Heat Trace
Electric heat trace, or surface heating, is the application of heat to an external surface that compensates for heat lost due to changes in temperature in ambient surroundings. In cold or freezing conditions, heat tracing systems help stabilize surface temperatures of pipes or vessels via electric trace heaters to protect the flow of liquids inside and reduce the risk of equipment damage. Electric trace heaters also maintain process temperatures for substances that can solidify or become overly viscous within a system such that it impedes the progress of critical processes. Freeze protection and temperature maintenance are the most common applications for electric trace heating. This versatile and powerful thermal technology is used in renewable energy systems, oil and gas processing, petrochemical/chemical processing, power generation, transportation, food and beverage production, environmental monitoring and more.
How Heat Trace Works
There are multiple components within an electric heat trace system that work in concert to make maintaining and adjusting temperatures across even complex systems possible. One key component is the heat trace cable, an electrical element that is fitted along the length of a pipe or other equipment surface. Once the heat cables are securely fixed to the length of the pipe, both are covered with layers of insulation and metal jacketing to prevent heat loss.
A well designed heat trace system should ensure that the heat trace cable’s input matches the pipe or equipment’s heat loss. Additional factors impacting heat loss include ambient temperature, wind speed and insulation. Thermon has a large variety of electric heat trace cables and can help you determine which cables meet your heat tracing needs.
Thermon Electric Heating Cables and Systems
Self-Regulating Heating Cables
Self-regulating heat trace cables allow automatic adjustments to heat output in response to the heat loss conditions along the entire circuit. When ambient temperature drops causing heat loss in the equipment, the cable responds by increasing its heat output. When ambient temperature rises and temperatures in the equipment increase, the cable output will decrease. Self-regulating cables can be used for tracing requirements on piping, vessels and equipment as well as commercial applications such as snow and ice melting for tracks, roof, gutter and concrete applications. There are several different types of self-regulating cables that range in maintain temperature from 65°C (150°F) to 200°C (392°F).
Power Limiting Heating Cables
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. A coiled resistor alloy heating element 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. The maximum maintain temperature for HPT cable is 210°C (410°F).
Parallel Constant Watt Heating Cables
FP cables provide consistent and reliable heat outputs regardless of circuit length and are designed to provide freeze protection or process temperature maintenance to piping, tanks and equipment. Because FP cables are not subject to the inrush current associated with self-regulating heating cables, the need for oversizing power distribution equipment is eliminated. The parallel resistance configuration allows the cable to be cut to length and terminated in the field with easy-to-use Thermon supplied kits. The maximum maintain temperature for FP cable is 65°C (150°F).
Skin Effect Heat Tracing System
A ThermTrac system provides a cost-effective alternative to conventional resistance heat tracing on long pipelines by eliminating the need for an extensive power distribution system. A pipeline up to 25 kilometers (15 miles) long can be traced from a single power point. The versatility of the system makes it ideal for temperature maintenance, freeze protection and heatup
applications.
applications.
Series Constant Watt Cables
Series resistance constant watt heating cables, such as TEK, HTEK and MIQ are used for temperature maintenance or freeze protection along lines where circuit lengths exceed the limitations of parallel resistance heating cables and high maintain temperatures or high temperature exposure is required. High performance HTEK and TEK series cable can be manufactured with prefabricated circuit lengths up to 3658 meters (12,000 ft). Maximum maintain temperature for TEK is 101°C (215°F) and for HETK maintain temperature is 204°C
(400°F.)
MIQ’s resistance configurations are available to provide tracing for pipes up to 1.6km (1mile). Thermon’s MIQ mineral insulated cables are manufactured using Alloy 825, a high nickel/chromium alloy ideally suited for high temperature service with a maximum maintain temperature of 500°C (932°F.) The circuitry of constant watt series cables provides consistent power output along the entire length of the cable with no voltage drop concerns associated with parallel tracer constructions and can be powered from a single power supply point. These high-performance series resistance constant watt cables can provide tracing for
pipes.
Electric Heat Thermostats
Electric heat thermostats are critical for proper operations in trace heating applications, and depending on the required temperature control and requirements for the controller itself, electrical or mechanical thermostat options are available.
An electronic controller uses temperature sensing devices such as RTDs and thermocouples. Electronic controllers are available for field or panel mount applications and provide communication features for remote control and monitoring. Examples of electronic controllers include RTD-100 and TraceNet ECM.
Mechanical thermostats have bulb and capillary style sensors that use expanding fluid to open or close contacts depending on temperature changes. Mechanical thermostats such as E7-25325 are rugged, less expensive than electronic thermostats and do not require any form of
control.
Control and Monitoring Systems
Control and monitoring systems play an essential role in heat tracing applications ranging from freeze protecting water lines to maintaining elevated process temperatures. While mechanical thermostats have been used successfully for many heat tracing applications, a more complete control and monitoring solution may be necessary for critical heat tracing applications. Advancements in technology have made electronic control and monitoring units both more cost effective and more reliable. These systems conserve energy, extend system life, and ensure accurate temperatures are maintained, for reduced operating cost and increased plant reliability.
Genesis Network™
Thermon’s Genesis Network provides full operational
awareness and supervisory control of heat trace systems with low total installed cost and maximum flexibility. The comprehensive Genesis Network connects all heat trace controllers through a network of adaptive, self-healing wireless mesh with a user-friendly interface that monitors the
entire system. Performance data, diagnostics and alarms are delivered in real time to management and maintenance teams, accessible from the control room, in the field or remotely from any PC or tablet. Components in the Genesis Network include the Genesis Controller and the Genesis Duo.
awareness and supervisory control of heat trace systems with low total installed cost and maximum flexibility. The comprehensive Genesis Network connects all heat trace controllers through a network of adaptive, self-healing wireless mesh with a user-friendly interface that monitors the
entire system. Performance data, diagnostics and alarms are delivered in real time to management and maintenance teams, accessible from the control room, in the field or remotely from any PC or tablet. Components in the Genesis Network include the Genesis Controller and the Genesis Duo.
The Genesis Controller monitors individual heat trace circuit performance offering a more complete monitoring and control solution for critical heat tracing applications. The Genesis Controller also features selectable control methods for each individual circuit, temperature sensor status identification, programmable “trip” set points, remote alarm acknowledgment and reset capabilities, and more.
The Genesis Duo is a dual-point heat trace temperature monitor and controller with a high temperature limiter. The Duo provides control and monitoring for one or two heat tracing circuits with input from up to two intrinsically safe RTDs per circuit. Native to the Genesis Network, the Duo requires no additional hardware to communicate with Thermon’s state-of-the-art supervisory management platform.
Designing Your Heat Trace System
Assembling an efficient heat trace system that is both economical and suitable for your heating needs can be complicated. There are many elements to consider, such as a wide selection of cable options in various wattage outputs, voltages, and jacket materials, heat sensors and accessories. The process can become complicated quickly. It is very important to consider specific heat calculations that are necessary to determine the proper cable, wattage and breaker sizes to ensure the system functions properly. Also, sensor placement can be critical for the proper operations in
trace heating applications. With all this in mind, the global experts at Thermon offer a wide variety of options to help ensure your heat trace project is a success.
Thermon provides world-class design software for your heat trace system design. Thermon’s CompuTrace design program provides the user with the capability of designing heat trace systems for instrument heating, vessels, tanks and pipe systems. Our sophisticated CompuTrace technology not only helps users create an outstanding project, but also generates reports and a quote-ready bill of materials. We also offer software automation options to assist in the development of an optimal heating system design using Thermon’s products
The Thermon Advantage
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Our world-class team of engineers is available to provide the ultimate solution to your heat process needs. At Thermon, we understand that every heat trace project is unique, from conducting comprehensive field studies to crafting high-quality, professional heat tracing system designs. We will work with you to consider which materials and accessories will best serve your specific needs and budget goals. With our highly skilled team and advanced software automation, you can be certain that our solutions will be coordinated and efficient.
Heat Trace Project and Engineering Services Include
Heat Trace Project and Engineering Services Include
- Field Study
- Quoting and
Estimating - Engineering
- Project
Management - Heat Trace System
Design - Power Distribution
System Design - Drawings/
Isometrics/ Specifications - Heat Trace Design
Products: CompuTrace
Reliable Support and Advice From the Industry
Experts
Not only do we provide outstanding industrial heating materials and custom-engineered solutions, but we also pride ourselves on offering expert advice and support. Whether it be for new installation or maintenance of an existing system, Thermon’s engineers are available to provide industry-leading expertise. We are dedicated to offering the best possible service and experience for our customers, and our engineering team is a vital part of that commitment. Whether you need help designing a new system or troubleshooting an existing one, Thermon’s engineers are here to help. Feel free to contact us anytime for help with your heat trace system
needs.
Browse Our Heat Tracing Products
Heat Trace Resources and Guides
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Click Any of the Links Below for More Information
Installation, Maintenance, & Troubleshooting Guide
Heat Trace for the Refrigeration Industry
Maintenance and Troubleshooting Guide
Complex Piping Design Guide for Self Regulating Heat Cable
For a Comprehensive list of heat trace guides and video resource material, visit our Thermon Resource Center
