What is an electric heat trace system?
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, renewable energy systems, 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
Parallel Constant Watt Heating Cables
Skin Effect Heat Tracing System
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
Genesis Network™
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
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
- 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
Installation, Maintenance, & Troubleshooting Guide:
https://content.thermon.com/pdf/ca_pdf_files/PN50207-EHT-Installation.pdf
Heat Trace for the Refrigeration Industry https://content.thermon.com/pdf/au_pdf_files/TEP0066AP-EHT-Maintenance-Troubleshooting.pdf
Maintenance and Troubleshooting Guide: https://content.thermon.com/pdf/au_pdf_files/TEP0186AP-Heat-Tracing-Refrigeration.pdf
Complex Piping Design Guide for Self Regulating Heat Cable
https://content.thermon.com/pdf/us_pdf_files/TEP0013-Complex-Piping-Design.pdf
FLX Design Guide:
https://content.thermon.com/pdf/ca_pdf_files/CPD1008-FLX-Design.pdf
HPT Heat Cable Specification Guide
https://content.thermon.com/pdf/uk_pdf_files/TEP0011U-HPT-Spec.pdf
USX Heat Cable Specifications Flyer
https://content.thermon.com/pdf/us_pdf_files/TEP0246-USX-Flyer.pdf
For a Comprehensive list of heat trace guides and video resource material, visit our Thermon Resource Center