regulating
Heating cables
Polymer Insulated
Heating cables
Mineral Insulated
Heating cables
Power limiting
Heating cables
HEW-THERM

23. PENTAIR
Wide range of products
Series
Constant Wattage
Mineral insulated (MI)
Parallel
Constant Wattage
(FMT, FHT)
Parallel
Power-limiting
(VPL)
Series
Constant Wattage
Polymer insulated
(XPI)
Series
Skin-effect Tracing
System (STS)
Parallel
Self-regulating
(BTV, QTVR, XTV, KTV)
260
240
220
200
180
160
140
120
100
80
60
40
20
0 50 150 250 400 500 700 1.000 1.500 2.5002.000
Circuit length (m)
25.000
600
MaintainTemp.(ºC)

24. PENTAIR
Parallel self-regulating heating systems
Parallel Construction Cut-to-length, easy to install
Self-regulating Uniform pipe temperature, lower energy costs, can be
overlapped, suitable for complex pipework
Unconditional T-rating Safe design (independent of length), cables don’t overheat,
complete system approval for hazardous areas
Cross-linking technology
(pioneered by Raychem)
Reliable, long life: successful in operation for decades
Parallel Construction Cut-to-length, easy to install
Key benefits:

25. PENTAIR
Parallel self-regulating heating systems
How does it work?
– The core is a mixture of polymer & conductive carbon black, creating electrical paths between
the conductors
– Lower pipe temperatures result in microscopic contraction of the core, more electrical paths
between conductors, higher current, and higher power output of cable
– Higher pipe temperatures result in microscopic expansion of the core, less electrical paths
between conductors, lower current, and lower power output of the cable
https://www.youtube.com/watch?v=GBJlo9JJ2EQ

26. PENTAIR
Polymer Insulated (PI) series heating systems
PI series resistance heating cables allow for circuit lengths exceeding those of parallel
heating cables (typically < 250 m).
• This makes them particularly suitable for long pipelines and large tanks / vessels.
• They offer an economical alternative to parallel heating systems.
https://www.youtube.com/watch?v=GBJlo9JJ2EQ

27. PENTAIR
Polymer Insulated (PI) series heating systems
How does it work?
• Heat is generated by the principle of ohmic resistance heating
of the central conductor, which uses various materials to
provide a specific resistance
• The heating cables are typically equipped at both extremities
with non-heating sections, referred to as cold lead(s), to avoid
a hot cable being exposed (safety purpose) and adding heat to
the power connection
Cold Lead
Heating Cable
Connection Kit
Heat
Heat
AC
MoviesPENTAIR - XPI-original.mp4

28. PENTAIR
Mineral Insulated (MI) series heating systems
MI heating cables are suitable to maintain temperatures up to 600°C* and can
withstand exposure temperatures up to 1000°C
• A wide resistance range makes them suitable from short instrument lines to very long transfer pipelines (up to 5
km from single power supply)
• Maximum power output well exceeds range of any polymeric heating cable making them often the only
alternative for high heat-loss and when fast heat-up is required
* Depending on the terminationmethod & materials used, higher temperatures are possible

29. PENTAIR
Advanced Control & Monitoring systems
Reduced Total Investment Cost & Total Operating Cost
Supervisory
software
Advanced Control
& Monitoring Systems
Local
Heat Tracing
Advanced
controller
NGC-30
Central
System
NGC-20
Local
System
NGC-40
Modular
System

30. PENTAIR
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Panelboards
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Insulation

31. PENTAIR
Engineered & Specialty Technologies
Leak Detection
Systems
Trac-Loc
Insulation systems
Oil Field
Flow assurance
systems
Long Pipeline
Heating systems
Unique technologies for specific market needs

32. PENTAIR
AGENDA
• BASICS OF HEAT-TRACING
• INDUSTRIAL HEAT-TRACING SOLUTIONS
• ELECTRICAL HEAT-TRACING SOLUTIONS
– Cables
– Connection kits & accessories
• DESIGN BASICS & CONTROLS

33. PENTAIR
Components for self regulating cables

34. PENTAIR
AGENDA
• BASICS OF HEAT-TRACING
• INDUSTRIAL HEAT-TRACING SOLUTIONS
• ELECTRICAL HEAT-TRACING SOLUTIONS
• DESIGN BASICS & CONTROLS

35. PENTAIR
5 Steps in heat-tracing design
1. Things to know: (Design base)
• Minimum ambient temperature
• Maintain temperature of the pipe
• Pipe diameter
• Operating temperature
• Max. exposure temperature (steam-cleaning?)
• Type and thickness of insulation material
• Indoor or outdoor application
• Hazardous area details
2. Calculate heat loss of pipe
3. Select a possible heating cable with at least this power output

36. PENTAIR
5 Steps in heat-tracing design
4. Validate heating cable suited for process by considering:
• Environment
– Jacket material
– Process or not
• Product degradation temperatures (max. allowable)
5. Validate heating cable suited for safety by considering:
• Hazardous zoning details and T-rating
• Design method / approach
– Stabilized design with product classification
– Stabilized design with systems approach
– Control limited design

37. PENTAIR
Optimal design of control system
37
• 4 control methods:
– uncontrolled
– Ambient sensing
– Proportional ambient sensing
– Line sensing
• Factors to consider
– Process temperature band
– Safety and hazardous area requirements
– Remote monitoring capabilities
– Complexity of flow paths
– …

38. PENTAIR
Optimal design of control system
HEAT-TRACING ALWAYS ON
38
Pipe temperature

39. PENTAIR
Optimal design of control system
HEATER ON/OFF, BASED ON MINIMUM AMBIENT TEMPERATURE
39

40. PENTAIR
Optimal design of control system
HEATER ON/OFF, BASED ON DUTY CYCLE ALGORITHM AND AMBIENT
TEMPERATURE
40
Proportional Ambient Sensing Control

41. PENTAIR
OPTIMAL DESIGN OF CONTROL SYSTEM
HEATER ON/OFF, BASED ON NARROW TEMPERATURE CONTROL AND
PIPE TEMPERATURE
41

42. PENTAIR