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general informaTion

use of the manual

This Installation and Maintenance manual applies to Pentair Thermal

Management Mineral Insulated (MI) series resistance heating cable systems

installed on thermally insulated pipes and vessels and associated equipment.

In particular it refers to mineral insulated (MI) series heating systems, which

feature a specific power output depending on various design parameters,

in particular, cable length and voltage. This manual provides general

information and shows an overview of the most common installations and

applications on MI as well as typical examples. In any case the information

provided for specific projects will take precedence over this manual. In case of

conflicts, please contact your Pentair Thermal Management representative.

Pentair Thermal Management offers two different cable constructions for

electrical heat-tracing purposes: single conductor cables, which are typically

laid in loop configurations and dual conductor cables, which are typically laid

in single runs.

figure 1: Typical cable construction

Various types of the mi bulk heating cables are available:

HCC/HCH: Copper sheathed MI heating cables

HDF/HDC: Cupro-nickel sheathed MI heating cables

HSQ: Stainless steel sheathed MI heating cables

HAx: Alloy 825 sheathed MI heating cables

HIQ: Inconel sheathed MI heating cables

figure 2: Typical heating unit designs

Design type b

Single conductor

Heating

conductor(s)

Insulation

(magnesium oxide)

Single-conductor cable

Dual-conductor cable

Metal sheath

Potted seal

Heating cable length

Hot/cold joint

Cold lead cable

(standard 2 m)

300 mm

Flexible

tail length

Gland

Содержание Mi Series

Страница 1: ...Mineral Insulated MI Series Heating Systems Installation Maintenance and Operation Manual Thermal management EN PyrotenaxMI IM DOC586 R4...

Страница 2: ...eating cable installation 9 Components selection and installation 23 Temperature control and limitation 24 Thermal insulation and marking 27 Power supply and electrical protection 31 System testing 32...

Страница 3: ...ating cable system dual conductor Junction box MI cold lead cable single conductor Circuit identification tag Hot cold joint MI cold lead cable dual conductor Hot cold joint Circuit identification tag...

Страница 4: ...ase contact your Pentair Thermal Management representative Pentair Thermal Management offers two different cable constructions for electrical heat tracing purposes single conductor cables which are ty...

Страница 5: ...installation inspection operation and maintenance must be in accordance with the standards IEC 60519 IEC 62086 EN 50019 and EN60079 7 where applicable Other local requirements and national electric co...

Страница 6: ...formation must also be provided about the T rating and temperature data relevant to the application max sheath temperature data to enable the correct representation of data on hazardous area tags atta...

Страница 7: ...ors 1 1 1 Maximum voltage U0 U 300 500 V Maximum withstand temp 1 Brazed heating unit 200 C 400 C 450 C Laser welded heating unit 700 C Temperatureclassification T6 T3 T6 T2 T6 T1 Minimum cable spacin...

Страница 8: ...n aspects refer to our product datasheets or contact Pentair Thermal Management for assistance Check the design specification to make sure the correct heating cable is installed on each pipe or vessel...

Страница 9: ...Check materials received Inspect heating cable and components for in transit damage Review the heating cable design and compare the list of designed materials to the catalogue numbers of heating cable...

Страница 10: ...installed must be reasonably clean Remove dirt rust and scale with a wire brush and oil and grease films with a suitable solvent 3 2 Heating cable pulling and laying Heating cable pulling tips Figure...

Страница 11: ...ions Do not bend the cable within 150 mm of the hot to cold junction or remote terminations When installing MI and other constant wattage heating cables ensure that they do not overlap or cross Doing...

Страница 12: ...insulation thickness equivalent to the pipe insulation Please refer to the engineering documentation for project specific allowances 2 For pipes requiring more than one run of heating cable apply the...

Страница 13: ...cable to move freely under its own weight Other attachments like aluminium tape or glass tape may be used if specified in the design documentation The heating cables may be installed in straight multi...

Страница 14: ...s additional fixing devices as pre punched steel strips as shown below Figure 7 Typical cable layout on large surfaces like tank walls Figure 8 Fixing device pre punched metal strap Avoid sharp edges...

Страница 15: ...ultiple runs of cable are applied e g HARD SPACER SS 25MM 25M Various types of metal meshes are available for installation on tanks valves pumps e g mesh types FT 19 and FT 20 3 5 Typical installation...

Страница 16: ...wire can damage the heating cable surface over time use wire cloth band wherever possible Figure 11 Allowances for valves flanges and pipe supports Use tie wire or wire cloth band to hold cable to irr...

Страница 17: ...spacing of heating cables Hot cold joint Tie wire wire cloth band 17 Stainless steel pipe straps banding or tie wire wire cloth band etc Drip loop Hot cold joint Cold lead Junction box 150 mm Insulati...

Страница 18: ...for specific heating cable length needed MI heating cable Apply tie wire wire cloth band or other appropriate fixing material to hold MI heating cable in place Stainless steel pipe straps banding tie...

Страница 19: ...el pipe straps banding tie wire or wire cloth band typical MI heating cable MI heating cable is applied to outside radius of elbow Flange Heating cable Apply tie wire or wire cloth band to hold heatin...

Страница 20: ...clearly states other values also refer to page 11 figure 5 Figure 21 Dummy supports 20 Insulation Dummy leg Pipe shoe Heating cable Stainless steel pipe straps banding tie wire or wire cloth band Stai...

Страница 21: ...tes other values also refer to page 11 figure 5 Cover the heating cable with metal foil or equivalent before applying insulation to ensure the cables do not become trapped in the insulation General no...

Страница 22: ...t traced system that increase the surface area of the insulated pipe vessel or metallic fins that protrude out of the insulation e g supports will increase the overall heat loss These areas of increas...

Страница 23: ...uch that power cable and heating cable entries point downwards to avoid water ingress in the insulation Confirm junction box glands and stopping plugs are appropriate for application and fixed firmly...

Страница 24: ...cases where stabilized design is not applicable a con trol thermostat must ensure that the heating system under normal conditions will be switched off as soon as maintain temperature is reached An add...

Страница 25: ...tripping of safety limiters The setpoint might need to be adjusted accordingly Contact Pentair Thermal Management or the supplier of the limitation device in order to obtain detailed information conc...

Страница 26: ...of the fluid best location upstream in case of warmer inrushing fluid Impact of heat sinks such as supports etc best location away from heat sinks Accessability for maintenance purposes best location...

Страница 27: ...e insulations materials to be used Contact your Pentair Thermal Management representative if you have any questions Check that all pipes including fittings wall penetrations and other areas are comple...

Страница 28: ...les are mechanically protected and properly sealed at all places where they penetrate the insulation cladding Ensure that all places are sealed where thermostat capillaries sensor cables or support br...

Страница 29: ...The reference temperature for the sheath temperature calculations is the control limited set point and must be assured by the use of an alarm capable control unit making sure the heating element is sw...

Страница 30: ...y be significantly lower than during start up phase in particular for heating cables using conductors with a high temperature coefficient e g copper conductor Refer to the design information for prope...

Страница 31: ...ion When design results in a higher leakage current a maximum 300mA RCD may be used All safety aspects need to be proven Also refer to local standards Special regard should be given to electrical safe...

Страница 32: ...dic maintenance see Section 9 2 The heating circuit electrical resistance needs to be measured and compared to the design documentation before initial startup 8 2 Test method for insulation resistance...

Страница 33: ...testing The system should be tested regularly Check in advance whether hazardous area conditions allow insulation testing A hot work permit might be required When measuring the insulation resistance f...

Страница 34: ...oting WARNING Damage to cables or components can cause sustained electrical arcing or fire Do not energize heating cables that have been damaged Damaged heating cable or terminations must only be repa...

Страница 35: ...nstaller Project Site name Area name Value Remarks Date Initials Heating circuit number P ID number Drawing number Panel Circuit breaker number Heating cable type Cable length m loop 2 x m star 3 x m...

Страница 36: ...insulation works Insulation resistance test voltage V DC 1000 V DC Insulation resistance test before thermal insulation M 20 M Loop resistance ohms Average pipe temperature when measuring loop resist...

Страница 37: ...n cladding yes Thermal insulation material and thickness meet designed values yes Warning labels installed on cladding every 5 m and at components yes Insulation resistance test voltage V DC 1000 V DC...

Страница 38: ...eating cable is causing a direct short 6 Presence of moisture in terminations or connections 7 Damaged termination 8 Moisture in junction boxes B Symptom Circuit breaker trips Probable Causes 1 Circui...

Страница 39: ...e pipe Replace damaged sections of heating cable 6 Dry out cold lead and or connections and replace termination if necessary 7 Replace termination 8 Check and replace seals on junction boxes Correctiv...

Страница 40: ...robable Causes 1 No input voltage 2 Temperature controller wired in the normally open N O position 3 Limiter has tripped 4 Broken or damaged heating element hot cold joint end cap or broken tail 5 Wro...

Страница 41: ...d entering pipe Corrective actions 1 Repair electrical supply lines and equipment 2 Confirm wiring using the normally closed N C terminals so that contacts close with falling temperature 3 Check the r...

Страница 42: ...42...

Страница 43: ...43...

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