91923-SP-E-012 Rev.

D1 Electrical Surface / Heat Tracing

Contents

1. SCOPE ............................................................................................................................... 3
2. STANDARDS AND SPECIFICATIONS ............................................................................. 3
3. SITE ENVIRONMENTAL CONDITIONS .......................................................................... 4
4. PURPOSE .......................................................................................................................... 4
5. SELECTION ....................................................................................................................... 4
6. SERVICE CONDITIONS .................................................................................................... 5
7. DRAWINGS AND SCHEDULES ....................................................................................... 5
8. DESIGN ............................................................................................................................. 6
9 TEMPERATURE CONTROL, MONITORING AND ALARM .......................................... 10
10 HEATER CABLE CONSTRUCTION ................................................................................. 11
11 FACTORY TEST REQUIREMENTS.................................................................................. 11
12 TAGGING AND IDENTIFICATION ................................................................................ 11
13 MISCELLANEOUSMATERIALS ...................................................................................... 12

APPENDIX 1 ............................................................................................................................ 13

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91923-SP-E-012 Rev. D1 Electrical Surface / Heat Tracing

1. SCOPE

This Standard covers the design and fabrication of Electrical Surface / Heat Tracing

This includes the following resistance type heating cables : Stainless steel sheath, alloy series
resistance type, Fluorinated Ethylene-Propylene (FEP) insulated Temperature requirement
200ºC, parallel resistance type, Teflon insulated, and series resistance type.

Other systems such as Skin Effect Current Tracing (SECT), impedance heating, etc., which may
be used for very long lines are not included in this standard.

DEFINITIONS:

OWNER IRPC Public Company Limited

OWNER REPRESENTATIVE Means any person or entity contracted by OWNER to

provide services to OWNER such as PMT or Consultant.

EPC CONTRACTOR The Engineering, Procurement and Construction Contractor

selected or shortlisted by the OWNER to execute the Project.

EQUIPMENT Means all apparatus, machinery, spare parts and vehicles

intended to form or forming part of the permanent works.

PROJECT Means the IRPC Maximum Aromatics Project (MARS)

PROJECT SPECIFICATION A set of documented requirements to be satisfied by a

material, design, product, or service supplied or to be
supplied to MARS project.

VENDOR Means persons and firms with whom EQUIPMENT are

purchased by EPC CONTRACTOR.

PURCHASER Means EPC CONTRACTOR.

2. STANDARDS AND SPECIFICATIONS

The Electrical Surface / Heat Tracing and auxiliary equipment and materials shall conform to
the requirements of the latest issues and most recent revisions and amendments of the
standards listed in Appendix 1.

The electrical equipment and installation shall comply with in order of precedence:

1) Thailand Standards and Statutory Regulations

2) Engineering Standards and Specifications

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3) Licensor Specifications
4) OWNER Specifications
5) International Codes and Standards
D1
6) Manufacturer Standards

Other standard may be acceptable subject to OWNER/OWNER REPRESENTATIVE approval.

2.1 Engineering Standards and Specifications

The equipment shall comply with the engineering standards and specifications, but not
limited to the following:

91923-SP-E-001 Electrical Standards

91923-SP-G-001 Basic Engineering Design Data
91923-SP-M-529 Hot service insulation for piping and equipment

3. SITE ENVIRONMENTAL CONDITIONS

All equipment shall be suitable for installation on the IRPC MARS site.
Site environmental conditions shall be in accordance with 91923-SP-G-001 Basic Engineering
Design Data.

All surface heating tape and associated components shall be suitable for installation outdoors
in salt laden, coastal, tropical atmosphere 30 m above sea level.

4. PURPOSE
The purpose of electrical heat tracing is to maintain minimum specified process temperatures
under no-flow conditions in order to prevent freezing or condensation in piping, equipment,
and instruments.

5. SELECTION
The selected line for electrical heat tracing shall comply in accordance with following
information.

- Process Flow Diagrams number

- Line description number
- Line description size
- Line location line source
- Line location line destination

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91923-SP-E-012 Rev. D1 Electrical Surface / Heat Tracing

- Normal temperature ºC operating

- Maximum temperature ºC operating

6. SERVICE CONDITIONS

6.1 Basic Design Data

This standard is supplemented by design data that shall give the following information:

- Hazardous Atmosphere (Electrical area classification).

- List of lines to be electrically traced, with the maximum operating temperature

(including steaming-out of lines) and the minimum temperature to be maintained.

- List of instruments to be electrically traced, with the temperature to be maintained.

Process Flow Diagrams with the extent of electric tracing indicated.

- Any exceptions to this standard that are deemed necessary because of special
conditions.

7. DRAWINGS AND SCHEDULES

7.1 General

Drawings and schedules that completely define the tracing system are required in order to
evaluate the proposed designs and to facilitate subsequent maintenance and
troubleshooting.

7.1.1 Contents

Each heater cable shall be shown on an installation drawing (plan and elevations) and/or
isometric drawing and shall clearly indicate the following:

a) Process line and tracer identification numbers.

b) Location of temperature sensing element hot-cold junction, if applicable, and power

supply point.

c) Representation of all flanges, valves, tap lines, drains, pumps, instruments, and
equipment nozzles.

d) Diagrammatic indication of heater style and interconnection of multiple heaters, i.e.,

series, parallel, or combination thereof.

e) Amount of tracing to be installed on pumps and other irregular shaped objects other
than valves and flanges.

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f) Junction boxes included for sectionalising tracing for maintenance such as at pumps
and removable spools.

7.1.2 Electrical Diagrams

Electrical diagrams shall include typical schematics for hook-ups utilised, and panel board
schedules (or single line diagrams) showing branch circuit loads.

7.1.3 Schedule

A heater cable schedule shall be prepared at least information as following.

a) Heater identification.
b) Line or equipment reference
c) Line size
d) Insulation type and thickness
e) Operating temperature; control (maintained) temperature
f) Number of heaters and conductors
g) Conductor size
h) Hot and cold section length
i) Voltage
j) Watts/m
k) Total heater wattage and current
l) Connection source and drawing number
m) Column for remarks

8. DESIGN
D1 8.1 REQUIREMENT

8.1.1 GENERAL

8.1.1.1 The system shall use 3-wire 100-ohm platinum Resistance Temperature Detectors (RTDs) for
temperature sensing.

8.1.1.2 The system shall allow multiple RTD temperature inputs per heat tracing circuit for
monitoring, control and fault indication. Each sensor shall be configurable for control,
monitoring or high temperature cut-out or combinations thereof.

8.1.1.3 The controllers shall support single and 3 or 4 wire 3-phase heating loads of up to 60 Amps
D1
and 600 VAC with ground-fault detection.

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8.1.1.4 Ground-fault detection equipment approved to UL1053 shall be integral to the controller. The
GF feature shall provide independent alarm and trip settings.

8.1.1.5 Each control module shall provide an individual fail-safe dry-contact alarm relay that may be
connected to an external annunciator.

8.1.1.6 The controllers shall be available to ramp the output from 0-100% over time to reduce heater
inrush currents.

8.1.1.7 The controller shall be capable of testing the heating circuit at a user defined interval. The
test shall terminate immediately upon detection of any unsafe condition (Ground fault, High
Temperature) and generate the appropriate alarms.

D1 8.1.2 SYSTEM

The system shall be compatible with all types of heating cables and capable of performing
the following functions:
a) Controlling and monitoring pipe temperatures.
b) Providing alarms in the event of low or high pipe temperature, low or high heater
current/Voltage, high ground-fault current,ground-fault trip, relay failure, and sensor
failure.
c) Providing local and remote alarm annunciation.
d) Control unit shall be approved for hazardous areas, safety temperature limiter shall be
approved as SIL 2 device.
e) The control unit shall have a dedicated control electronics per heating circuit and high
capacity of 25A with a hybrid switch.
f) Interfacing with DCS systems by modbus TCP/IP.

8.2 Waranty

The design of equipment for installation shall be warranted for continuous operation
under the loading and service conditions stated and capable of maintaining the process
temperatures at the specified conditions.

All materials, components, and accessories shall be guaranteed against defects in material
and workmanship for a period of five years following installation.

8.3 Design Basis

The electric heat tracing system design shall comply with the relevant IEC standards.
The heat tracing system design shall be based upon the minimum design temperature to be
maintained by electric tracing at the design site climatic conditions and minimum ambient
temperature (11ºC) specified.

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8.4 Heat Transfer Calculations

Heat loss from pipes shall be calculated from Supplier's standard insulation tables, using
125% of the calculated required Watts to cover the assumptions made, normal windage and a
factor of safety. As an alternative, the heat loss may be derived from Supplier’s heating cable
graphs. These graphs shall be corrected for the actual "K" factor at the mean temperature of
the insulation used. Supplier's computer programs based on actual job data may also be used
for heat transfer calculations.

Insulation thickness shall not be less than that specified in Hot Service Insulation for Piping
and Equipment (91923-SP-G-001).

Additional thickness may be used as required to obtain an efficient and economical system.
Unless otherwise specified, insulation material shall be assumed to be calcium silicate.

Heat transfer calculations shall not be based on the use of heat transfer cement.

8.5 Heater Cable Design

All heater cables shall have an overall grounded metal covering.

Heater cables shall not be designed for spiral wrap installations on pipe.

8.6 Control

Heater cables or systems shall be thermostatically controlled except where omitted by

specific statement. In general, temperature-sensing bulbs shall be located on the pipelines,
preferably on the downstream end of product flow.

Ambient sensing bulbs may be utilised on low-density heat loads.

8.7 Piping and Equipment

8.7.1 The heat tracing system design shall be based on ambient conditions and shall include:

a) Minimum Wattage 125% of the calculated required wattage. This excess is provided to
cover heat transfer efficiency, assumptions made in calculations, and safety factor.

b) Minimum design temperature to be maintained in heat-traced piping, i.e. the

temperature shown on the flow diagrams for process piping and for water piping.

c) Heat tracing requirements for minimum temperature and for thawing (if required).

8.7.2 Pipes that may simultaneously contain flowing and non-flowing products shall not be traced
by the same heating circuit or controlled by a single thermostat.

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8.7.3 Pipes that are located indoors and outdoors and/or above and below grade shall not be
combined under the same heating circuit or controlled by a single thermostat.

8.8 Instrument Piping and Enclosers

8.8.1 Instrument piping requiring heating shall be traced in the same manner as process piping.

8.8.2 Instrument enclosures requiring heating shall be provided with electric strip heaters and
separate thermostats.

8.9 Power Supply and Distribution System

8.9.1 Heat tracing systems shall be supplied from their own distribution panels. Preferred heater
cable voltage shall be 220AC Volts.

8.9.2 The power supply devices shall support single and 3 or 4 wire 3-phase heating loads of up to
D1
60 Amps and 600 VAC with ground-fault detection.

8.9.3 Heat tracing distribution panels shall be provided with a main breaker. Individual circuit
breaker units shall be provided with a positive lockout means in the "OFF" position. Circuit
breaker positions shall be identified. Distribution panel and enclosure construction shall be
suitable for outdoor installation at local and safe area.

8.9.4 Distribution panels shall have a minimum initial spare capacity of 15% or as specified for the
particular installation.

8.9.5 The distribution panels of heat tracing system shall be fed from relevant plant MCCs.

8.9.6 The circuit breaker and an earth leakage detector, 30mA is preferred shall be provided by
means of electrical protection for power supply and distribution system.

8.10 Cable Length

8.10.1 High losses at flanges, valves, pipe shoes etc. shall be compensated by limited additional use
of heating cable. The use of aluminium tape or heat transfer cement over the heating cable
and/or added thickness of insulation shall also be considered in the design.

8.10.2 Extra cable shall be provided for pumps to maintain the same temperature as the line under
no-flow conditions. When specified, such heaters shall be easily disconnected within junction
boxes provided at the pump piping connection.

8.10.3 The pump heating cable shall be controlled from the line thermostat. Total heated cable
length shall be the pipeline length plus the extra length required to compensate for the
components noted above. The above total shall be increased by 5%, to determine purchase
requirements.

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8.10.4 Heating cables longer than 60 meters shall be fabricated in multiple sections with cold
junction splices made in an accessible junction box having drain and breather fittings.

8.10.5 The voltage drop for the supply cabling between the heat tracing distribution board and the
most distant junction box feeding a trace tape, shall be limited to a maximum of 2.5%

9 TEMPERATURE CONTROL, MONITORING AND ALARM

9.1 Temperature Control

All heaters shall be controlled to maintain the specified temperature. The controllers shall be
kept as simple as possible. The sensing probes shall be selected with due regard to the
maximum operating temperature. Controllers shall be one of the following types described
below.

9.1.1 Thermostats

The thermostat set point shall be at the maintained temperature indicated on the electrical
data sheets and shall be adjustable. Contacts shall be arranged to close on falling
temperature. Thermostats for pipe line and instrument tubing installation shall be capillary
tube type with switch enclosures suitable for the area classification. Where the heater current
exceeds the rating of the thermostat contacts, the thermostat shall be used as a pilot device
for a magnetic contactor rated to control the heater current. The thermostats shall be located
so as to be easily accessible for maintenance.

9.1.2 Thermistor - Solid State

The controller will consist of a temperature-sensing probe with a thermistor and solid-state
relay. Each solid-state relay shall be capable of being adjusted over a temperature range by
means of a potentiometer.

Thermistors for pipeline at instrument tubing installation shall be bead type probe or equal.
Resistance tolerances shall be 5% maximum.

9.1.3 High Temperature Limiters

High temperature limit switches shall be used as a backup for the temperature controller in
cases where overheating the line must be prevented, such as caustics, acids, etc.

Switch action shall provide heater shut down and at the same time actuate a local alarm.

9.2 Monitoring and Alarm

D1 Central monitoring is required. When central monitoring of the heating system is required,
careful consideration shall be given to the type of heating cable to be monitored, and
centralising the monitoring with the power distribution system. Where possible, the alarm
system, monitoring and power distribution shall be housed in a single enclosure. The
enclosure shall be suitable for the area classification.

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10 HEATER CABLE CONSTRUCTION

Electrical heat tracing cables shall be either parallel resistance (constant wattage or self-
limiting) heating cables; or series resistance heating cables.

10.1 Parallel Resistance Type Cables

10.1.1 Constant wattage cable shall consist of two parallel copper bus wires – FEP insulated,
nichrome wire heating element FEP insulation, tinned copper braid.

10.1.2 Self-limiting cables shall consist of two parallel bus wires with matrix heating core FEP
insulation, tinned copper braid.

10.2 Series Resistance Type Cables

10.2.1 Heater cable shall be insulated with magnesium oxide Mineral Insulation (MI) with an overall
inconel sheath.

10.2.2 Each heating cable circuit shall consist of a heating (hot) section and a lead-in(cold) section,
and shall be factory fabricated to the required length. The lead-in cable shall be connected to
the heater cable by a factory made joint.

10.2.3 Hot end terminations and hot-cold junctions shall utilise silver brazing at conductor
connections. The metallic sleeve joining the sheath/sleeve shall be silver soldered to produce
a liquid tight joint.

10.2.4 The line side of the cold section shall have a factory applied liquid tight connection. The
mineral insulation shall be sealed from moisture with an epoxy compound.

10.2.5 Each cable shall be capable of field bending to an inside radius of 6 times the cable diameter
without damage.

11 FACTORY TEST REQUIREMENTS

Each shipped length, whether a bulk or individually fabricated circuit, shall comply with IEC
60079-30-2.

12 TAGGING AND IDENTIFICATION

Each heater assembly (Mineral Insulated cable only) shall be factory tagged with a
permanently stamped, legibly written, stainless steel metal tag securely attached to the
junction box end of the "cold" section. The metal tag shall state the heater number, wire type
and size as indicated on the electrical data sheet, "hot" section length, voltage and amperes.
These tags shall state U.L. or F.M. listed.

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13 MISCELLANEOUSMATERIALS

13.1 Fasteners

13.1.1 Glass or polyester tape shall be applied along the heater cables for securing them to piping
having operating temperatures below 148ºC. Above 148ºC, black enamelled or stainless steel
straps, 1/2" wide, shall be used every 300mm, to hold down the cable.

13.1.2 Tie wire to fasten the heater cable to irregular surfaces shall be 1.3mm², galvanised, annealed
iron wire.

Junction boxes, conduit fittings and other miscellaneous electrical materials required to
complete the heat tracing system shall be in accordance with the electrical standard (91923-
SP-E-001).

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APPENDIX 1
LIST OF APPLICATION STANDARDS

All relevant IEC and BRITISH standards including the following specific standards.

IEC & BS Subject

IEC 60079-30-1 Electrical apparatus for explosive atmospheres part 30-1: Electrical
resistance trace heating - General and Testing Requirements

IEC 60079-30-2 Electrical apparatus for explosive atmospheres part 30-2: Electrical
resistance trace heating - Application Guide for Design, Installation and
Maintenance

IEC 60079-14 Electrical installation in hazardous area

All heating cables and ancillary materials for installation in a classified area, shall be approved for
the purpose by Underwriter's Laboratories or Factory Mutual Laboratories.

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