Calcuation For Electrical Heat Tracing System: SUNGUN Copper Ore Heap Leaching Plant Project

National Iranian Copper Industries Company
Pyro and Hydro Metallurgy Programs
SUNGUN Copper Ore Heap Leaching

Plant Project
Contract No: 309736 Document Number: 11L1-BG-P-021-EL-CAL-1005 Rev: 00 Date: 2021-06-01
Document Title: CALCULATION FOR ELECTRICAL HEAT Page 1 of 18
Class: A
TRACING SYSTEM
CALCUATION FOR ELECTRICAL HEAT TRACING

SYSTEM
00 6/9/2021 IFR M.S E.GH E.H A.H
Rev. Date Purpose of Issue Prepared By Checked By Approved By Authorized By


Plant Project
Class: A
TRACING SYSTEM
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Plant Project
Class: A
TRACING SYSTEM
CONTENTS
1. INTRODUCTION ............................................................................................................ 3
2. SCOPE OF WORK: ................................................................................................... 5
3. CODES & STANDARDS: ........................................................................................... 6
4. DESIGN BASIS......................................................................................................... 7
5. PIPE HEAT TRACING CACULATION…………………………………………………………….…….……8
6. CALCULATION SHEET………………………………………………………………….………………………18

Plant Project
Class: A
TRACING SYSTEM
1. INTRODUCTION
The SUNGUN copper ore Heap Leaching Plant Project is to engineer and construct a
small crushing, heap leaching, solvent extraction, Electro winning operation together
with the supporting infrastructure to produce LME Grade A cathodes. The project is
located at the Sungun Copper Complex in East Azerbaijan province at 130Km North
East of Tabriz.
In heap, acidic solution (Sulphuric acid solution) leached crushed copper ore to
produce impure aqueous solution. Then Cu from this impure solution is transferred to
pure, high‐Cu electrolyte via solvent extraction. In the electro winning cells, the
electrolysis process reduces copper, which deposits on the cathodes and oxidizes the
oxygen component in the water to gaseous oxygen at the lead anodes. Cathodes are
harvested and processed in a semi‐automated cathode stripping. Cathode sides
collected in a stack box. The forklift operator removes the cathodes from the stacking
box in the stripping station and moves it to the manual bundle weighing, strapping and
labelling station. At this station the cathodes are set onto the weigh scale by operator.
The cathodes are weighed by a “legal for trade” scale. Certification of the scale will be
by the owner, in conjunction with the local weights and measures authority. After the
cathodes is weighed, the weight information is transferred to the labeler and a self‐
adhesive paper label is printed with the weight and other relevant information. The
label is manually affixed to the surface of the top copper sheet of the bundle.
The Trace Heating system are including the transformers and distribution boards,
together with all necessary Heating elements (trace heat tapes), junction boxes, cable
glands, thermostats, fixing materials, labels and markers.

Plant Project
Class: A
TRACING SYSTEM
2. SCOP OF WORK:
Electric Surface Heating (ESH) system is designing for:

Maintaining temperature requires the provision of heat to a surface equal
to the rate of heat loss due to the temperature difference and its
surrounding at the required surface temperature. When starting from a
lower temperature the time taken to achieve the required temperature will
vary according to the ambient temperature and whether the pipe or vessel
is empty, partially filled or completely filled under no flow conditions.

Plant Project
Class: A
TRACING SYSTEM
6. CODES AND STANDARDS:
The equipment’s covered by this specification shall comply with the requirements of
the latest edition of applicable standards issued by IEC and IEEE including the following:
Electrical apparatus for explosive gas atmosphere Electrical Resistance trace
ATEX n.
heating, Part –1, General and testing requirements.
0P161017.AHHQ001
Electrical apparatus for explosive gas atmosphere Electric al Resistance trace
ATEX n.
eating, Part –2, Application guide for design, installation and maintenance.
0P161025.AHHQU28
This EU-type examination certificate relates only to the design,

examination and tests specified equipment in accordance with Directive
2014/34/EU. Further requirements of the Directive shall be applied to the ATEX n.
manufacturing process and supply condition: these requirements are not 0P161025.AHHQU26
covered by this certificate.
This EU-type examination certificate relates only to the design, examination

and tests specified equipment in accordance with Directive 2014/34/EU.
Further requirements of the Directive shall be applied to the manufacturing
process and supply condition: these requirements are not covered by this ATEXn.
certificate. 0P161025.AHHQU27
The equipment and any acceptable variations to it specified in the schedule

IECExLCIE
of this certificate and the identified documents, was found to comply with
the following standards 19.0056U
IEC 60079-0:2011
In compliance with the requirements for documentation specified in Annex
III (art.
2) of the European Parliament and of the Council on the market of electrical IEC 60800:2009
equipment designed for use within certain voltage limits, this certificate
applies to
the electrical equipment:

Plant Project
Class: A
TRACING SYSTEM
7. DESIGN BASIS OF SITE
Ambient Temperature
Average maximum (summer) 33 ℃
Average minimum (winter) -16 ℃
Annual absolute maximum temperature 32.3 ℃
Annual absolute minimum temperature -30 ℃
Annual average temperature 5.5 ℃
Average temperature in the hottest month 16.7 ℃
Average temperature in the coldest month -3.8 ℃
Hottest month July
Coldest month January
Average dry bulb temperature 22 ℃
Maximum temperature for equip. exposed to sunlight 48 ℃
Average wet bulb temperature 17.6 ℃
Wind
Hot season N to S
Cold season SW to NE
Windiest Month February
Design wind speed 36.1m/s (130 Km/hr)
Relative humidity
Annual maximum humidity 91.7 %
Annual minimum humidity 42.3 %
Annual average humidity 68.0 %
Max. average humidity in the hottest month 84.3 %
Min. average humidity in the hottest month 54.3 %
Max. average humidity in the coldest month 73.6 %
Min. average humidity in the coldest month 50.3 %

Plant Project
Class: A
TRACING SYSTEM
4. Pipe Heat Tracing Application
Any object that is hotter than its surroundings will lose that heat at a specific rate. This is
known as heat loss. The purpose of heat trace cable is to replace heat faster than it is
lost. The information below will assist in determining the amount of heat required for a
specific application. To determine the amount of power to maintain a specific pipe
temperature the information below must first be determined.
 Diameter of pipe.
 Length of pipe.
 Temperature to be maintained.
 Minimum possible ambient temperature.
 Insulation type.
 Insulation thickness.
Now we should determine the watts per foot or meter needed for your application. The
example provided will assist in following each step.


Plant Project
Class: A
TRACING SYSTEM
Example:
Required information:
Diameter of pipe. ------------------------ 2”
Length of pipe. --------------------------- 100’
Temperature to be maintained. ------ 50 °F
Minimum possible ambient temperature -20 °F
Insulation type. --------------------------- R .W
Insulation thickness. --------------------------------------------------------- 1”.
ONE-Determine the pipe temperature difference. This is known as the delta T.
__________________________ - _________________________ = _________
(Temperature to be maintained) - (Minimum ambient temperature) = ∆T.
Example: 50 F – (-20 F) = 70 F
TWO- Refer to Chart 1 Heat Loss Chart for Pipes and determine the required watts
per linear foot or meter.
This is done by finding the intersection of the ∆T and the pipe diameter at the given
insulation thickness.

Plant Project
Class: A
TRACING SYSTEM
Example: 2” pipe, 1” insulation, 70 °F ∆T = 4.6 watts per foot.
NOTE: Because the ∆T of 70° F is not on the chart the next highest of 75 °F must be
used.
THREE. Using Chart 2 Insulation Factor determine the insulation adjustment
factor.
Example: 50 °F maintenance temperature, Rock wool = 1.53
FOUR. Determine the adjusted heat loss.
____________ X ________________________ = _______________
(Watts per foot) X (Insulation adjustment factor) = Adjusted heat loss.
Example: 4.6 x 1.53 = 7.04 5. Select cable. a)
FIVE. Select a cable with a watt per foot or watt per meter rating higher or equal with the
required wattage.
Example: 7.04 watts required, 8 watt or higher cable can be used.


Plant Project
Class: A
TRACING SYSTEM
NOTE: For best results on pipes larger then 4”, multiple straight runs or spiral wrapping
should be used instead of a single straight run.
CALCULATE HEAT LOSS WITHOUT USING TABLES FOR INFORMATION

EXAMPLE OF HEAT LOSS CALCULATION FOR 4 INCH PIPE
LINE PROCESS DATA
Normal temperature Tn 5.5 ℃
Pipe diameter OD 0.1143 M
Maximum intermittent exposure Temperature Te 48 ℃
Pipe wall thickness Th 0.00856 M
AMBIENT DATA
Minimum ambient temperature Ta 30 ℃
Maximum wind speed Ws 36.1 M/S
Surface resistance Fs 0.03
INSULATION DATA
Insulation thickness Ith 0.025 M
Maximum insulation conductivity Ki 0.05 W/M.K
HEAT LOSS THROUGH PIPE PER EACH METER
𝑅𝑜 = 𝐼𝑡ℎ + 𝑂𝐷 ÷ 2 Inside diameter ODi OD 2Th

𝟑. 𝟏𝟒
𝑸 = (𝑻𝒏 − 𝑻𝒂). 𝑲𝒊. 𝟐.
𝑹𝒐
𝑰𝒏 ( 𝑶𝑫 ) + 𝑭𝒔
𝟐
𝑊
HEAT LOSS PER METER Q 28.373
𝑚

Plant Project
Class: A
TRACING SYSTEM
Multiple straight runs of cable.
Example: 7.04 watts required, 2 straight runs of 4 watts cable can be used
( STRAIGHT RUN SIDE WIEW )
↖HEATING CABLE
↑ FIBER GLASS TAPE ↑ FIBER GLASS TAPE
(END VIEW)
↖HEATING CABLE
↑HEATING CABLE
Spiral wrap lower wattage cable around the pipe.


Plant Project
Class: A
TRACING SYSTEM
Example: 4 watt cable can be wrapped with a 5” pitch (( SPRIAL WRAP SIDE VIEW))↓↓
SIX. If spiral wrapping is chosen; determine the required amount of cable per foot or
meter of pipe.
________________ / _________________ = _______________________
(Adjusted heat loss) / (Cable watts per foot) = Required cable per foot of pipe.
Example: 7.04 / 4 = 1.76 7.
SEVEN. Using Chart 4, Wrap Factor determine the required pitch (space between
wraps).
EGHT. Determine the heat loss for valves or pipe supports a Refer to Chart 3 and
determine the valve multiplication factor.
___________________ X _________________ = ________________
(Adjusted heat loss) X (Valve multiplication) = Heat loss for valves
Example: For 1 gate valve on 2” pipe, 1.76 x 1.92 = 3.38 10.


Plant Project
Class: A
TRACING SYSTEM
Determine the additional cable required.
________________________ / __________________ = ____________________
(Adjusted heat loss for valves) / (Cable watts per meter or foot) = Cable required for
valves.
Example: 3.38 / 4 = 0.845 additional feet of cable required.
NINE. Determine the total amount of cable required for the pipe and valves.
___________________ + ______________________ = ______________________
(Cable required for pipe) + (Cable required for valves) = Cable for pipes and valves
Example: 96.5 + 0.845 = 97.345 12. Round the total amount of cable required up to the
nearest number divisible by the cable module length. Example: 97.345 must be
increased to 98 to be evenly divided by 2, 98 / 2 = 49 module lengths 13. Add a
minimum of 1 extra module length for terminations, or two feet for Self-Regulating cable.
Example: 98 feet + 2 foot module length = 100 feet of cable required for proper
installation.

Plant Project
Class: A
TRACING SYSTEM
10% safety factor has been added for contingencies. 1. Find the insulation thickness in the right
column. 2. Find the specific pipe size at the top. 3. Find the 'T in the left column. 4. Find where these
three values intersect in the body of the table, this is the required watts per foot.

Plant Project
Class: A
TRACING SYSTEM

Plant Project
Class: A
TRACING SYSTEM

Plant Project
Class: A
TRACING SYSTEM
Piple line data Ele ctrical data
No. Cable
Ins ulati No. Heat Los s Cable Requri
of No. of Heat Output Cable for pipes NO. Of E.H.T Total
Pipe on of No. of Gate Multiplica Cable Output in ed Cable Cable for NO. OF
Pipe Size Pipe Length Othe Support los s Maintain Heating Cable Heat Los s Heat los s in and Mounting Total Heater Cable T Pitch LOCAL Heater
Fluid Length Thickn Gate Flange(p valve tion required for Maintain Cable required for pipes and SPLICE Pitch MM Line No. P&ID
(mm) (m) r Suppo factor for Temp.(°C) Type (W/m) (W/Ft) Maintain valves (m)+20 Figure Qty.(m) SPLICE inches PANEL Cable
(ft) es s Valve c) Factor Factors valves Temp. per foot pipe (ft) valves (ft) KIT
Valv rt(pc) valves Temp. % Add KIT Tag no. Qty.(m)
(mm) (pc) for Valves (W/Ft) of pipe
e(pc) (W/m)
POTABLE WATER 40 12.30 40.35 50 01 00 00 02 01.33 00.67 02.67 02.87 00.92 5 Self Regulating 10.25 3.12625 11 3.355 1.073 43.307 44.224 16.186 Spiral 23.45 0 0 18 457.2 CR-LP-01 23.45 11L1-CM-D-230-PR-PID-1003-07
0001
POTABLE WATER 40 162.10 531.82 50 01 00 00 02 01.33 00.67 02.67 02.87 00.92 5 Self Regulating 10.25 3.12625 11 3.355 1.073 570.738 571.655 209.226 Spiral 248.15 1 0 18 457.2 EHT-LP-01 248.15 11L1-CM-D-230-PR-PID-1003-07
0001
SULPHURIC ACID , CONCENTRATED 40 1.50 4.92 50 00 00 00 01 01.33 00.67 00.67 00.69 00.14 25 Self Regulating 15.64 4.7702 16 4.88 1.023 5.035 5.178 1.895 Spiral 3.75 0 0 18 457.2 EHT-LP-01 3.75 11L1-CM-D-230-PR-PID-1005-07
0100
0101
RAW WATER 50 12.70 41.67 50 01 00 00 02 01.70 00.85 03.40 04.91 01.46 5 Self Regulating 11.07 3.37635 16 4.88 1.445 60.223 61.678 22.574 Spiral 30.4 0 0 7 177.8 EHT-LP-01 30.4 11L1-CM-D-230-PR-PID-1011-05
0100
0060
0100
0101
0001
0100
0060
SULPHURIC ACID , CONCENTRATED 25 1.40 50 00 00 00 02 25 Self Regulating 12.22 3.7271 35 1.40 Stright 5.8 0 0 2 50.8 EHT-LP-02 5.8 11L1-CM-D-230-PR-PID-1001-06
0100
POTABLE WATER 40 7.90 25.92 50 01 00 00 03 01.33 00.67 03.34 03.58 01.15 5 (Note1) Self Regulating 10.25 3.12625 11 3.355 1.073 27.815 28.962 10.600 Spiral 18.35 0 0 18 457.2 EHT-LP-02 18.35 11L1-CM-D-230-PR-PID-1001-06
0001
RAW WATER 50 34.40 112.86 50 01 00 00 01 01.70 00.85 02.55 03.69 01.09 5 (Note1) Self Regulating 11.07 3.37635 16 4.88 1.445 163.123 164.215 60.103 Spiral 72.3 0 0 7 177.8 EHT-LP-02 72.3 11L1-CM-D-230-PR-PID-1001-06
0050
0001
SULPHURIC ACID , CONCENTRATED 25 1.50 50 00 01 00 02 25 Self Regulating 12.22 3.7271 35 1.50 Stright 8 0 0 2 50.8 EHT-LP-02 8 11L1-CM-D-230-PR-PID-1005-07
0100
0050
PERM EATE WATER (COLD) 32 205.50 50 00 00 00 01 5 (Note1) Self Regulating 9.01 2.74805 11 411.00 Stright 412.5 3 1 2 50.8 EHT-LP-03 412.5 11L1-CM-D-230-PR-PID-1003-07
0001
0001
0100
PERM EATE WATER (COLD) 32 205.50 50 01 02 01 02 5 Self Regulating 9.01 2.74805 11 205.50 Stright 421.5 4 1 2 50.8 EHT-LP-03 421.5 11L1-CM-D-240-PR-PID-1001-07
0001
0001
0100
0015
SULPHURIC ACID , CONCENTRATED 100 6.00 19.69 50 00 06 00 03 02.92 01.46 21.90 25.42 02.76 25 Constant Power 30.15 9.19575 35 10.675 1.161 22.852 25.616 9.376 Spiral 40.5 0 0 36 914.4 EHT-LP-04 40.5 11L1-CM-D-230-PR-PID-1005-07
0001
SULPHURIC ACID , CONCENTRATED 100 6.00 19.69 60 00 03 00 02 02.92 01.46 11.68 13.56 01.47 25 (Note1) Constant Power 30.15 9.19575 35 10.675 1.161 22.852 24.326 8.903 Spiral 33 0 0 36 914.4 EHT-LP-04 33 11L1-CM-D-230-PR-PID-1005-07
0002
SULPHURIC ACID , CONCENTRATED 80 6.40 21.00 60 00 04 00 03 02.40 01.00 12.60 22.03 03.61 25 (Note1) Constant Power 20.02 6.1061 35 10.675 1.748 36.709 40.316 14.756 Spiral 38.1 0 0 9 228.6 EHT-LP-04 38.1 11L1-CM-D-230-PR-PID-1005-07
0003
0004
SULPHURIC ACID , CONCENTRATED 40 18.20 59.71 50 00 01 01 02 01.33 00.67 04.00 04.09 00.86 25 Self Regulating 15.64 4.7702 16 4.88 1.023 61.086 61.944 22.671 Spiral 33.8 0 0 18 457.2 EHT-LP-04 42 11L1-CM-D-230-PR-PID-1005-07
0071
0014
0015
SULPHURIC ACID , CONCENTRATED 50 3.00 9.84 50 00 02 01 03 01.70 00.85 07.65 15.85 03.08 25 Self Regulating 16.89 5.15145 35 10.675 2.072 20.396 23.473 8.591 Spiral 16 0 0 4 101.6 EHT-LP-04 16 11L1-CM-D-230-PR-PID-1005-07
0007
0005
0006
SULPHURIC ACID , CONCENTRATED 50 5.00 16.40 50 00 04 00 02 01.70 00.85 08.50 17.61 03.42 25 (Note1) Self Regulating 16.89 5.15145 35 10.675 2.072 33.993 37.413 13.693 Spiral 21 0 0 4 101.6 EHT-LP-04 21 11L1-CM-D-230-PR-PID-1005-07
0018
0019
SULPHURIC ACID , CONCENTRATED 40 477.00 1564.96 50 00 00 00 03 01.33 00.67 02.01 04.50 00.94 25 Self Regulating 15.64 4.7702 35 10.675 2.238 3502.150 3503.093 1282.132 Spiral 720 6 2 4 101.6 EHT-LP-04 720 11L1-CM-D-230-PR-PID-1005-07
0020
0045
0017
SOFT WATER 50 118.50 388.78 50 01 00 00 03 01.70 00.85 04.25 06.14 01.82 5 Self Regulating 11.07 3.37635 16 4.88 1.445 561.922 563.741 206.329 Spiral 243.5 1 0 7 177.8 EHT-LP-08 243.5 11L1-CM-D-230-PR-PID-1003-07
0083
KEROSENE 80 13.00 42.65 60 00 07 00 02 02.40 01.00 18.80 32.46 05.25 20 Constant Power 20.27 6.18235 35 10.675 1.727 73.645 78.896 28.876 Spiral 69 0 0 9 228.6 EHT-LP-05 69 11L1-CM-D-230-PR-PID-1015-05
0001
M IXED DILUENTS 50 5.00 16.40 50 00 05 00 02 01.70 00.85 10.20 10.57 02.24 20 Self Regulating 15.44 4.7092 16 4.88 1.036 16.999 19.244 7.043 Spiral 23 0 0 18 457.2 EHT-LP-05 23 11L1-CM-D-230-PR-PID-1015-05
0014
KEROSENE 80 2.50 8.20 60 00 03 00 02 02.40 01.00 09.20 15.89 02.57 20 Constant Power 20.27 6.18235 35 10.675 1.727 14.162 16.732 6.124 Spiral 19 0 0 9 228.6 EHT-LP-05 19 11L1-CM-D-230-PR-PID-1015-05
0003
KEROSENE 50 32.00 104.99 50 00 06 01 01 01.70 00.85 12.75 13.21 02.81 20 Self Regulating 15.44 4.7092 16 4.88 1.036 108.795 111.600 40.846 Spiral 79 0 0 18 457.2 EHT-LP-05 79 11L1-CM-D-230-PR-PID-1015-05
0002
KEROSENE 50 3.60 11.81 50 00 04 00 01 01.70 00.85 07.65 07.93 01.68 20 Self Regulating 15.44 4.7092 16 4.88 1.036 12.239 13.923 5.096 Spiral 16.7 0 0 18 457.2 EHT-LP-05 16.7 11L1-CM-D-230-PR-PID-1015-05
0004
M IXED DILUENTS 40 16.50 54.13 50 00 05 01 02 01.33 00.67 09.32 10.44 02.39 20 Self Regulating 14.29 4.35845 16 4.88 1.120 60.612 63.006 23.060 Spiral 39.25 0 0 10 254 EHT-LP-05 39.25 11L1-CM-D-230-PR-PID-1015-05
0017
0016
M IXED DILUENTS 50 16.40 53.81 50 00 03 00 02 01.70 00.85 06.80 07.05 01.50 20 Self Regulating 15.44 4.7092 16 4.88 1.036 55.757 57.254 20.955 Spiral 41.8 0 0 18 457.2 EHT-LP-05 41.8 11L1-CM-D-230-PR-PID-1015-05
0015
0020
0031
0022
0021
M IXED DILUENTS 40 16.50 54.13 50 00 04 00 03 01.33 00.67 07.33 08.21 01.88 20 (Note1) Self Regulating 14.29 4.35845 16 4.88 1.120 60.612 62.495 22.873 Spiral 37.25 0 0 10 254 EHT-LP-05 37.25 11L1-CM-D-230-PR-PID-1015-05
0023
M IXED DILUENTS 50 2.00 6.56 50 00 01 00 02 01.70 00.85 03.40 03.52 00.75 20 Self Regulating 15.44 4.7092 16 4.88 1.036 6.800 7.548 2.763 Spiral 9 0 0 18 457.2 EHT-LP-05 9 11L1-CM-D-230-PR-PID-1015-05
0030
REYSOL 8411 50 4.20 13.78 50 00 02 01 02 01.70 00.85 06.80 07.05 01.50 20 Self Regulating 15.44 4.7092 16 4.88 1.036 14.279 15.776 5.774 Spiral 16.9 0 0 18 457.2 EHT-LP-05 16.9 11L1-CM-D-230-PR-PID-1015-05
0005
REYSOL 8401 50 1.50 4.92 50 00 03 02 02 01.70 00.85 10.20 10.57 02.24 20 Self Regulating 15.44 4.7092 16 4.88 1.036 5.100 7.344 2.688 Spiral 15 0 0 18 457.2 EHT-LP-05 15 11L1-CM-D-230-PR-PID-1015-05
0011
0007
REYSOL 8401 50 3.00 9.84 50 00 00 01 01 01.70 00.85 02.55 02.64 00.56 20 Self Regulating 15.44 4.7092 16 4.88 1.036 10.200 10.761 3.938 Spiral 9 0 0 18 457.2 EHT-LP-05 9 11L1-CM-D-230-PR-PID-1015-05
0008
0009
0010
0012
0013
0006
M IXED DILUENTS 25 1.50 50 00 01 01 02 00.67 20 Self Regulating 11.16 3.4038 35 25 Stright 9.5 0 0 2 50.8 EHT-LP-05 9.5 11L1-CM-D-230-PR-PID-1015-05
0040

Calcuation For Electrical Heat Tracing System: SUNGUN Copper Ore Heap Leaching Plant Project

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National Iranian Copper Industries Company

Pyro and Hydro Metallurgy Programs

SUNGUN Copper Ore Heap Leaching