This document provides installation and maintenance instructions for self-regulating heater cable. It discusses product selection, receipt and storage of materials, installation procedures including cable attachment and routing, system components, insulation, thermostats, electrical requirements, testing, start-up, operation and maintenance, troubleshooting damaged products. The document contains diagrams to illustrate cable installation details on pipes, valves, elbows, hangers and supports.
Electric Heat tracing maintenance and troubleshooting by ThermonCarotek
This document provides an overview of electric heat tracing systems and components, installation and testing procedures, maintenance guidelines, and troubleshooting tips. A typical system includes electric heating cable, power connections, controls, splices and terminations. It should be tested after installation but before insulation using a megohmmeter. Ongoing maintenance includes periodic inspections and testing to monitor performance over time. Proper thermal insulation is critical for heat retention and system effectiveness. Common issues like damaged insulation, low temperatures, and excessive cycling are addressed along with potential causes and remedies.
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive function. Exercise causes chemical changes in the brain that may help protect against mental illness and improve symptoms.
Basic training water based fire protectionSabrul Jamil
This document provides an introduction and overview of various water-based fire protection systems, including standpipe systems, wet pipe sprinkler systems, dry pipe sprinkler systems, deluge sprinkler systems, and pre-action sprinkler systems. It defines key terminology, describes common system components, and explains the purpose and function of different sprinkler head types and special application nozzles. Standards for installation and maintenance are also referenced.
Fundamental training on Fire Detection & Alarm SystemSabrul Jamil
This is a basic training on Fire Detection and Alarm System, created to give my colleagues from non-engineering divisions a comprehensive brief on the system. This is most suitable for individuals with little or no technical knowledge. This training introduces the devices and the system in a whole, not how to design it.
- Fire pumps are centrifugal pumps selected to operate between 90-140% of rated capacity and less than 150% to avoid overpressure.
- Pump rooms require 1-hour fire rated separation, emergency lighting, ventilation, and drainage.
- Suction and discharge piping must be sized properly and have the correct fittings like gauges, valves, and relief valves. Jockey pumps maintain system pressure.
- Electric and diesel fire pump controllers prioritize system operation over equipment protection to ensure reliable fire suppression.
The document discusses fire protection systems, including statistics on fires in 2010. It then covers fire protection goals of detecting and extinguishing fires without damaging contents or harming occupants. It focuses on clean agent and inert gas fire suppression systems as alternatives to sprinklers. These systems can extinguish fires quickly without water damage, but require detection systems and plan reviews. They work by releasing pressurized gases to flood an area and reduce oxygen levels. Common agents discussed include FM-200, NOVEC-1230, and inert gases like Inergen and Argonite.
Hopefully this page will help to answer your trace heating questions. If you would like any advice on your present or future heat trace and surface heating requirements, please don't hesitate to contact ESH Trace Heating Ltd.
The document provides an overview of heat tracing methods used for freeze protection and temperature maintenance of pipes, tanks, and instruments. It discusses different types of heat tracing cables like self-regulating, power limiting, mineral insulated, and series constant watt cables. It also covers heat tracing circuits, thermostats, installation best practices, and troubleshooting tips for low/high system temperatures, temperature variations, and excessive cycling.
Electric Heat tracing maintenance and troubleshooting by ThermonCarotek
This document provides an overview of electric heat tracing systems and components, installation and testing procedures, maintenance guidelines, and troubleshooting tips. A typical system includes electric heating cable, power connections, controls, splices and terminations. It should be tested after installation but before insulation using a megohmmeter. Ongoing maintenance includes periodic inspections and testing to monitor performance over time. Proper thermal insulation is critical for heat retention and system effectiveness. Common issues like damaged insulation, low temperatures, and excessive cycling are addressed along with potential causes and remedies.
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive function. Exercise causes chemical changes in the brain that may help protect against mental illness and improve symptoms.
Basic training water based fire protectionSabrul Jamil
This document provides an introduction and overview of various water-based fire protection systems, including standpipe systems, wet pipe sprinkler systems, dry pipe sprinkler systems, deluge sprinkler systems, and pre-action sprinkler systems. It defines key terminology, describes common system components, and explains the purpose and function of different sprinkler head types and special application nozzles. Standards for installation and maintenance are also referenced.
Fundamental training on Fire Detection & Alarm SystemSabrul Jamil
This is a basic training on Fire Detection and Alarm System, created to give my colleagues from non-engineering divisions a comprehensive brief on the system. This is most suitable for individuals with little or no technical knowledge. This training introduces the devices and the system in a whole, not how to design it.
- Fire pumps are centrifugal pumps selected to operate between 90-140% of rated capacity and less than 150% to avoid overpressure.
- Pump rooms require 1-hour fire rated separation, emergency lighting, ventilation, and drainage.
- Suction and discharge piping must be sized properly and have the correct fittings like gauges, valves, and relief valves. Jockey pumps maintain system pressure.
- Electric and diesel fire pump controllers prioritize system operation over equipment protection to ensure reliable fire suppression.
The document discusses fire protection systems, including statistics on fires in 2010. It then covers fire protection goals of detecting and extinguishing fires without damaging contents or harming occupants. It focuses on clean agent and inert gas fire suppression systems as alternatives to sprinklers. These systems can extinguish fires quickly without water damage, but require detection systems and plan reviews. They work by releasing pressurized gases to flood an area and reduce oxygen levels. Common agents discussed include FM-200, NOVEC-1230, and inert gases like Inergen and Argonite.
Hopefully this page will help to answer your trace heating questions. If you would like any advice on your present or future heat trace and surface heating requirements, please don't hesitate to contact ESH Trace Heating Ltd.
The document provides an overview of heat tracing methods used for freeze protection and temperature maintenance of pipes, tanks, and instruments. It discusses different types of heat tracing cables like self-regulating, power limiting, mineral insulated, and series constant watt cables. It also covers heat tracing circuits, thermostats, installation best practices, and troubleshooting tips for low/high system temperatures, temperature variations, and excessive cycling.
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive functioning. Exercise causes chemical changes in the brain that may help boost feelings of calmness, happiness and focus.
A BMS consultant document discusses inputs and outputs for building management systems. It describes various sensors like temperature, humidity, pressure, and flow sensors that provide inputs. It also discusses output devices like control valves, VFD speed commands, and damper actuators. The document provides details on common sensor types, proper installation of sensors, and BMS protocols.
The goal of this maintenance plan is to maintain campuses within the region that effectively represent the quality of the programs housed in its buildings. Safety, comfort, functionality, efficiency, and aesthetics are the guiding principles
Dry riser systems provide fire protection for high-rise buildings where main water pressures are insufficient for normal firefighting. The systems are installed in staircases with riser valves on each floor connected to an inlet breeching on the ground level for firefighters to connect hoses. Equipment is manufactured to BS 5041 standards and includes breeching inlets, cabinets, riser valves, and air valves to release or admit air in the risers.
Basics of HVAC - Part 1 (Heating Ventilation Air Conditioning)MOHAMMED KHAN
The document provides an overview of the basics of HVAC (heating, ventilation, and air conditioning) systems. It was prepared by Mohammed Abdul Mujeeb Khan, a mechanical engineer. The document defines HVAC, describes common HVAC system types like direct expansion and chilled water systems, and covers topics like temperature and humidity control, load calculation, equipment selection, and system design.
Overview and Maintenanaces of HVAC system Srinath Menon
This document provides an overview and introduction to centralized air conditioning systems. It discusses the key components of a chilled water central air conditioning system, including chillers, cooling towers, air handling units, and grills. It describes how chilled water is circulated throughout a building to cool air in air handling units serving different floors. Issues commonly faced by maintenance personnel are also listed, such as surging problems, difficulty maintaining condenser approach, and ensuring proper water quality and flow rates. The document focuses on analyzing a large commercial building's HVAC system in Bangalore, India as a case study.
This document provides an overview of HVAC systems, including the different types of HVAC systems and their components. It discusses air conditioning chillers, air handling systems, fans and pumps, HVAC piping, instrumentation and controls, and the HVAC commissioning process. The primary purpose of HVAC systems is to provide healthy and comfortable interior conditions for occupants using minimal energy and reducing pollutant emissions. Key components include chillers, air handling units, fans, ducts, coils, filters and controls. Proper commissioning ensures systems are installed correctly and perform as intended.
Fire alarm , detection and suppression systemKamran Hassan
fire detection and suppression system. Types of fire and different fire extinguishing material and agents like FM200, NOVEC and ECARO, water, foam and dry agents
The document discusses the design of Novec 1230 gas fire suppression systems for a library and store/pharmacy in a hospital. It includes calculations to determine the hazard volumes, required agent quantities, number and sizes of cylinders, pipe sizes, and pressure venting requirements. Design layouts are also provided. The key advantages of using Novec 1230 are highlighted as protecting the environment and valuable/irreplaceable items without causing damage like traditional agents.
This document discusses the importance of proper air balancing in buildings and facilities. It begins with defining building pressure and listing symptoms of negative pressure. Unbalanced facilities can cost thousands per year in unnecessary energy expenses. Common causes of imbalance are equipment issues and poor maintenance. Regular air balancing checks the HVAC system's performance and ensures positive pressure and proper airflow. Facility managers should schedule balancing to improve comfort, efficiency and equipment lifespan. A case study shows how balancing found many issues across 4 locations.
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Key Characteristics and Requirements of Diesel Fire Pump Engines
1) Air handling units (AHUs) are devices used to regulate and circulate air as part of HVAC systems. They contain components like fans, filters, coils, and dampers.
2) AHUs can be classified based on fan location as draw-through or blow-through units. Draw-through units have fans after coils while blow-through units have fans before coils.
3) Other classifications include vertical, horizontal, ceiling-suspended, and packaged AHUs. Packaged AHUs have components in a single casing and are commonly used in smaller buildings.
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive functioning. Exercise causes chemical changes in the brain that may help alleviate symptoms of mental illness and boost overall mental well-being.
This document provides information on various electric heating cables and accessories for heat tracing applications. It describes self-regulating, power-limiting, and constant watt heating cables that can maintain temperatures from -40°F to 500°F. Accessories include termination kits for power connections and splices, tapes for securing cable, and control/monitoring modules. The document also outlines heated tubing bundles and panels for tank and vessel heating applications.
This document discusses different types of HVAC systems and their applications. It provides information on direct expansion systems versus chilled water systems, package units, split units, air handling units, fan coil units, and chilled water systems. Specific HVAC system considerations and requirements are discussed for different building types like hospitals, hotels, and frozen food storage facilities. Key factors in HVAC system selection include temperature and humidity control, air movement and distribution, filtration, and achieving proper indoor environmental conditions for the building type and use.
Testing, Adjusting, and Balancing of all HVAC Systemsd-airconditioning
The purpose of testing, adjusting, and balancing (TAB) is to assure that an HVAC system is providing maximum occupant comfort at the lowest energy cost possible.
The document discusses different types of wiring used in building management systems, including control wiring, power wiring, and communication wiring. It provides details on wire types for various applications, such as CAT5 or CAT6 cable for communication between DDC controllers. Diagrams show typical system architectures and wiring schematics for HVAC components like VAV boxes and precision air conditioners connected over a BACnet network through a gateway.
The document discusses fire hydrant systems used for fire protection. It describes the components of a fire hydrant system including hydrants, monitors, hoses, and pipes. It also outlines international and national standards for fire hydrant system design including spacing of hydrants, sizing of pumps and reservoirs, and classification of fire risks. The goal of a fire hydrant system is to provide a reliable water supply for extinguishing fires.
This document provides information on water mist fire suppression systems. It begins with a history of water mist technology dating back to the 1880s. It then defines water mist as a fine water spray with droplets less than 1000 microns. The benefits of water mist over gas or sprinkler systems are discussed, including immediate activation and minimized water damage. Relevant codes and standards are also mentioned. The document discusses water mist mechanisms, components, applications, limitations, and provides a case study example of designing a water mist system for a machinery space.
This document provides information on fire protection equipment used in electric substations. It discusses the importance of electricity as critical infrastructure and the objectives of transmission utilities. It then covers various aspects of fire prevention and fighting including standards, elimination of electric fire hazards, grounding practices, and maintenance procedures. The document also describes classifications of fires according to different materials involved and appropriate extinguishing methods. Finally, it explains different types of fire extinguishing equipment like water, foam, dry chemical powder, carbon dioxide, and their mechanisms of fire extinction.
Hot Water Heat Tracing - Maintenance and Troubleshooting GuideThorne & Derrick UK
This document provides an overview of electric heat tracing systems and components, including cables, power connections, controls, insulation, and labels. It discusses testing cables after installation but before insulating, and performing final inspections which establish baseline measurements for ongoing maintenance. Troubleshooting tips are provided for issues like low/no heat, temperatures too high or low, and cold sections. Wet or damaged insulation is a common problem.
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive functioning. Exercise causes chemical changes in the brain that may help boost feelings of calmness, happiness and focus.
A BMS consultant document discusses inputs and outputs for building management systems. It describes various sensors like temperature, humidity, pressure, and flow sensors that provide inputs. It also discusses output devices like control valves, VFD speed commands, and damper actuators. The document provides details on common sensor types, proper installation of sensors, and BMS protocols.
The goal of this maintenance plan is to maintain campuses within the region that effectively represent the quality of the programs housed in its buildings. Safety, comfort, functionality, efficiency, and aesthetics are the guiding principles
Dry riser systems provide fire protection for high-rise buildings where main water pressures are insufficient for normal firefighting. The systems are installed in staircases with riser valves on each floor connected to an inlet breeching on the ground level for firefighters to connect hoses. Equipment is manufactured to BS 5041 standards and includes breeching inlets, cabinets, riser valves, and air valves to release or admit air in the risers.
Basics of HVAC - Part 1 (Heating Ventilation Air Conditioning)MOHAMMED KHAN
The document provides an overview of the basics of HVAC (heating, ventilation, and air conditioning) systems. It was prepared by Mohammed Abdul Mujeeb Khan, a mechanical engineer. The document defines HVAC, describes common HVAC system types like direct expansion and chilled water systems, and covers topics like temperature and humidity control, load calculation, equipment selection, and system design.
Overview and Maintenanaces of HVAC system Srinath Menon
This document provides an overview and introduction to centralized air conditioning systems. It discusses the key components of a chilled water central air conditioning system, including chillers, cooling towers, air handling units, and grills. It describes how chilled water is circulated throughout a building to cool air in air handling units serving different floors. Issues commonly faced by maintenance personnel are also listed, such as surging problems, difficulty maintaining condenser approach, and ensuring proper water quality and flow rates. The document focuses on analyzing a large commercial building's HVAC system in Bangalore, India as a case study.
This document provides an overview of HVAC systems, including the different types of HVAC systems and their components. It discusses air conditioning chillers, air handling systems, fans and pumps, HVAC piping, instrumentation and controls, and the HVAC commissioning process. The primary purpose of HVAC systems is to provide healthy and comfortable interior conditions for occupants using minimal energy and reducing pollutant emissions. Key components include chillers, air handling units, fans, ducts, coils, filters and controls. Proper commissioning ensures systems are installed correctly and perform as intended.
Fire alarm , detection and suppression systemKamran Hassan
fire detection and suppression system. Types of fire and different fire extinguishing material and agents like FM200, NOVEC and ECARO, water, foam and dry agents
The document discusses the design of Novec 1230 gas fire suppression systems for a library and store/pharmacy in a hospital. It includes calculations to determine the hazard volumes, required agent quantities, number and sizes of cylinders, pipe sizes, and pressure venting requirements. Design layouts are also provided. The key advantages of using Novec 1230 are highlighted as protecting the environment and valuable/irreplaceable items without causing damage like traditional agents.
This document discusses the importance of proper air balancing in buildings and facilities. It begins with defining building pressure and listing symptoms of negative pressure. Unbalanced facilities can cost thousands per year in unnecessary energy expenses. Common causes of imbalance are equipment issues and poor maintenance. Regular air balancing checks the HVAC system's performance and ensures positive pressure and proper airflow. Facility managers should schedule balancing to improve comfort, efficiency and equipment lifespan. A case study shows how balancing found many issues across 4 locations.
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Key Characteristics and Requirements of Diesel Fire Pump Engines
1) Air handling units (AHUs) are devices used to regulate and circulate air as part of HVAC systems. They contain components like fans, filters, coils, and dampers.
2) AHUs can be classified based on fan location as draw-through or blow-through units. Draw-through units have fans after coils while blow-through units have fans before coils.
3) Other classifications include vertical, horizontal, ceiling-suspended, and packaged AHUs. Packaged AHUs have components in a single casing and are commonly used in smaller buildings.
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive functioning. Exercise causes chemical changes in the brain that may help alleviate symptoms of mental illness and boost overall mental well-being.
This document provides information on various electric heating cables and accessories for heat tracing applications. It describes self-regulating, power-limiting, and constant watt heating cables that can maintain temperatures from -40°F to 500°F. Accessories include termination kits for power connections and splices, tapes for securing cable, and control/monitoring modules. The document also outlines heated tubing bundles and panels for tank and vessel heating applications.
This document discusses different types of HVAC systems and their applications. It provides information on direct expansion systems versus chilled water systems, package units, split units, air handling units, fan coil units, and chilled water systems. Specific HVAC system considerations and requirements are discussed for different building types like hospitals, hotels, and frozen food storage facilities. Key factors in HVAC system selection include temperature and humidity control, air movement and distribution, filtration, and achieving proper indoor environmental conditions for the building type and use.
Testing, Adjusting, and Balancing of all HVAC Systemsd-airconditioning
The purpose of testing, adjusting, and balancing (TAB) is to assure that an HVAC system is providing maximum occupant comfort at the lowest energy cost possible.
The document discusses different types of wiring used in building management systems, including control wiring, power wiring, and communication wiring. It provides details on wire types for various applications, such as CAT5 or CAT6 cable for communication between DDC controllers. Diagrams show typical system architectures and wiring schematics for HVAC components like VAV boxes and precision air conditioners connected over a BACnet network through a gateway.
The document discusses fire hydrant systems used for fire protection. It describes the components of a fire hydrant system including hydrants, monitors, hoses, and pipes. It also outlines international and national standards for fire hydrant system design including spacing of hydrants, sizing of pumps and reservoirs, and classification of fire risks. The goal of a fire hydrant system is to provide a reliable water supply for extinguishing fires.
This document provides information on water mist fire suppression systems. It begins with a history of water mist technology dating back to the 1880s. It then defines water mist as a fine water spray with droplets less than 1000 microns. The benefits of water mist over gas or sprinkler systems are discussed, including immediate activation and minimized water damage. Relevant codes and standards are also mentioned. The document discusses water mist mechanisms, components, applications, limitations, and provides a case study example of designing a water mist system for a machinery space.
This document provides information on fire protection equipment used in electric substations. It discusses the importance of electricity as critical infrastructure and the objectives of transmission utilities. It then covers various aspects of fire prevention and fighting including standards, elimination of electric fire hazards, grounding practices, and maintenance procedures. The document also describes classifications of fires according to different materials involved and appropriate extinguishing methods. Finally, it explains different types of fire extinguishing equipment like water, foam, dry chemical powder, carbon dioxide, and their mechanisms of fire extinction.
Hot Water Heat Tracing - Maintenance and Troubleshooting GuideThorne & Derrick UK
This document provides an overview of electric heat tracing systems and components, including cables, power connections, controls, insulation, and labels. It discusses testing cables after installation but before insulating, and performing final inspections which establish baseline measurements for ongoing maintenance. Troubleshooting tips are provided for issues like low/no heat, temperatures too high or low, and cold sections. Wet or damaged insulation is a common problem.
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Trace Heating Series Constant Wattage Trace Heating CablesThorne & Derrick UK
This document provides installation procedures and guidelines for electric heat tracing systems. It includes:
- Illustrations of typical heat tracing installations on pipes, elbows, supports and flanges
- Requirements for receiving, storing and handling heat tracing cables properly
- Guidelines for initial installation including cable allowances and minimum bend radii
- Procedures for completing the installation including securing cables, insulation resistance testing, and making power connections
- Tables listing recommended cable allowances for valves, pumps and other equipment to ensure adequate heat distribution
Electric Heat Tracing - Installation Procedures (Thermon Cables)Thorne & Derrick UK
This document provides guidelines for installing an electric heat tracing system on pipes. It describes the components of a heat tracing system and outlines the installation process. Key steps include laying out the heating cable along the bottom of the pipe, allowing extra cable for valves and joints, and securing it in place with attachment tape every 12 inches. Additional cable is needed on valves, pumps, elbows and other areas with increased heat loss.
Hot Water Temperature Maintenance Heat Tracing - Planning InstructionsThorne & Derrick UK
This document provides planning instructions for installing warm water heating cable systems. It discusses selecting the appropriate heating cable type based on pipe constraints. It also discusses choosing accessories like connection units, fastening materials, and additional controls like thermostats. The document provides steps for installing the heating cable along pipes and making connections. It discusses operation of the system and provides troubleshooting for common issues like circuit breakers interrupting, temperature control problems, and locating faults.
Self-regulating systems are the preferred choice for most complex pipe-tracing applications. This is due to their parallel construction, which allows them to be cut to length and spliced in the eld, and their self-regulating output, which provides more heat where it is needed.
This step-by-step design guide provides the tools necessary to design a self-regulating heat-tracing system for insulated pipes and tubing. For other applications or for design assistance, contact ISI at 407.324.7800 or www.isisales.com.
The document provides installation and programming instructions for the Control4 Wireless Thermostat, including connecting wiring, setting switches to match the HVAC system, testing the thermostat, and advanced programming options available through Composer Pro like scheduling and locking the buttons.
This document provides installation procedures for electric heat tracing systems. It includes guidelines for installing heating cables on pipes, valves, pumps, elbows and other components. Specific instructions are provided for attaching cable in these areas using approved attachment tape. The document also outlines best practices for receiving, storing and testing heating cables before and during the installation process.
This document provides installation procedures for electric heat tracing systems. It includes guidelines for installing heating cables on pipes, valves, pumps, elbows and other components. Specific instructions are provided for attaching cable in these areas using approved attachment tape. The document also outlines best practices for receiving, storing and testing heating cables before and during the installation process.
Anticipating freezing conditions and protecting buildings, equipment, and grounds against freeze damage is a vital part of a Facility Maintenance Program. A good freeze protection plan includes steps for inspection, preventative maintenance, and corrective maintenance prior to the beginning of cold weather conditions. This guide is designed to make the planning process easier for you.
“Trumen Technologies Pvt. Ltd.” is an ISO 9001:2015 certified ,Indian based Manufacturer and Exporters of Level and Pressure sensing instruments. We at Trumen is a team of professionals having years of experience in Level and Pressure Instruments manufacturing who understands what customer needs, and try to fulfill those requirements in appropriate time with best Quality.
We have wide range of CE certified product like Radar Level Transmitters, Ultrasonic Level ,Vibrating fork solid level switch, Vibrating fork liquid level switch, Admittance point level switch, Capacitance point level switch, Vibrating rod point level switch, Conductivity point level switch, Capacitive continuous level transmitter, Hydrostatic continuous level transmitter, etc.
Our products used in different industrial applications in various industries like Power and Water, Oil and Gas, Petrochemical, Mining and Metal, Food and Beverages, Cement ,Pharmaceutical and many more. We are regularly supplying our products to NTPC, IOCL,BPCL, BORL, Cipla, Lupin, Cadila healthcare, Praj High Purity Systems , Ultratech Cement, Shree Cement ,Jindal Group ,TATA, Asian Paints, Procter & Gamble, Hindustan Unilever Ltd, Kirloskar, Vedanta, Nestle, Pepsi, BASF, Novartis and many more.
We are regularly exporting our products to USA, UK, South Korea, Italy ,Thailand, Taiwan, UAE, Tanzania, Turkey ,Sri Lanka ,Saudi Arabia , Kuwait ,Malaysia, Sweden, Canada, Egypt , Brazil ,Singapore etc.
Address: 39, Mangal Nagar, Behind Sai Ram Plaza, Near Rajeev Gandhi Circle, AB Road, Indore, Madhya Pradesh 452001
Web: https://trumen.in/
Contact: 0731 497 2065
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Thermon is a leading manufacturer of heat tracing products that has over 30 years of experience supplying electric heating solutions for foundation heating systems for facilities that store liquids like LNG, LPG, and ammonia at subfreezing temperatures. Thermon offers complete heating solutions including heating cables, control systems, engineering services, and installation. Their constant wattage and self-regulating heating cables have a history of reliable performance for these applications.
1. This document provides guidelines for installing an electric heat tracing system on pipes. It describes components of a complete system and procedures for installing heating cables on pipes, elbows, supports, flanges, valves and pumps.
2. Key steps include laying out the cable according to piping layout, allowing extra cable for connections and splicing. Cable is attached to pipes using tape every 12 inches. Additional cable is required on valves, pumps and other areas with increased heat loss.
3. Instructions are given for testing cables upon receipt and completing installation by securing terminations.
This document provides information on Nelson Easy Heat Europe's Type CLT and LT self-regulating heater cables. The cables consist of stranded copper conductors, a continuous self-regulating conductive core, and protective jackets. They are designed to maintain temperatures for applications such as freeze protection of pipes. The document includes specifications, performance data, and application information for the CLT23-JT, CLT25-JT, CLT28-JT, LT23-J, LT25-J, LT28-J, and LT210-J cable models.
Trumen is a technocrat driven organization aimed at providing top-of-the-range and high quality level measurement and process control instruments. Formed by the pioneers who devoted their respective lives in development, design and delivery of solution to the problems faced in the field of level sensing and process measurements. Trumen has a fixed point agenda about "sensing matters", and each device created at Trumen is thoroughly tested to pass the quality norms set in-house, in order to give the best performance in all operating conditions.
Address: 39, Mangal Nagar, Behind Sai Ram Plaza, Near Rajeev Gandhi Circle, AB Road, Indore, Madhya Pradesh 452001
Web: https://trumen.in/
Contact: 0731 497 2065
#VibratingForkLevelSensor
#VibratingForkLevelSwitch
#VibratingRodPointLevelSwitch
#Vibratingrodpointlevelswitchmanufacturersinindia
#Vibratingrodpointlevelswitchsupplierinindia
#TuningForkPointLevelSwitch
#AdmittancePointLevelSwitch
#RotatingPaddleLevelSwitch
#RadarLeveltransmitter
#LevelSensor
#solidlevelswitch
#powderlevelswitch
#limestone
#coalbunker
#PVCpowder
#levelinstruments
#Levelswitch
#levelindicator
#leveltransmitter
“Trumen Technologies Pvt. Ltd.” is an ISO 9001:2015 certified ,Indian based Manufacturer and Exporters of Level and Pressure sensing instruments. We at Trumen is a team of professionals having years of experience in Level and Pressure Instruments manufacturing who understands what customer needs, and try to fulfill those requirements in appropriate time with best Quality.
We have wide range of CE certified product like Radar Level Transmitters, Ultrasonic Level ,Vibrating fork solid level switch, Vibrating fork liquid level switch, Admittance point level switch, Capacitance point level switch, Vibrating rod point level switch, Conductivity point level switch, Capacitive continuous level transmitter, Hydrostatic continuous level transmitter, etc.
Our products used in different industrial applications in various industries like Power and Water, Oil and Gas, Petrochemical, Mining and Metal, Food and Beverages, Cement ,Pharmaceutical and many more. We are regularly supplying our products to NTPC, IOCL,BPCL, BORL, Cipla, Lupin, Cadila healthcare, Praj High Purity Systems , Ultratech Cement, Shree Cement ,Jindal Group ,TATA, Asian Paints, Procter & Gamble, Hindustan Unilever Ltd, Kirloskar, Vedanta, Nestle, Pepsi, BASF, Novartis and many more.
We are regularly exporting our products to USA, UK, South Korea, Italy ,Thailand, Taiwan, UAE, Tanzania, Turkey ,Sri Lanka ,Saudi Arabia , Kuwait ,Malaysia, Sweden, Canada, Egypt , Brazil ,Singapore etc.
Address: 39, Mangal Nagar, Behind Sai Ram Plaza, Near Rajeev Gandhi Circle, AB Road, Indore, Madhya Pradesh 452001
Web: https://trumen.in/
Contact: 0731 497 2065
1) Foundry safety is important as working with molten metal is inherently dangerous, but proper safety measures can make melt shops accident-free.
2) Key roles like melt shop supervisors and management must make safety a top priority through training, oversight of safe equipment operation, and establishing safety as a core value.
3) Identifying and preventing hazards through adherence to manufacturer and regulatory guidelines, use of protective equipment, emergency plans, and automated processes can help reduce foundry accidents.
This document provides installation and operation instructions for Autotrol Logix 764 control valves and Performa CV series water softening valves. It includes sections on safety, location selection, equipment installation, control and valve features, system specifications, programming options, service/maintenance, troubleshooting, and wiring/assembly diagrams. The document is intended to guide installers on setting up water softening systems using these Autotrol components.
Infrared thermography uses infrared sensors to detect abnormal temperatures that can indicate developing equipment problems. It allows for non-contact temperature measurement of moving, electrically hot, fragile, small, or remote targets. Infrared thermography creates images from the infrared light emitted by objects and converts it to a surface temperature map. It is useful for predictive maintenance across various applications including electrical equipment, mechanical systems, commercial buildings, and more.
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This document provides contact and location information for ROTRONIC Instrument Corp. and its subsidiaries and partners worldwide. ROTRONIC is a Swiss-owned company with headquarters in Switzerland and subsidiaries across Europe, North America, Asia, and elsewhere. Contact information is provided for ROTRONIC's offices and representatives in Switzerland, Germany, France, Italy, the UK, USA, Canada, Singapore, China, and elsewhere. The document also provides ROTRONIC's warranty terms and conditions.
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4. Insulation
Heater Cable
Pipe
Figure 1
PRODUCT SELECTION
Check and verify that the proper heater cables are being installed on each pipe and vessel. If no
design/installation documents exist, check Nelson Heat Tracing Systems Design & Selection Guides to
determine the proper equipment for the application.
RECEIPT & STORAGE
Receipt
• Compare the materials against the shipping bill to verify receipt of proper materials.
• Inspect heating cable and components for transit damage. Insulation resistance tests on each spool of
cable are recommended.
• If design documents (line lists or per circuit bills of material) exists, check the received materials against
the lists to verify of all needed materials. If no design documents exists, keep a receipt log of all materials
received.
Storage
Cables and system components should be stored in a clean, dry area. The equipment should be protected
from mechanical damage during storage. The storage temperature range is (-40°F to 140°F) -40°C to 60°C.
Withdrawal from Storage
It is recommended that a check out record be kept (in conjunction with the receipt records) on equipment as it
is removed from storage. This will serve to identify developing material shortages before they happen - since
project additions often cause the use of material for other than designated piping.
5. INSTALLATION
!
WARNINGS:
While there are many acceptable ways of installing nelson heat tracing systems’ electric heating equipment,
certain actions can be dangerous to personnel and your installations. Please take care to avoid the following
problems:
• Do not twist the bus wires together at either end of the heater cable. Each of these wires has a voltage or
neutral applied to it; twisting them together will cause a short circuit.
• Insulate black polymer surrounding bus wires. The black compound extruded around the bus wires is
electrically conductive and should be treated as a conductor.
• All electrical connections in the system should be sealed against moisture. To prevent electrical arcing and
fire hazard, all cable connections and electrical wiring connections should be sealed against moisture. This
includes the use of proper cable sealing kits and the moisture proofing of all wire connections.
• Do not expose heater cables to temperatures above their maximum ratings. Higher temperatures can
greatly shorten the life of a heater cable.
• Immediately replace any damaged heater cable or components. Failure to replace any damaged
components (heater cable, components, or thermal insulation) will result in system failure.
• Classified areas (explosive dust or gases) require the use of special electrical components. Any area having
explosive gases (such as chemical / petrochemical installations) or explosive dusts (such as coal handling
or graineries) require special cable, connection components and control components that are approved for
use in these areas. Installation of non-approved products can result in fires or explosions.
• Installation on plastic pipe requires special considerations in selections & installation. See the nelson heat
tracing systems design guide for details in design and selection.
Scheduling
The installation of the electric heat tracing needs to be coordinated with the piping, insulation, electrical and
instrument groups. It should begin only after the majority of mechanical construction is complete. Pressure
testing of the pipe and installation of the instruments should be complete prior to the start of the heater cable
installation.
Pre-Installation Check
Walk the piping system and plan the routing of the heater cable. Use this check to verify completion of
instrumentation and mechanical work. All coatings (paint, etc.) must be dry before attempting the heater cable
installation.
Heater Handling
• Use a reel holder to roll out the heater cable.
• Keep the cable strung loosely, but close to the pipe being traced. This will avoid interference with supports
and other equipment.
• Leave an extra 305-457mm (12-18”) of heater cable at all power connections, tee splices and end seal
connections to facilitate easy working of the connections.
• ADDITIONAL HEATER CABLE IS REQUIRED ON VALVES, PIPE SUPPORTS AND OTHER
EQUIMENT. See the installation detail section for exact lengths and method of installation.
• When handling the heater cable, avoid pulling it over or installing against sharp edges.
• Do not kink or crush the cable, including walking on it or driving over it with equipment.
Heater Cable Location
The heater cable may be installed in either straight runs or spiraled around the pipe. Spiraling is generally
used when a limited number of cable types are available.
6. Straight Tracing
When straight tracing is used, install the heater cable on the lower quadrant of the pipe. This helps prevent
physical damage to the heater cable from falling objects and being walked on.
Alternate Locations
120°
Install heater cable at the
4 or 8 o'clock positions
Figure 2
Spiraling
Spiraling increases the length of heater cable installed per foot of pipe. Installed cable length = Pipe Length
X Spiral Factor.
The following example and table will allow you to determine the correct pitch for each pipe size and spiral
factor:
PITCH (P)
in inches
Example: When using .43m (1.4ft) of heater cable on102mm (4”)
IPS pipe, the Pitch (P) would be 356mm (14”)
Figure 3
Table I
Spiral Pitch Table (Inches)
SPIRAL FACTOR
Pipe Size
(feet of heater cable per foot of pipe)
(IPS)
1.1
1.2
1.3
1.4
1.5
1.0
NR
NR
NR
NR
NR
1.5
NR
NR
NR
NR
NR
2.0
17
NR
NR
NR
NR
2.5
20
14
NR
NR
NR
3.0
24
17
13
NR
NR
3.5
28
19
15
13
NR
4.0
31
21
17
14
NR
4.5
35
24
19
16
14
5.0
39
26
21
18
15
6.0
46
31
25
21
18
8.0
59
41
33
28
24
1 inch = 25mm
7. Attachment
For regular installations, the heater cable may be attached with fiberglass tape. Plastic wire ties may also be
used, provided the plastic has a maximum temperature rating equal to or better than the system
requirements. The cable should fit snugly against the pipe and be secured at one 305mm (12”) intervals, as
shown in
Figure 4.
Fiberglass Tape
Aluminum Foil Tape
(AT-50)
305mm (12")
Figure 4
Figure 5
Notes:
1) To prevent possible damage to the heater cable, do not fasten with metal straps, wire, vinyl electrical tape
or duct tape.
2) Aluminum foil tape should only be used if specified by design. The foil is most often used on plastic pipe to
offset the insulate effect of the plastic. See the Nelson Heat Tracing Systems’ Design Guide for details.
See Figure 5 above.
Cutting the Heater Cable
Do not cut the cable until it is attached to the pipe. Confirm the allowances for terminations, connections and
heat sinks (valves, support, etc.) before cutting the cable. Heater cable power is not affected by cutting to
length. Protect all heater cable ends from moisture or mechanical damage if exposed for long periods of time.
Installation Details
Heater cables should be applied in a manner to facilitate the easy removal of valves and small in-line devices
without the removal of excessive thermal insulation or having to cut the heater cable. The best way to
accomplish this is to loop the cable. The amount of heater cable installed on each valve, hanger, etc. varies
with the pipe size and type of device. Table II gives the correct additional cable to be installed on each device.
8. Pipe Fitting Type
Pipe
Size
Flange
Pair
Vent &
Drain
Pipe
Support
Globe, Ball &
Butterfly Valves
Gate
Valve
.50
.30
1.0
1.0
1.0
1.0
.75
.30
1.0
1.5
1.0
1.5
1.00
.30
1.0
1.5
1.0
2.0
1.50
.30
1.0
2.0
1.5
2.5
2.00
.30
1.0
2.0
2.0
2.5
3.00
.30
1.0
2.0
2.5
3.0
4.00
.50
1.0
2.5
3.0
4.0
6.00
.80
1.0
2.5
3.5
5.0
8.00
.80
1.0
2.5
4.0
7.0
10.00
.80
1.0
3.0
4.5
8.0
12.00
.80
1.0
3.0
5.0
9.0
14.00
1.0
1.0
3.0
5.5
10.0
16.00
1.0
1.0
3.5
6.0
11.0
18.00
1.0
1.0
3.5
7.0
12.0
20.00
1.0
1.0
3.5
7.5
13.0
24.00
1.0
1.0
4.0
8.0
15.0
Notes:
1) Nominal pipe length in feet. Adders are for various in-line pipe fittings to compensate for greater areas of
heat loss.
2) Values above are based on area average of various fittings available, with the assumption that fitting
insulation will be equivalent to pipe insulation. The nominal length of tracer to be applied to a particular
fitting would be the value shown in this chart plus the flange-to-flange length of the fitting.
3) For a Flanged Valve Adder choose Valve Type then add one Flange Pair for total adder length.
The following figures show installation details for various typical situations:
Valve
Typical installation method
(may vary for different valve shapes)
Fiberglass Tape
Heater Cable
Figure 6
9. Elbow
Fiberglass Tape
Heater cable should be positioned on
the outside radius of all elbows on
51mm (2") diameter pipes & larger.
Flange
Heater Cable
Fiberglass Tape
Heater Cable
Figure 7
Figure 8
Shoe Support
Hanger Support
Side View
Bar Hanger
Heater Cable
Bar Hanger
Fiberglass Tape
Heater Cable
Fiberglass Tape
Pipe Shoe Support
Heater Cable
Bottom View
Heater Cable
Fiberglass Tape
Pipe Shoe Support
Do not clamp heater cable
under hanger bracket
Figure 9
Figure 10
10. !
WARNING:
Connecting bus wires together
will create an electrical short.
End Seal - LT-ME, LT-SE or LT-E
In-line splice under insulation (shown) LT-SS or LT-HSS. Above insulation PLT-BS or LT-BS.
Heater cable loop
Power Connection Kit - PLT-BC or LT-BC use with
cable power seal kit - LT-MP, LT-SP or LT-HSP.
Heater Cable
Fiberglass Tape
Pipe Clamps
Insulation
Tee splice under insulation (shown) - LT-ST or LT-HST
Above insulation - PLT-BY or LT-BY.
Note: Heater cable power connections and end seals are required for each heater cable. Heater
cable splices, tees, and thermostats are used as needed.
Figure 11
THERMAL INSULATION
Pre-Installation Checks
Inspect the heater cable and components for correct installation and possible damage. In particular, verify
that:
• The proper extra amount of heater cable has been installed at each valve, flange, pipe support,
etc. and that it is free from physical nicks, tears or gouging. Additional cable beyond the specified
amount at a heat sink is not a problem due to the self-regulation effect of the heater cable.
• Connections, splices and end seals are correctly installed, including cable seals at power
connection enclosures.
Installation
Check the thermal insulation type and thickness against the design criteria. Changes in insulation type or
thickness may require a different wattage heater cable. Verify that all pipe work, including wall penetrations,
fittings, etc. has been completely insulated.
11. Check the system to verify that:
• Insulation is not wet from rainfall prior to the application of waterproofing.
• Lap joints on vertical piping are properly overlapped - higher piece lapped over the top of lower
piece.
• Band seals are used at lap joints to prevent the ingress of water.
• All penetrations of lagging (valve stems, hanger rods, etc.) are properly water proofed.
• Irregular shaped items (i.e. pumps, etc.) are properly waterproofed.
To minimize potential damage to the heater cable, install the insulation as soon as possible. It is
recommended that another insulation resistance (megger) test be done after the insulation has been installed
to verify that the heater cable was not damaged during the insulation installation.
Marking
Install “Electric Trace” signs on alternate sides of the piping at regular intervals, as a warning to maintenance
personnel. Permanently mark the outside of the insulation lagging with the location of heater cable
components. This will facilitate maintenance in the event of a problem.
THERMOSTATS & SENSORS
Temperature sensitive applications will require the use of a thermostatic control. Selection of the proper
thermostat must consider voltage and amperage ratings of the device as well as the suitability of housing for
the environment (explosion proof, rain tight, corrosion resistance, etc.). Thermostat housing should be
mounted as close as possible to the power connection kit. It may be attached to the power connection kit
provided code requirements are met with regard to conduit connections seals, etc. To sense the coolest air
temperature, ambient (air sensing) thermostats should be mounted in the shade when possible. When using
pipe-sensing thermostats, the bulb (sensor) should be mounted on the opposite side of the pipe from the
heater, or as far away as is practical. This will allow the thermostat to sense the actual pipe temperature and
not be influenced by the heater temperature. Mount the bulb at least three (3) feet from the closest heat sink if
possible.
Moisture inside the enclosure will cause both corrosion and electrical shorting problems. The potential for this
type of problem, can be greatly reduced by:
• Proper sealing of all enclosures openings.
• Keeping enclosure cover closed and secured as mush as possible during installation sequence.
• Proper closing and sealing of the cover to prevent leaking into the housing.
• Use of a moisture proofing/electrical spray (aerosol) sealant on thermostat and electrical
connections (including all metal parts) at completion of installation.
• Connection and use of space heater if thermostat is so equipped. Do not de-energize space
heater during summer months.
ELECTRICAL REQUIREMENTS
Voltage Rating
Verify that the heater cable voltage rating is suitable for the service being used. 240 volt rated cables may be
used from 208 to 277 volts, with an accompanying change in power output. See Nelson Heat Tracing
Systems Design Guide for power correction factor. Voltage and wattage ratings are printed on the heater
cable.
12. Electrical Loading
Size over-current protective devices according to Nelson Heat Tracing Systems Literature/Design Guide. If
devices are other than standard thermal magnetic circuit breakers, consult factory.
Ground Fault Protection
Ground fault circuit breakers are required on all heater constructions per the 1996 National Electric Code.
Typically, 30ma trip devices are required due to the capacitive leakage of the heater cable construction.
Waterproofing
Moisture penetration of the electrical system is the single largest source of problems in a heater cable system
installation. Therefore, particular care must be given to the proper sealing of all electrical connections and
splices. Heater cable sealing kits will provide a proper seal for the heater cable itself, when used per kit
instructions. All other electrical connections (heater to power wiring, thermostat connections, panel and
breaker connections, etc.) should be sealed or moisture proofed in some fashion. Either mastic shrink tube or
an aerosol electrical insulative sealant should be used on all connections to reduce any moisture penetration.
The sealant will also reduce the potential for corrosion on exposed metal parts.
TESTING
Recommendations
Electrical tests are recommended at specific points in the receipt and installation of the heater cable. This
periodical testing is designed to prevent the expenditure of wasted labor in the even of damage to the
product. Installation costs of the cable and thermal insulation are much greater that the heater cable. Quick
identification of any heater cable damage is the most economic approach to an installation. An insulation
resistance test is recommended at the following point of the installation process:
• UPON RECEIPT of the heater cable
• BEFORE thermal INSULATION installation
• IMMEDIATELY AFTER thermal insulation installation
• As part of a PERIODIC MAINTENANCE program
Procedure
The insulation resistance test is used to check for damage to extruded jackets. Connections for the megger
are made as shown in Figures 12 & 13.
13. FOR HEATER CABLES WITH BRAID
Test from heating cable bus to braid
500 VDC MEGGER
Figure 12
Note: Test should use at least a 500 VDC megger. Do not use a megger with an excess of 2500 VDC.
Minimum acceptable readings should be 20 megohms per circuit, regardless of length.
FOR HEATER CABLES WITH BRAID AND OUTER JACKET
Test A - (solid lines) from heater cable bus wires to braid.
Test B - (dotted lines) from braid to metal pipe.
500 VDC MEGGER
Figure 13
A record should be kept of the readings taken from the time the cable is first installed on the pipe. A history of
the insulation resistance reading can be helpful in spotting moisture ingress into the electrical system (by
seeing a gradual decline in the insulation resistance or physical damage to the heater cable (sharp decline in
the insulation resistance). A sample record for this is shown in Figure 14.
14. Circuit Number
Heater Type
Circuit Length
Periodic Inspection Record
Freeze Protection Circuits Perform these checks as season
requiring use approaches.
Temperature Maintenance Circuits Perform these checks at least twice per year.
Maintenance Checks for _______________________ Month __________________ Year_____________
Visual inspection inside connection box
corrosion, moisture, etc.
Damage or cracks (leaks) in insulation
seals at valves, hangers, pumps, etc.
Heater cable properly connected and
grounded. Heater cable and connections
insulated from connection box.
Thermostat checked for moisture, corrosion,
set point, switch operation, and capillary
damage
Initial
Date
Initial
Date
Initial
Date
Set Point
Initial
Date
Reading
Initial
Date
Reading
Reading
Reading
Initial
Date
Initial
Date
Initial
Date
Remarks & Comments
Periodic Inspection Record Form
Megger tests performed at power
connection with both bus wires disconnected
from power wiring.
Circuit voltage at power connection.
Circuit amperage after 5 minutes
Pipe temperature at time amps were measured.
Watts/Ft.
Volts x Amps = w/ft.
feet
All connections, boxes, and thermostats
have been resealed.
End seals, covered splices and tees marked
On insulation cladding.
Figure 14
Periodic Inspection Record Form
The Periodic Inspection record Form may be used in one of two ways:
1) One sheet per circuit. - The results of periodic tests of a single circuit are posted in vertical
columns, beginning on the left and working toward the right. This allows easy comparison of test
values for up to seven test sequences on an individual circuit.
2) One circuit per column. - Test data for a single test sequence on as many as seven circuits can
be recorded on a single sheet.
15. START-UP
Heat-up Time
Heat-up capacity (the ability to heat the pipe and it’s contents rapidly) is not normally designed into the
system. Cold start-ups should allow adequate time for the pipe to come up to temperature.
Diversity Factor
If the electrical supply capability is limited, then a diversity factor may be used in a cold start situation (trying
to start the entire system up in very cold weather). This is accomplished by staggering the initial turn on of the
heater cable circuits to allow the inrush currents to occur in a sequential fashion rather than all at once.
OPERATION & MAINTENANCE
System Design, Installation & Documentation
The heater cable system must be properly designed, installed and documented. This documentation should
at least included line lists and location identification documentation. As built installation drawings provided the
optimum maintenance tool. Test records should also be considered as part of the system documentation
requirements. See Figure 15.
Preventive Maintenance
A preventive maintenance program is needed which will encompass both visual and electrical checks of the
system. These should be done not only before initial operation of the system, but also on a scheduled basis.
The checks should also be done after any maintenance has been performed.
Visual Inspections
• Thermal insulation - check weatherproofing for damage, missing seals, cracks or gaps in caulking and
mastic coatings, damaged or missing lagging. When damage does exist, the insulation will need to be
repaired or replaced, and then resealed. WET INSULATION HAS POOR INSULATING PROPERTIES,
THEREFORE THE INSULATION MUST BE KEPT DRY. If insulation has been damaged, check the heater
cable for damage - replace the damaged section.
• Inspect junction boxes, connection boxes and thermostats for corrosion, moisture or foreign matter.
• Tightness of electrical connections, proper electrical insulation of heater cable wires, adequacy of moisture
seal on electrical connections and that a minimum of one (1) inch of electrically insulated heater extends
above the grounding connection. No strands of the ground braid should extend above this connection.
• Check all thermostats or sensor capillary leads to verify they are tied back and shielded from physical
damage.
• Verify all enclosure, connection box, etc. covers are properly closed and that the thermostat is switching off
and on by measuring current flow in the circuit when the unit switches on. Reset the knob to the proper
temperature after completion of the test.
Frequency
Inspections should be made prior to the start of the freeze season on freeze protection systems. Process
maintenance systems should be checked on a frequent base, at least twice a year.
Personnel Training
Qualified maintenance personnel must be used to maintain the system. It is recommended that periodic
training programs be utilized to assist in keeping maintenance personnel up to date on equipment and
procedures.
16.
17. SYMPTOMS
PROBABLE CAUSE
2.
4.
Connection and/or
splices may be shorting
out.
5, 6.
6.
Physical damage to the
heater cable may be
causing a short.
7.
Wires connected at end
seal.
7.
Disconnect wires and perform a current
check for possible other damage.
1.
All of section A.
1.
All of section A.
2.
Excessive moisture in
connection boxes or
splices.
2.
Dry out and re-seal connections and
splices. Megger per Installation
Instructions (20 megohms min.) Work
on connections outside the thermal
insulation first, going to the below
insulation connections and seals after
the others have been eliminated.
3.
Circuit Breaker Trips
(Ground Leakage Type)
Defective circuit breaker
5.
B.
Start-up at too low temp.
4.
Circuit Breaker Trips
(Standard)
Circuit breaker
undersized
Circuit oversized
3.
A.
1.
CORRECTION
1, 2, 3.
Re-establish what the current loads are
going to be and resize the breakers.*
Nick or cut in heater or
power feed wire with
moisture present.
3.
Locate and repair or replace damaged
heater cable or power wire.**
Replace circuit breaker.
Locate and repair incorrect connections,
splices, or damaged sections of heater
cable.** Megger per installation
instructions.
*Check to see if existing power wire sizing is compatible with larger sized breakers.
**To locate shorting problems, follow these steps:
1) Visually inspect the power connections and splices that are outside of the thermal insulation for proper
installation.
2) Check around the valves, pumps, and any area where there may have been maintenance work done,
for visual indications of damage.
3) Look for crushed or damaged insulation lagging along the pipe.
4) Inspect heater cable splices under the thermal insulation.
5) If you have not located the problem by now, you will have to isolate one section of the heater cable at
a time until you determine the general area of damage. First, isolate by disconnecting any tees or
splices then remove insulation from that area until the specific damage is found. For long runs of
cable, it may be necessary to cut the cable in half to isolate the shorted section.
18. SYMPTOMS
PROBABLE CAUSE
CORRECTION
Power output is zero or
lower than rated.***
1.
Low or no input voltage.
1.
Repair electrical supply lines and
equipment.
2.
C.
Circuit is shorter than design
shows.
2.
Check routing and length of heater cable
(use “as-builts”), and recalculate power
requirements.
a. Connect and recheck the power.
a.
b.
Splices or tees may not
have been connected.
Heater cable may have
been severed.
b.
Locate and repair the damaged
heater cable. Recheck the power.
3.
Re-crimp using correct procedure.
Control thermostat is wired in
the opened position.
4.
Rewire in the normally closed position.
5.
Pipe is at an elevated
temperature.
5.
Check pipe temperature and recalculate
the output.***
6.
Heater cable has been
exposed to excessive
moisture.
7.
Heater cable has been
exposed to excessive
temperatures.
1.
Insulation is wet.
1.
Remove and replace with dry insulation
and insure proper weatherproofing.
2.
Insufficient heater cable was
used on valves, supports, and
other heat sinks.
2.
Splice in additional heater cable but do not
go over maximum circuit length.
3.
Thermostat was set incorrectly
3.
Reset the thermostat.
4.
Power output appears
correct but pipe
temperatures are below
design value.
3.
4.
D.
Improper crimping causing a
high resistance connection.
There are thermal design
inconsistencies.
4.
Check with the local or factory
representatives for design conditions.
Modify as recommended.
6, 7.
Replace the heater cable.
*** The power output on lower resistance heater cables is temperature sensitive and requires a special
procedure to determine it’s value.
1) Check the pipe temperature under the thermal insulation.
2) Allow heater cable to stabilize for 10 minutes and then measure the current.
3) Calculate the power (watts / ft.) of the heater cable by multiplying the current by the input voltage and
dividing by the actual circuit length, I x V / Ft. = Watts / Ft.
4) Compare this measured value to the power output curves for the heater cable at the measured pipe
temperature. If the heater cable’s actual output is substantially below the theoretical output, the bus
wire interface with the core has been damaged by the fault current and the cable must be replaced.
This is not a highly accurate method of analysis, so use discretion in comparing theoretical and actual
values.
19. HEAT TRACE INSTALLATION RECORD
1.
Circuit No. _______________________________
2.
Receiving Documentation
Item
Date _____________________________________________
DESIGN
ACTUAL
A.
_______________________
_______________________
B.
3.
Cable Type
Cable Length
_______________________
_______________________
Receiving Testing
Date _____________________________________________
A.
Check for physical damage
O.K. ___________________
Damage_________________
B.
Continuity Check
Check for continuity between power leads.
O.K. ___________________
Open ___________________
C. 500VDC min., 2500VDC recommended,
megger check between leads and
sheath, 20 megohms min.
D. Lot No.
4.
Megohms _________________________________________
No. ______________________________________________
Post Installation Testing
Date _____________________________________________
A.
O.K. ___________________
B.
500VDC min., 2500VDC recommended,
megger check between leads and
sheath, 20 megohms min.
Megohms _________________________________________
C. Visually Check Cable Installation Prior to
Release for Thermal Insulation.
Visual Check O.K. __________________________________
Final Testing and Commissioning
Date _____________________________________________
A.
Circuit approved for testing by client.
Approved _________________________________________
B.
5.
Continuity Check
Check for continuity between cold leads.
500VDC min., 2500 VDC recommended,
megger check between leads and
sheath, 20 megohms min.
Megohms _________________________________________
C. Energized Testing
(all test data to be within 10% of design data)
Open ___________________
DESIGN
ACTUAL
1.
_______________________
_______________________
2.
Initial Current
_______________________
_______________________
3.
Current after 15 minutes of operation
_______________________
_______________________
4.
Current after 30 minutes of operation
_______________________
_______________________
5.
6.
Circuit Voltage
Pipe temperature
_______________________
_______________________
_______________________
_______________________
Circuit Acceptance
This circuit has been tested and documented in accordance with the above itemized data. This circuit by:
Contractor _____________________________________
Date _________________________________________
Client _________________________________________
Date _________________________________________
The Heat Trace Installation Record can be used to monitor the initial installation and check out process. This
form can be used in conjunction with the Periodic Inspection Record for shown in Figure 14.
Figure 15
Tel: +44 (0)191 490 1547
Fax: +44 (0)191 477 5371
Email: northernsales@thorneandderrick.co.uk
Website: www.heattracing.co.uk
www.thorneanderrick.co.uk