Freeze Protection: Heat Tracing

Electric heat tracing is used in many process industries to maintain process fluids at the desired
temperatures. It is important to understand the requirements of the application as well as each

heat-tracing technology’s capabilities and limitations before selecting a specific heat-tracing
technology for the application.
Manufacturers have developed various heat-tracing cable technologies that are suited for certain
applications. The range of electric heat-tracing technologies available on the market vary with
respect to their maximum maintain temperature and their maximum circuit length capabilities.
At a high level, the technologies are categorized as series resistance or parallel resistance. The
parallel-resistance technologies have advantages such as being able to be cut to length, field
terminable, flexible and usually available off the shelf. The series-resistance technologies have
advantages of being able to be used for longer circuit lengths from one power source.
A look at five types of heat-tracing applications will demonstrate some of the key characteristics
and requirements that can help users select the most appropriate technology. These are most
commonly encountered in the industrial sector and usually have unique needs.
1. Freeze Protection
The main purpose of a freeze-protection system is to prevent fluids such as process water, drain
water and fire water lines from freezing in pipes. A plant does not necessarily need to be located
in the extreme, remote cold regions of the world to experience freezing temperatures.
Temperatures can easily drop below 32°F (0°C) overnight and put the process in jeopardy if the
pipes are not properly insulated or heat traced.
Parallel self-regulating technology is well suited for this The main purpose of a
application. Self-regulating heating cables incorporate a heating freeze-protection system is to
element made of polymer mixed with conductive carbon black. prevent fluids such as
This special formulation creates an electrical path for conducting process water, drain water
current between the parallel bus wires along the entire cable and fire water lines from
length. In each heating cable, the number of electrical paths freezing in pipes.
between the bus wires changes in response to temperature
fluctuations. Simply put, as the surrounding temperature decreases, the heating cable increases
its current flow to provide heat to the pipe, tank or vessel. Conversely, as the temperature
increases, the heating cable reduces its current flow to provide less heat because it is not needed.
This self-regulating behavior is important for freeze-protection applications because it enables

energy-efficient and cost-effective solutions for freeze protection. For freeze-protection
applications, typically tight temperature control is not required, and a group of electric heat-trace
circuits is controlled by a single ambient-sensing controller or thermostat. Once the ambient
temperature falls below the preset temperature, the heaters are fully powered. The self-regulating
heaters adjust their power output in response to their immediate ambient conditions and save
energy. The self-regulating behavior also results in more uniform pipe temperatures than other
technologies.
Self-regulating cables can be cut to length, so the wattage is not affected by the cable length. The
cut-to-length feature is important because the pipe length in the field may be different than
originally designed. The cut-to-length feature enables a true off-the-shelf offering for urgent
needs.
Although most water lines are maintained at 35 to 40°F (2 to 4°C), for freeze-protection
applications, you want to be able to choose a self-regulating cable that can maintain process
temperatures up to 150°F (65°C) and can withstand intermittent exposure temperatures up to
185°F (85°C).
2. Process Temperature Maintenance without Steam

Exposure
With process temperature-maintenance applications, there is usually a need for viscosity control
of certain fluids such as fuel oils, acids and fertilizers at higher temperatures beyond freeze-
protection applications. These maintain temperature requirements typically range from 140 to
230°F (60 to 110°C). Self-regulating technology can still be used in this case. However, because
the maintain temperatures are higher, the heat losses are high in these applications. Hence, it may
make more sense to choose a cable that meets the temperature requirement and provides more
power output — up to 10, 15 or even 20 W/ft. This will allow users to have fewer runs of cables
while producing more heat for your application.
3. Process Temperature Maintenance with Steam Exposure

In some freeze-protection and process temperature-maintenance applications, the heat-tracing
cable is exposed to higher temperatures than the maintenance temperature when steam is used to
clean the pipes. In these applications, the cable not only needs to meet the maintain temperature
requirements but also the exposure temperature. Although the steam-cleaning temperature
exposure typically is for short term, it can damage the cable.
In other freeze-protection and process temperature-maintenance applications, the process

normally operates at temperatures higher than the maintain temperature. In such cases, the
heating cable needs to withstand these normal operating temperatures over the longer term.
In these applications, self-regulating technology is a preferred method of heat tracing. In addition

to the benefits already cited, in these applications, using self-regulating cables results in lower
cable-sheath temperatures, which is critical for hazardous area applications. Users should be able
to specify a cable with maintain temperatures up to 250°F (120°C) and maximum exposure
temperature of 420°F (215°C). The key is for the cable to be able to withstand the higher steam
temperatures.
There are some high maintain temperature applications — sulfur, various fuel oils and lubes,
waxes, resins and certain plastics, for example — where the fluid must be maintained at
temperatures greater than 250°F (120°C) and the process could run up to very high temperatures
such as 500°F (260°C). For such applications, power-limiting heaters could be a good choice.
These heaters have some of the same characteristics of a self-regulating cable such as flexibility,
parallel circuitry and cut-to-length construction. In addition, they have higher maintenance and
exposure temperature capabilities.
4. High Temperature Heat Tracing

Some applications such as asphalt or bitumen have a requirement for very high maintenance
temperatures. Mineral-insulated (MI) technology is well suited for such applications because the
cable can withstand maintain temperatures up to 1022°F (550°C) and exposure temperatures up
to 1200°F (650°C). MI construction consists of conductors embedded in a highly dielectric
magnesium-oxide insulation surrounded by a seamless metal sheath. This allows the cable to be
rugged and to withstand harsh environments and cold climates. Power outputs can go as high as
61 W/ft.
5. Long-Line Heating
Long-line heat-tracing applications are required when circuit lengths from 1,000 feet (300
meters) up to several miles are powered from a single power point. They are needed to heat long
pipelines for freeze protection or for viscosity control and temperature maintenance of certain
fluids. Applications include:
• Transfer lines between processing plants.
• Storage facilities needing to transfer product to and from tank farms.
• Loading and unloading facilities at piers for ocean transport vessels.
• Loading and unloading facilities at depots for rails and trucks.
Manufacturers have developed specialized technologies that can be used to heat trace long circuit
lengths from a single power source. To choose the appropriate technology, you still need to
determine the process requirements, including:
• Circuit lengths.
• Power outputs.
• Type of fluids.
• Pipe materials.
• Insulation type and thickness.
• Field labor costs.
• Temperature requirements within the project.
The long-line heat-tracing systems typically are engineered systems. Many variables can be
customized to provide the most cost-effective and reliable solution for a specific application.
Skin-effect heat-tracing systems (STS) are well suited for extremely long pipelines. STS are
custom engineered heat-management systems that can be designed for circuit lengths up to 15
miles (25 kilometers); power outputs up to 49 W/ft (150 W/m); and to withstand maintain
temperatures up to 390°F (200°C) with exposure temperatures up to 480°F (250°C).
Self-regulating products also are available that can be used for long-line heating, but they are
limited to a few thousand feet of circuit lengths. Polymer-insulated cables can also be used up to
12,000 feet of circuits. They offer advantage of field terminations, flexibility and high maintain
and exposure temperatures.
The key point is to avoid limiting your options by specifying one particular type of technology
for all applications. Understanding what your application requirements are will help you choose
the most suitable heat-tracing technology for your specific application.

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Electric heat tracing is used in many process industries to maintain process fluids at the desired

temperatures. It is important to understand the requirements of the application as well as each

This self-regulating behavior is important for freeze-protection applications because it enables

2. Process Temperature Maintenance without Steam

3. Process Temperature Maintenance with Steam Exposure

In other freeze-protection and process temperature-maintenance applications, the process

In these applications, self-regulating technology is a preferred method of heat tracing. In addition

4. High Temperature Heat Tracing

• Transfer lines between processing plants.

• Storage facilities needing to transfer product to and from tank farms.

• Loading and unloading facilities at piers for ocean transport vessels.

• Loading and unloading facilities at depots for rails and trucks.

• Insulation type and thickness.

• Field labor costs.

• Temperature requirements within the project.

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