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Design Guide

Self-regulating trace heating systems
for hazloc / industrial applications

Design guide

Self-regulating trace heating systems
for pipes and tanks in hazardous locations
with BARTEC self-regulating trace heaters

Summary of Contents for HSB

Page 1: ...de Self regulating trace heating systems for hazloc industrial applications Design guide Self regulating trace heating systems for pipes and tanks in hazardous locations with BARTEC self regulating trace heaters ...

Page 2: ......

Page 3: ... 26 Accessories 27 Temperature sensors 29 Spare parts 30 Installation 31 Preparation 31 Required tools equipment 31 Unrolling the trace heater 31 Installation on pipes 31 Fastening 32 Trace heater routing 32 Installation on tanks and vessels 34 Tests and commissioning 36 Measurement of the insulation resistance 36 Acceptance test and acceptance test report 37 Commissioning 37 Operation 37 System d...

Page 4: ...gulating property prevents overheating which would cause damage to the trace heater Even crossing or overlap ping with other trace heaters or other portions of the same trace heater are possible high power output low temperature high temperature low power output The trace heaters are fixed equipment heating systems for pipes in ordinary and hazardous areas Thanks to the parallel design the trace h...

Page 5: ... in this manual must be followed WARNING Risk of fire or electrical shock Follow these guidelines to avoid personal injury or material damage All electrical systems and installations must comply with BARTEC GmbH requirements and be installed in accordance with the relevant electrical codes and any other applicable national and local codes BARTEC GmbH and many international electrical and safety co...

Page 6: ...ations Each trace heater is marked with a product code that contains relevant information as shown in the following example Trace heater family PSB 07 5801 MSB 07 5804 HSB 07 5803 HTSB 07 5819 Trace heater output in W m 10 C Outer jacket CT 5 Y A or 2 fluoropolymer CR 6 polyolefin Voltage rating 1 120 Vac nominal 2 230 Vac nominal Trace heater output in W ft 10 C Example A trace heater that bears ...

Page 7: ...8 26 9 31 5 39 7 48 4 56 5 75 10 4 11 7 13 1 15 0 17 2 19 9 21 8 25 4 30 0 34 1 41 6 49 2 57 6 100 14 8 16 8 18 8 21 5 24 6 28 5 31 2 36 4 42 9 48 8 59 6 125 19 8 22 4 25 1 28 7 32 9 38 1 41 6 48 7 57 3 40 25 2 6 2 9 3 2 3 6 4 1 4 7 5 1 5 9 6 9 7 8 9 4 11 0 12 8 16 0 19 4 22 6 35 3 7 4 2 4 6 5 2 5 9 6 8 7 4 8 6 10 0 11 3 13 6 16 0 18 6 23 2 28 1 32 8 45 5 0 5 5 6 2 7 0 7 9 9 1 9 8 11 4 13 3 15 0 1...

Page 8: ...72 0 0567 Cellular glass ASTM C552 15 Type II 1 46 0 0481 Rigid cellular urethane ASTM C591 13 Type I 0 83 0 0275 Foamed elastomer Grade 2 ASTM C534 14 1 29 0 0425 Expanded perlite ASTM C610 15 2 06 0 0678 Pyrogel XT ASTM C1728 12 0 56 0 0206 Example Pipe diameter DN25 Insulation thickness 20 mm Insulation material calcium silicate Minimum ambient temperature 20 C Maintain temperature 25 C We obta...

Page 9: ...the narrow axis 25 mm Do not bend on the narrow axis 25 mm Do not bend on the narrow axis 35 mm Do not bend on the narrow axis Cable weight 10 9 kg 100 m 12 5 kg 100 m 12 5 kg 100 m 14 6 kg 100 m Heater dimensions fluoropolymer outer jacket polyolefin outer jacket 11 6 x 5 6 mm 10 2 x 4 8 mm 10 2 x 4 8 mm 12 1 x 5 4 mm 11 8 x 5 8 mm n a n a n a Temperature classes5 10 15 W m T6 26 33 W m T5 10 15 ...

Page 10: ...ve heat loss as calculated in Step 2 Find the required power output in the graph that contains the trace heater type and voltage you use see tables on pages 11 to 13 If the required power output is between 2 trace heater types choose the one with the higher rating If the required power output exceeds the output of the trace heater with the highest rating you may Use 2 or more trace heaters on the ...

Page 11: ...data subject to change without notice No claims for damage arising from alternations errors or misprints shall be allowed Page 11 46 Table D PSB 230 V For MSB trace heaters see page 12 For HSB trace heaters see page 13 For HTSB trace heaters see page 14 ...

Page 12: ...05 2019 EHT 432712 Notice Technical data subject to change without notice No claims for damage arising from alternations errors or misprints shall be allowed Page 12 46 Table E MSB 230 V For PSB trace heaters see page 11 For HSB trace heaters see page 13 For HTSB trace heaters see page 14 ...

Page 13: ...data subject to change without notice No claims for damage arising from alternations errors or misprints shall be allowed Page 13 46 Table F HSB 230 V For PSB trace heaters see page 11 For MSB trace heaters see page 12 For HTSB trace heaters see page 14 ...

Page 14: ...05 2019 EHT 432712 Notice Technical data subject to change without notice No claims for damage arising from alternations errors or misprints shall be allowed Page 14 46 Table G HTSB 230 V For PSB trace heaters see page 11 For MSB trace heaters see page 12 For HSB trace heaters see page 13 ...

Page 15: ...applications in the oil industry fluoropolymer outer jacket Trace heater catalog no that meets the required power output and environmental conditions 10PSB2 CT Type 07 5801 2335 Determination of the required trace heater length The total required trace heater length is determined by taking into account the trace heater length for piping as well as allowances for valves pumps flanges pipe supports ...

Page 16: ...o of pumps pump allowance value no of valves valve allowance value no of flanges flange allowance value no of pipe supports pipe support allowance value 1 2 1 m 2 0 6 m 6 0 3 m 24 0 3 m 12 3 m Step 9 Add all lengths allowances together Add the lengths for piping as determined in step 6 and allowances as determined in step 7 and step 8 together to obtain total required trace heater length Example r...

Page 17: ... m 30 C 195 m 160 m 100 m 82 m Circuit breaker size Start up temperature MSB trace heaters Operating voltage 230 Vac 3 MSB MSB 10 5 MSB MSB 15 8 MSB MSB 25 10 MSB MSB 30 12 MSB MSB 40 16 A 10 C 200 m 165 m 120 m 85 m 70 m 25 C 175 m 117 m 88 m 69 m 49 m 50 C 165 m 110 m 80 m 65 m 45 m 20 A 10 C 235 m 189 m 140 m 114 m 82 m 25 C 235 m 152 m 120 m 92 m 66 m 50 C 225 m 144 m 114 m 86 m 62 m 32 A 10 C...

Page 18: ...nt of a trace heating system varies greatly especially at valves pipe supports and other heat sinks It is therefore seldom possible to achieve very tight temperature control The temperature of a heat tracing system is based on ambient temperature and can vary by as much as 20 C when the system is uncon trolled You can choose between 2 approaches for temperature control Ambient sensing control Ambi...

Page 19: ... Recommendations for selecting the appropriate control equipment Base your selection on the number and type of trace heating circuits to be installed the type of control you need and the area classification TABLE K Control Equipment Selection Recommendations Heating circuit type Application Control options Suitable BARTEC control product Quantity required Self regulating heating circuits on pipes ...

Page 20: ...a monitoring system that reliably reports physical damage to the trace heating system which is a common failure mode For sensitive applications add end of line monitoring with either a high profile end seal or an end of line light The end of line light gives the most direct visual feedback on system performance Conventional system layout with monitoring panel and ground fault equipment protection ...

Page 21: ...erature control High profile end seal ELS 200 1 per circuit Example The application is temperature maintenance 25 C of a pipe in a hazardous area The maintenance team wants to be able to quickly locate the end seal appropriate monitoring equipment ELS 200 Step 13 Finalize the required Materials List BOM Accessories including the glass tape for attachment and pipe straps for the components and elec...

Page 22: ...ows a sample heating circuit including typical components The following pages list compatible components for BARTEC Self regulating trace heating systems in hazardous locations The respective instal lation instructions are included in the scope of delivery PBS splice kit Trace heater Electrically traced warning label Pipe insulation 3rd party Power supply 3rd party End of line lamp High profile en...

Page 23: ...c Fluoropolymer outer jacket suitable for exposure to organic chemicals Maximum maintain temperature power on 110 C Maximum withstand temperature power off 130 C Approved for Zone 1 and Zone 2 areas See data sheet for full details W m 10 W m 15 W m 25 W m 30 W m 40 W m Catalog No 3MSB2 CT 5MSB2 CT 8MSB2 CT 10MSB2 CT 12MSB2 CT Order No 320845 320846 320847 320849 320851 Part No 07 5804 210Y 07 5804...

Page 24: ...ipe straps per stand required For a complete list of kit contents and approvals see data sheet PBS 300 E Catalog No PBS 300 E Order No 430205 Part No 27 54P2 4211 1210 PBS 300 E10 Catalog No PBS 300 E10 Order No 430206 Part No 27 54P2 4311 3B10 PBM 200 E E10 Multiple power entry con nection kit on pipe For connection of up to 3 trace heaters inside a junction box Includes a mounting stand for on p...

Page 25: ...lation Select this thermostat when the control unit is located in a hazardous location rugged ness is important and the control device is integrated with the power connection and is to be mounted off the pipe For a complete list of temperature range options kit contents and approvals see datasheet Sensor temperature range 20 C to 50 C Catalog No BSTW 300 E50 Order No 345675 Part No 27 6DF2 5232 12...

Page 26: ...or connection of a trace heater Includes a mounting stand for on pipe installation The kit is approved for Zone 1 and Zone 2 areas Available with a Green or Red lens 2 pipe straps per stand required For a complete list of kit contents and approvals see data sheet Green lens Catalog No ELL 200 E Order No 430215 Part No 27 54E2 4212 F210 Red lens Catalog No ELL 200 A Order No 407406 Part No 27 54E1 ...

Page 27: ...on all pipes including stainless steel required during preparation of power limiting trace heat ers 12 mm x 50 m per roll Minimum installation temperature dry surface 10 C Maximum withstand temperature 200 C Catalog No GT 164 Order No 392328 Part No 02 5500 0047 Tip Refer to the following table to estimate the required number of tape rolls for your installation for fixation of trace heaters on pip...

Page 28: ...atalog No SSC 06 Order No 126228 Part No 03 6510 0209 Stainless steel strapping ribbon buckles 3 4 for bulk installation of mounting stands on pipes etc Note tensioning tool is required SST 34 30 19 mm x 30 m per roll SSB 34 100 pack of 100 pcs SST 34 30 Catalog No SST 34 30 Order No 126227 Part No 03 6510 0208 SSB 34 100 Catalog No SSB 34 100 Order No 126228 Part No 03 6510 0209 Tensioning tool f...

Page 29: ...FR Order No 120300 Part No 05 2144 0703 Russian Catalog No HTWL RU Order No 207439 Part No 05 2144 0860 Polyester fixing straps for installation of trace heaters on tanks and vessels for tank diameters up to 3 m 19 mm x 850 m on full roll Catalog No PFS 850 Order No 117932 Part No 03 6500 0100 Tensioning buckle for use with the PFS 850 polyester fixing straps Catalog No TB 075 Order No 117939 Part...

Page 30: ...l lengths are available for special order PT100 with 300 mm sensor and 2 m lead Catalog No PT 100 300 Order No 289768 Part No 27 7125 1333 0220 PT100 Ex e enclosure Catalog No PT 100 Ex e Order No 122629 Part No 07 5103 9024 Spare parts On pipe cable gland kit and end seal Spare parts kit for use with PBS PBM 200 kits for replacement of damaged or lost parts Catalog No CAK SRS Order No 434968 Part...

Page 31: ...500 Vdc and a maximum testing voltage of 2500 Vdc Unrolling the trace heater WARNING Risk of short circuit and or material damage Keep the trace heater ends dry before and during installation Unroll the required trace heater in a straight line and cut to the correct length Cut off the trace heater ensuring a straight cut Do not bend or pinch the trace heater or pull it over sharp edg es Installati...

Page 32: ...flat flush fit over the whole length If necessary reduce the distances between the fixing points Apply the pipe s insulation according to the manufacturer s in stallation instructions Apply an electrical warning label every 3 m on a clearly visible place Trace heater routing On fittings valves etc you should leave a sufficiently large trace heater loop to ensure that the equipment is easily access...

Page 33: ...to change without notice No claims for damage arising from alternations errors or misprints shall be allowed Page 33 46 Installation on valves Installation on flanges Installation on pipe supports Installation on pressure gauges Installation on pumps 15 16 14 12 13 ...

Page 34: ...e allowed Page 34 46 Installation on tanks and vessels For tank diameters of up to 2 m the trace heater is attached using polyester fixing straps and tensioning buckles To fasten the fixing straps thread the polyester straps through the tensioning buckle as shown and pull the ends of the straps At first install fixing straps around the beginning and end of the tank and fasten them with slight tens...

Page 35: ...or material addition for the bases Align the trace heater exactly and fix it firmly to the bases and the cylinder using additional fixing straps To avoid damage to the trace heater make sure that the fixing straps are not tightened too firmly It should be possible to move the trace heater slightly under the fixing straps The distances between the fixing straps should not exceed 250 mm Finally plac...

Page 36: ...ce heater Connect the positive lead to both trace heater bus wires simultaneously Turn on the megohmmeter and set the voltage to 500 Vdc Apply the voltage for 1 minute The meter reading should stabilize Rapid changes in the reading indicate a breakdown of the insulation Record the insulation resistance value in the Inspection Record Repeat the measurement at 1000 and 2500 Vdc Test 2 Conducting the...

Page 37: ...ts of the system are operated within the operating data specified by BARTEC This applies particularly to observation of the maximum temperature Operation within these operating data is a precondition for possible later warranty claims System documentation Complete documentation must be carried out for each system from the project planning stage through installation and commissioning up to periodic...

Page 38: ...ained experienced maintenance personnel It is recommended that maintenance personnel is updated on new developments in application technology and maintenance Repairwork on piping or thermal insulation Ensure that all safety procedures and precautions in the area for repairs are followed Take care that the heat tracing system is not damaged during repairwork on the pipes or insulation After complet...

Page 39: ...ion instructions Identify the cause and remedy the fault e g ensure that trace heater bus wires are not twisted together Dry the components For junction boxes be sure that the cable gland is correctly installed and sealing properly Ground fault protection is disengaged Trace heater damaged Moisture in the components Ground fault protection defective Replace the trace heater at the point where it i...

Page 40: ...______ m _____________________ m _____________________ m Serial No connection kit Serial No junction box Voltage _____________________ V _____________________ V ______________________ V ______________________ V Current Switch on opera tion ___________ __________ A ___________ __________ A ___________ __________ A ___________ __________ A Output power trace heater __________________ W m ___________...

Page 41: ...00 7N0012 05 2019 EHT 432712 Notice Technical data subject to change without notice No claims for damage arising from alternations errors or misprints shall be allowed Page 41 46 EC Declaration of conformity ...

Page 42: ...ustrial Self regulating trace heating systems 01 5800 7N0012 05 2019 EHT 432712 Notice Technical data subject to change without notice No claims for damage arising from alternations errors or misprints shall be allowed Page 42 46 ...

Page 43: ...01 5800 7N0012 05 2019 EHT 432712 Notice Technical data subject to change without notice No claims for damage arising from alternations errors or misprints shall be allowed Page 43 46 ...

Page 44: ...ustrial Self regulating trace heating systems 01 5800 7N0012 05 2019 EHT 432712 Notice Technical data subject to change without notice No claims for damage arising from alternations errors or misprints shall be allowed Page 44 46 ...

Page 45: ...r the product replace the product or refund the purchase price paid for the product This warranty gives you specific legal rights and you may also have other rights which vary by country state or province Except as specifically provided otherwise in this limited product warranty the BARTEC Group General Terms and Conditions shall apply General terms and conditions BARTEC Global Terms and Condition...

Page 46: ...ustrial Self regulating trace heating systems 01 5800 7N0012 05 2019 EHT 432712 Notice Technical data subject to change without notice No claims for damage arising from alternations errors or misprints shall be allowed Page 46 46 ...

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Page 48: ... Volkvovsky Business Center Office 401 141006 MYTISCHI MOSCOW REGION Russia Tel Fax 7 495 249 0542 mail bartec russia ru www bartec russia ru BARTEC MIDDLE EAST BARTEC Middle East HB 01 Near Round About 8 Jebel Ali Free Zone P O Box 17830 DUBAI United Arab Emirates Tel 971 4 8876 162 Fax 971 4 8876 182 bartec bartec ae www bartec de BARTEC SAUDI ARABIA Bartec MIDDLE EAST LLC 31952 AL KHOBER P O Bo...

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