Electric Heat Tracing

INSTALLATION PROCEDURES
Electric Heat Tracing
Complete Electric Heat Tracing System . . . Illustration A: Typical Heat Tracing Installation
A complete electric heat tracing system will typically include the
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following components1:
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1. Electric heat tracing cable2 (self-regulating, power-limiting, parallel
constant watt or series constant watt). 5

2. Power connection kit.

3. RTD sensor or control thermostat3.
4. In-line/T-splice kit (permits two or three cables to be spliced together).
5. Cable end termination.
6. Attachment tape (use on 12” intervals or as required by code
or specification).
7. “Electric Heat Tracing” label (peel-and-stick label attaches to insulation
vapor barrier on 10’ intervals or as required by code or specification).
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8. Thermal insulation4 and vapor barrier (by others).
The absence of any of these items can cause a system to malfunction or 6
represent a safety hazard. 7

Types of Heating Cables . . .

Self-Regulating Heating Cables:
BSX™ Self-Regulating Heating Cable (refer to Form TEP0067)
RSX™ Self-Regulating Heating Cable (refer to Form TEP0004)
KSX™ Self-Regulating Heating Cable (refer to Form TEP0072)
TSX® Self-Regulating Heating Cable (refer to Form TEP0006)
HTSX™ Self-Regulating Heating Cable (refer to Form TEP0074)
VSX™ Self-Regulating Heating Cable (refer to Form TEP0008)
Power-Limiting Heating Cable:
HPT™ Power-Limiting Heating Cable (refer to Form TEP0011)
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Parallel Constant Watt Heating Cable:
FP Parallel Constant Watt Heating Cable (refer to Form TEP0016)
Series Constant Watt Heating Cables:
TEK™ Series Constant Watt Heating Cable (refer to Form TEP0021)
HTEK™ Series Constant Watt Heating Cable (refer to Form TEP0022)
MIQ™ Mineral Insulated Heating Cable (refer to Form TEP0020)
Notes . . .
2 1
1. Illustration depicts a typical self-regulating heating circuit.
2. Ground-fault equipment protection is required for all heat tracing circuits.
3. Temperature control is recommended for all freeze protection and temperature maintenance heat
tracing applications.
4. All heat-traced lines must be thermally insulated.

The National Electric Code and Canadian Electrical

Code require ground-fault protection be provided
for electric heat tracing .
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 INSTALLATION PROCEDURES
The following installation procedures are suggested guidelines Applications . . .
for the installation of a Thermon electric heat tracing system1.
1. Electric heat tracing cables are used for freeze protec-
They are not intended to preclude the use of other methods
tion or temperature maintenance of piping, tanks and
utilizing accepted engineering or field construction practices.
instrumentation.

Upon Receiving, Cable . . . 2. Heat tracing cables may be installed in ordinary (nonclassi-
fied) and hazardous (classified) locations depending on the
1. Upon receiving heating cable, check to make sure the proper
specific cable options and approvals2.
type and output have been received. All flexible cables have
the catalog number, voltage rating and watt output printed Before Installing Cable . . .
on the jacket.
1. Be sure all piping and equipment to be traced is completely
2. Visually inspect cable for any damage incurred during installed and pressure tested.
shipment. The heating cable should be tested to ensure
electrical integrity with at least a 500 Vdc megohmmeter 2. Surface areas where heat tracing is to be installed must be
(megger) between the heating cable bus wires and the reasonably clean. Remove dirt, rust and scale with a wire
heating cable metallic braid. IEEE 515 recommends that the brush and oil and grease films with a suitable solvent.
test voltage for polymer insulated heating cables be 2500
Vdc and 1000 Vdc for MI Cable. Minimum resistance should Initial Installation . . .
be 20 megohms. (Record 1 on Cable Testing Report.) 1. Begin temporary installation at the proposed end-of-circuit
location and lay out heating circuit on the pipe, allowing
extra cable for the power connection and for any splice
locations3. Refer to Illustration B for temporary installation.
2. Make heating cable allowances for valves, flanges, elbows
and supports as per the applicable drawings and table on
pages 3 and 4 of these installation procedures.
Notes . . .
1. Termination kits to fabricate a heat tracing circuit are not addressed in detail in these
installation procedures. Refer to installation instructions included with cable termina-
Connect the positive lead of the megger to the cable bus tion kits or contact Thermon for specific instructions to fabricate heating cable.
wires and the negative lead to the metallic braid. 2. For information on specific cable types and options, refer to Types of Heating Cables
on page 1.
3. See product specifications sheet for heating cable minimum bend radius.

Illustration B: Temporary Installation

Proposed End-of-Circuit
Proposed Power Location
Connection Location

Pipe Support

Cable Allowance for

In-Line Heat Sinks

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 Electric Heat Tracing
Installation on Elbows, Supports and Flanges . . .
1. Install heating cable in accordance with Illustrations C, D length of the pipe support plus an additional 15” (40 cm) of
and E below. Secure heating cable to piping using attach- heating cable.
ment tape. 4. Flanges: Allow cable to be looped around pipe on each side
2. Elbows: Locate the cable on the outside radius of an elbow of and adjacent to the flange. Heating cable must maintain
to provide sufficient heat to compensate for the added pip- contact with flange when bending around pipe flanges to
ing material. Secure the cable to the pipe on each side of compensate for additional heat loss.
the elbow with attachment tape. 5. Refer to the product specifications sheet for minimum bend
3. Pipe Supports: Insulated pipe supports require no additional radius for the specific cable type. Do not exceed bend
heating cable. For uninsulated supports, allow two times the radius when completing installation.

Illustration C: Pipe Elbow Illustration D: Pipe Support

Attachment Tape
(Typical)

Heating Cable Heating Cable

Attachment Tape
(Typical)

3” Min.
(8 cm)

Support
Illustration E: Pipe Flange 3” Min. Length
(8 cm)
Attachment Tape
(Typical)

Heating Cable

Circuit Layout on Support

12” Max.
Note: Flange allowance will vary based on method of (30 cm)
insulating flange and adjacent piping.

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 INSTALLATION PROCEDURES
Installation on Valves and Pumps . . . Table 1: Valve and Pump Allowances
Valve Type Pump Type
1. Install heating cable in accordance with Illustrations F and Pipe Size
Screwed Flanged Welded Screwed Flanged
G below. Secure heating cable to piping using attachment
½” 6” 1’ 0 1’ 2’
tape.
¾” 9” 1’ 6” 0 1’ 6” 3’
2. Additional cable is required to provide extra heat at valves, 1” 1’ 2’ 1’ 2’ 4’
pumps and miscellaneous equipment to offset the increased 1¼” 1’ 6” 2’ 1’ 3’ 4’ 6”
heat loss associated with these items. Refer to Table 1 for 1½” 1’ 6” 2’ 6” 1’ 6” 3’ 5’
estimated cable requirements for installation on typical 2” 2’ 2’ 6” 2’ 4’ 5’ 6”
3” 2’ 6” 3’ 6” 2’ 6” 5’ 7’
valves and pumps.
4” 4’ 5’ 3’ 8’ 10’
3. Install heating cable on valves and pumps utilizing a looping 6” 7’ 8’ 3’ 6” 14’ 16’
technique (this allows the valve or pump to be removed if 8” 9’ 6” 11’ 4’ 19’ 22’
required). Crossing constant watt heating cable over itself 10” 12’ 6” 14’ 4’ 25’ 28’
should be avoided. 12” 15’ 16’ 6” 5’ 30’ 33’
14” 18’ 19’ 6” 5’ 6” 36’ 39’
4. Refer to the product specifications sheet for minimum bend 16” 21’ 6” 23’ 6’ 43’ 46’
radius for the specific cable type. Do not exceed bend 18” 25’ 6” 27’ 6’ 6” 51’ 54’
radius when completing installation. 20” 28’ 6” 30’ 7’ 57’ 60’
24” 34’ 36’ 8’ 68’ 72’
30” 40’ 42’ 10’ 80’ 84’

Illustration F: Typical Valve Detail Illustration G: Typical Pump Detail

Attachment Tape
(Typical)
Heating Cable

Heating Cable
Attachment Tape
(Typical) Heating Cable Serpentined on Pump

Heating Cable Serpentined on Valve

Circuit Layout on Valve Circuit Layout on Pump

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Electric Heat Tracing
Completing the Installation . . .
1. Begin final cable attachment by securing the end-of-circuit 4. Before making power connections, The heating cable
termination kit and working back toward the power supply. should be tested to ensure electrical integrity with at least
• Flexible heating cables are to be installed using attachment a 500 Vdc megohmmeter (megger) between the heating
tape. Circumferential bands of tape should be installed at cable bus wires and the heating cable metallic braid. IEEE
12” (30 cm) intervals to keep the cable in proper contact 515 recommends that the test voltage for polymer insulated
with the pipe. Refer to Table 2 below to calculate the num- heating cables be 2500 Vdc and 1000 Vdc for MI Cable.
ber of rolls of attachment tape required based on the pipe Minimum resistance should be 20 megohms. (Record 2 on
diameter1. Cable Testing Report.)

• MlQ mineral insulated heating cables are typically installed 5. Install power connection kit in accordance to the detailed
with stainless steel banding. These cables may also be in- installation instructions provided with the kit. (MIQ series
stalled with heat transfer compound and metal channels. resistance heating circuits are typically prefabricated at the
factory. Pipe-mounted junction boxes to complete a typical
• If applicable, refer to installation details provided with the MIQ circuit connection to power may not be supplied as
project drawings or contact Thermon for additional infor- part of the system.)
mation regarding installation.
6. Secure temperature sensor (if required) to pipe utilizing
2. In addition to the circumferential tape requirements, a attachment tape. Locate temperature sensor as shown in
continuous covering of aluminum foil tape may be required Illustration H.
when:
• Spray or foam urethane2 thermal insulation is applied. Notes . . .

• Heat tracing nonmetallic piping. 1. Table 2 assumes circumferential bands every 12” (30 cm) along the length of the pro-
cess piping.
• Design requirements dictate the use of aluminum tape to 2. Verify exposure temperature of heating cable versus curing temperature of insulation.
improve heat transfer.
3. Complete splice connections (if required) in accordance
with the installation instructions provided with the splice kit.

Illustration H: Heating Cable vs. Sensor Location Heating Cable

(Typical)

Pipe Wall

Temperature Sensor
(Typical)
Single Cable Installation Dual Cable Installation Triple Cable Installation

Table 2: Attachment Tape (Value Represents Approximate Linear Pipe Length Allowance Per Roll)
Pipe Diameter in Inches
Tape
Length ½"-1" 1¼" 1½" 2" 3" 4" 6" 8" 10" 12" 14" 16" 18" 20" 24" 30"
36 yd 130' 115' 110' 95' 75' 65' 50' 40' 35' 30' 26' 23' 21' 19' 16' 13'
60 yd 215' 195' 180' 160' 125' 105' 80' 65' 55' 50' 43' 38' 35' 31' 27' 22'

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 INSTALLATION PROCEDURES
Final Connections . . . Thermal Insulation . . .
1. Follow the circuit fabrication instructions for the specific 1. The need for properly installed and well-maintained thermal
cable type. Power connection and end-of-circuit termina- insulation cannot be overemphasized. Without insulation,
tion kits are designed for each type of cable; substitutions heat losses are generally too high to be offset by a conven-
should not be made. tional heat tracing system.

2. For ambient controlled power, the heating circuit should be 2. In addition to piping and in-line equipment such as pumps
connected directly to the switched power feed wiring. and valves, all heat sinks must be properly insulated. This
includes pipe supports, hangers, flanges and, in most cases,
CB valve bonnets.
L1 3. Regardless of the type or thickness of insulation used, a
protective barrier should be installed. This protects the
L2/N Ambient Sensing
NO
insulation from moisture intrusion, physical damage and
NC Thermostat helps ensure the proper performance of the heat tracing
system. Seal around all penetrations through the thermal
insulation.
4. After the installation of the thermal insulation and weather
COM barrier but BEFORE ENERGIZING THE HEATING CIRCUIT,
the megohmmeter test should be repeated. This should call
attention to any damage to the heating cable that may have
occurred during the insulation installation. (Record 3 on
Cable Testing Report)
Heat Tracing Heater 5. Apply caution labels to insulation weather barrier at required
Junction Box
intervals along pipe
(SPDT Thermostat Shown)
Final Inspection and Documentation . . .
1. It is recommended that the circuit be temporarily energized
3. For pipewall sensing thermostatic control, the heating circuit
so that the volts, amps, pipe temperature and ambient
is to be connected in series with the control contacts as
temperature may be recorded. This information may be of
shown in Illustration I. The pipewall sensing thermostat may
value for future reference and should be maintained for the
require more than one support point.
historical operating data log (Record 4 on Cable Testing
CB Report).
L1 2. Stabilized design can be used for self-regulating heating
Pipewall Sensing
L2/N Thermostat cables to assign a lower T-class through the use of the
Thermon CompuTrace software or Thermon Engineering.
NO NC
3. Stabilized design can be used for power-limiting and con-
stant watt heating cables without a limiting device to deter-
mine the T-class through the use of the Thermon Compu-
Trace software or Thermon Engineering.

COM 4. A sample historical operating data log form is included in

Heat Tracing Thermostat the Electric Heat Tracing Maintenance and Troubleshooting
Junction Box Sensor Guide, Thermon Form TEP0066).

Heater The National Electric Code and Canadian Electrical

Code require ground-fault protection be provided
for branch circuits supplying electric heat tracing.
(SPDT Thermostat Shown)

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 Cable Testing Report
1. Refer to Thermon Installation Procedures, FORM PN 50207, for general installation procedures, requirements and guidelines.
2. Upon receiving heating cable, check the cable to make sure the proper type and output have been received. All flexible cables
have the catalog number, voltage rating and watt output printed on the outer jacket.
3. Visually inspect cable for any damage incurred during shipment. The heating cable should be tested to ensure electrical integrity
with at least a 500 Vdc megohmmeter (megger) between the heating cable bus wires and the heating cable metallic braid.
IEEE 515 recommends that the test voltage for polymer insulated heating cables be 2500 Vdc and 1000 Vdc for MI cable
Minimum resistance should be 20 megohms.
(Record 1 on Cable Testing Report.)
A. Connect the positive lead of the megger to the cable bus wires.
B. Connect the negative lead of the megger to the metallic braid.
C. Energize the megger and record the reading. Readings between
20 megohms and infinity are acceptable. Readings below 20
megohms may mean the electrical insulation has been dam-
aged. Recheck the heating cable for physical damage between
the braid and the heating element; small cuts or scuffmarks on the outer jacket will not affect the megger reading unless
there was actual penetration through the braid and dielectric insulation jacket.
4. Once the installation is complete, but prior to installation of thermal insulation, recheck the heating cable with at least a 500 Vdc
megohmmeter (megger) between the heating cable bus wires and the heating cable metallic braid. IEEE 515 recommends that
the test voltage for polymer insulated heating cables be 2500 Vdc and 1000 Vdc for MI cable Minimum resistance should be 20
megohms. (Record 2 on Cable Testing Report.)
5. After the thermal insulation is installed, the megohmmeter test should be repeated. Minimum resistance should be 5 megohms.
(Record 3 on Cable Testing Report.)
6. After the thermal insulation is installed and power supply is completed, record the panel and circuit breaker information. Ensure
all junction boxes, temperature controllers, cable glands, etc. are properly secured. Set the temperature controller (if appli-
cable) to the manual setting and apply rated voltage to the heat tracing circuit(s) for 5 minutes. Record the ambient temperature,
measure and record the circuit(s) voltage and current. (Record 4 on Cable Testing Report.)

NOTE: To ensure the heating cable warranty is maintained through installation, the testing outlined on
this sheet must be completed on the installed heating cables, and the test results recorded and
mailed/faxed to:
Thermon Customer Service
100 Thermon Drive
San Marcos, Texas 78666
Fax: 512-754-2420

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 Cable Testing Report
make additional copies as required for each circuit.
Customer: Contractor:
Address: Address:

Phone No: Phone No.

Project Reference:

Record 1: Prior to Installation

Cable Type:
Reel Length:
Reel Number:
Insulation Resistance M Ohms:
Tested By: Date:
Witnessed By: Date:

Record 2: After Installation of Heating Cable

Insulation Resistance M Ohms:
Heater Length:
Heater Number:
Tested By: Date:
Witnessed By: Date:

Record 3: After The Thermal Insulation Is Installed

Insulation Resistance M Ohms:
Tested By: Date:
Witnessed By: Date:

Record 4: Final Commissioning

Panel Number:
Breaker Number:
Volts:
Ambient Temperature (deg. F):
Recorded Amps (After 5 Min.):
Tested By: Date:
Witnessed By: Date:

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 Printed in U.S.A.
© Thermon Manufacturing Co.
Form PN 50207-0606

The Heat Tracing Specialists®

www.thermon.com
With Design, Manufacturing, and Warehouse Facilities Worldwide.
Corporate Headquarters
100 Thermon Dr. • San Marcos, TX 78667-0609 • USA
Phone: 512-396-5801 • Fax: 512-396-3627 • 1-800-820-HEAT
www.thermon.com In Canada call 1-800-563-8461