SPECIFICATION FOR Petro-Energy

ELECTRIC HEAT TRACING

DOCUMENT NO : GEN-SPC-ELC-6102 REV. : B PAGE 1 of 13

Petro-Energy E&P Co., Ltd.

(Sudan Branch)

SPECIFICATION FOR
ELECTRIC HEAT TRACING

B RE-ISSUED FOR EXECUTION 28.12.06

A ISSUED FOR EXECUTION 08.08.06 CPE/VECO YZX CHL

PREPARED CHECKED APPROVED
REV DESCRIPTION DATE BY BY BY

GEN-SPC-ELC-6102 REV. B (ELEC.HEAT TRACING)

 SPECIFICATION FOR Petro-Energy
ELECTRIC HEAT TRACING

DOCUMENT NO : GEN-SPC-ELC-6102 REV. : B PAGE 2 of 13

Revision Record Information:

No. Rev. Date Revision Information

1. B 28.12.2006 Changing company name from CNPC International Ltd. (Sudan

Branch) to Petro-Energy E&P Co. Ltd. (Sudan Branch), the
related abbreviation from CNPCIS to Petro-Energy.

GEN-SPC-ELC-6102 REV. B (ELEC.HEAT TRACING)

 SPECIFICATION FOR Petro-Energy
ELECTRIC HEAT TRACING

DOCUMENT NO : GEN-SPC-ELC-6102 REV. : B PAGE 3 of 13

TABLE OF CONTENTS

1.0 GENERAL........................................................................................................................... 4

2.0 SCOPE................................................................................................................................ 4

3.0 CODES, REGULATIONS AND STANDARDS ................................................................... 4

4.0 SITE CONDITIONS............................................................................................................. 5

5.0 GENERAL DESIGN REQUIREMENTS .............................................................................. 5

5.1 Suppliers Responsibilities ............................................................................................... 5
5.2 Safety ................................................................................................................................. 6
5.3 Degree of Protection......................................................................................................... 6
5.4 Electrical Supply System ................................................................................................. 6
5.5 Spare Or Over-Capacity.................................................................................................... 7
5.6 Operation and Maintenance ............................................................................................. 7
5.7 Heater Selection ................................................................................................................ 7

6.0 TECHNICAL REQUIREMENT ............................................................................................ 8

6.1 Panel Details...................................................................................................................... 9

7.0 INSTALLATION .................................................................................................................. 10

7.1 Heater Distribution............................................................................................................ 10
7.2 Temperature Controller .................................................................................................... 11
7.3 Local Thermostats ............................................................................................................ 11
7.4 Connection Boxes............................................................................................................. 11
7.5 Heater Installation ............................................................................................................. 11

8.0 IDENTIFICATION ............................................................................................................... 12

9.0 Testing and commissioning............................................................................................. 12

9.1 Factory Testing ................................................................................................................. 13
9.2 Commissioning ................................................................................................................. 13

GEN-SPC-ELC-6102 REV. B (ELEC.HEAT TRACING)

 SPECIFICATION FOR Petro-Energy
ELECTRIC HEAT TRACING

DOCUMENT NO : GEN-SPC-ELC-6102 REV. : B PAGE 4 of 13

1.0 GENERAL

This specification is to establish the quality of work and technical requirements for the
supply, installation, testing and documentation for Electric Heat Tracing.

The SUPPLIER shall use this specification together with other documents provided in
the requisition to establish the detail design and final installation of the system.

This specification shall not be considered all-inclusive. The SUPPLIER shall

incorporate in their design all features necessary for the safe and efficient operation of
the facility whether explicitly stated or not.

2.0 SCOPE

The electric heat tracing system shall consists of the following:

• Electric heating cables.

• Temperature controller’s c/w RTD’s, junction boxes etc.
• Feeder wiring, raceway, trays.
• Electric Heat Tracing Panel.

SUPPLIER shall perform heat demand calculations for OWNER’s review. The
calculations shall be based on temperature range and warm up time based on project
specific requirements.

SUPPLIER shall supply all necessary drawings, installation details, datasheets,

instruction manuals, recommended commissioning spare parts list and spare parts list
for two (2) years of operation.

SUPPLIER shall provide training manual, video and/or sample material for training the
OWNER’s operating and maintenance personnel.

3.0 CODES, REGULATIONS AND STANDARDS

SUPPLIER shall meet or exceed the requirements of the latest edition of the following
codes, regulations and standards, except as superseded herein. In cases where more
than one code, regulation or standard apply to the same condition, the most stringent
shall be followed. In the event of a conflict between this specification and other
specifications or correspondence, the OWNER shall be consulted and a ruling, in
writing, shall be obtained before any fabrication can start.

The Electric Heat Tracing Equipment shall be in accordance with the following
minimum IEC standards or Equivalent:

IEC 60529 Classification of Degrees of Protection Provided by Enclosures

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ELECTRIC HEAT TRACING

DOCUMENT NO : GEN-SPC-ELC-6102 REV. : B PAGE 5 of 13

IEC 60540 Test Methods for Insulation and Sheaths of Electric Cables and Cords

IEC 60751 Platinum Resistance Thermometer Sensors Thermocouples

IEC 62086 Electrical Apparatus for Explosive Gas Atmospheres, Electrical

Resistance Trace Heating

IEC 60079 Electrical Apparatus for Explosive Gas Atmospheres

IEC 60331 Fire resisting characteristics of electric cable.

IEC 60332-3 Flame retardant characteristics of electric cables. Part 3 Test on bundled
wires or cables.

BS 6351 Electrical Surface Heating

Certification by other internationally recognized organizations may also be considered.

Some requirements in this specification may be modified by specific requirements in

the Purchase Specification. In case of conflict, the specific requirements supersede
this specification.

4.0 SITE CONDITIONS

The SUPPLIER shall ensure that the equipment supplied will work properly under the
site conditions.

The equipment and installation shall be suitable for the minimum environment
conditions, unless otherwise specified.

For details about Site Conditions, please refer the Project Site Data.

5.0 GENERAL DESIGN REQUIREMENTS

The Electric Heat Tracing shall be utilized to maintain temperature of fluid (oil) in pipes,
instruments or instrument bundles.

The heat race cable shall be suitable for the continuous surface temperature as
indicated.

All the necessary parameter like temperature etc shall be indicated in the line list and
P&IDs.

5.1 Suppliers Responsibilities

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ELECTRIC HEAT TRACING

DOCUMENT NO : GEN-SPC-ELC-6102 REV. : B PAGE 6 of 13

The overall responsibility for the heating system shall rest with the SUPPLIER.

The design shall be based on the specific requirements, stated on the P&IDs,
drawings, Isometrics and Line lists.

5.2 Safety

For safe and reliable application of electrical heating systems, the climatic,
environmental and operating conditions shall be taken into consideration.

5.2.1 Hazardous Areas

When installed in a hazardous area, the construction of electrical equipment shall

comply with the requirements of the relevant parts of IEC 60079 or EN 50 020
inclusive, EN 50 028 and EN 50 039 and IEC 62086-1. Equipment complying with
standards different from the above may only be used with the specific approval from
the OWNER.

For installations in Zone 1 and Zone 2 areas, the following types of protection shall be
used:

• Junction boxes: Ex “e” enclosure

• Temperature control systems: Ex “i” (for example, RTD connections)

For the above-mentioned electrical apparatus, a Certificate of Conformity from IEC Ex

approved testing bodies shall be obtained from the Manufacturer.

The heating cable shall be suitable for Zone 1 and Temperature Class T3.

5.2.2 Non-Hazardous Areas

For standardization, material as specified for Zone 1 and 2 areas should also be used
in non-hazardous areas.

However the control panel installed in outdoor safe area shall be weather proof with
IPW 55 degree of protection.

5.3 Degree of Protection

As a minimum, the enclosures installed outdoors shall have a degree of protection

IPW 65 in accordance with IEC 60529.

5.4 Electrical Supply System

The AC supply to the heating system shall be symmetrical 3-phase + neutral, sub-
divided into single phase with a nominal voltage and frequency as indicated in the
requisition. The supply variations at the distribution board, under steady-state
conditions, shall be limited to:

GEN-SPC-ELC-6102 REV. B (ELEC.HEAT TRACING)

 SPECIFICATION FOR Petro-Energy
ELECTRIC HEAT TRACING

DOCUMENT NO : GEN-SPC-ELC-6102 REV. : B PAGE 7 of 13

Nominal system voltage: 400 V + 10%

Nominal system frequency: 50 Hz + 5%

5.5 Spare Or Over-Capacity

The design of initial spare or over-capacity of the heating system shall be considered if
for critical applications the power output is not allowed to drop below the design values.

A minimum of 20% additional design heat requirement shall be taken into account.
This may not be applicable if self-regulating cable is used.

The safety factor used in the design shall be stated in the heat balance calculation.

5.6 Operation and Maintenance

All electrical equipment subject to operating and maintenance activities shall be easily
accessible and shall allow for safe and convenient performance of such activities.

System components shall be standardized.

5.7 Heater Selection

For winterizing and compensation heating the following heater types may be used, in
order of preference:

Self-regulating/ self-limiting heaters

Constant wattage parallel heaters
Mineral Insulated Heaters

In the case of welded pipelines (i.e. without flanges) the system of skin electric current
tracing heaters shall be considered.

5.7.1 Self-Regulating/ Self-limiting Heaters

Self-regulating/ self-limiting heaters shall be utilized where possible, within the

restrictions of heat output and operating temperatures. They can be used for all
winterizing and the majority of compensation heating requirements. Heating tape shall
consist of two parallel copper conductors, both being in contact with a self-regulating/
self-limiting semi-conductive material. This basic element shall be insulated by one or
more non-hygroscopic jackets, and shall be covered with a braided metal screen
covering at least 70% of the surface and a fluor-polymer outer jacket. The braided
metal screen shall have an electrical conductivity not less than the conductivity of one
of the conductors.

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ELECTRIC HEAT TRACING

DOCUMENT NO : GEN-SPC-ELC-6102 REV. : B PAGE 8 of 13

The heaters shall vary the power output in response to the sensed temperature at
every point of the surface. As the temperature increases, the heater output shall
decrease automatically and vice versa. The natural reduction in heat output by
increasing temperatures shall be at least so much that the heater will not be damaged
due to overheating as result of e.g. overlapping, irrespective of the application.

5.7.2 Constant Wattage Parallel Heaters

Constant wattage parallel heaters may be utilized when the required heat output or the
operating temperature is beyond the capabilities of self-regulating/ self-limiting heaters.
A constant wattage parallel heating cable shall consist of two insulated copper
conductors. Heating elements (wires or other types of elements) are connected to the
two conductors at certain distances, forming heated zones. The maximum length of a
heating zone shall not be more than 1 metre.

The conductor and the heating elements shall be provided with one or more layers of
insulating material. All insulating material shall be heat resistant and non-hygroscopic
and shall be covered with a braided metal screen covering for at least 70% of the
surface together with a polymer outer jacket. The electrical conductivity of the braided
metal screen shall not be less than the conductivity of one of the conductors.

The heating pad shall have an external metal earth screen or foil over the entire
surface for mechanical and personnel protection.

The heaters (both, cables and pads) shall provide a constant power output regardless
of the operating temperature.

5.7.3 Mineral Insulated Heaters

Mineral Insulated Heaters may be used, if the required temperatures are beyond the
capabilities of the constant wattage parallel heaters.

Mineral insulated heating cable shall consist of a metal outer tube with a concentric
heating conductor inside, insulated with compressed magnesium oxide powder. The
cable shall have a constant power output per meter which shall be determined by the
specific conductor resistance, the total length of the cable and the applied voltage.
The cable shall be prefabricated for the required length and provided at both ends with
proper seals, cold connection leads and metal cable glands.

Heating pads with mineral insulated heating cable shall consist of a metal plate on
which the cable is fixed, to guarantee heat transfer over the entire length of the heating
cable.

6.0 TECHNICAL REQUIREMENT

GEN-SPC-ELC-6102 REV. B (ELEC.HEAT TRACING)

 SPECIFICATION FOR Petro-Energy
ELECTRIC HEAT TRACING

DOCUMENT NO : GEN-SPC-ELC-6102 REV. : B PAGE 9 of 13

All heat-tracing systems for use at temperatures up to a continuous exposure

(maintain) of 121°C (250°F) and intermittent exposure temperature of 190°C (375°F)
shall use a self-regulating (SR) type of heating cable.

The SR heating cable shall vary its power out relative to the temperature of the surface
of the pipe. Also unlike mineral insulated (MI) and constant wattage (CW) cables, SR
cable can be overlapped during installation without fear of burnout.

Self-regulating heating cable shall be designed for useful life of 20 years or more with
“power on” continuously, based on the following useful life criteria:

• Retention of at least 75 percent of rated power after 20 years of operation at the

maximum published continuous exposure (maintain) temperature;

• Retention of at least 90 percent of rated power after 1000 hours of operation at the
maximum published intermittent exposure temperature. The testing shall conform
to UL 7468, IEC 60214-1 Part 1.

All cables shall be warranted against manufacturing defects for a period of 10 years.

All cables shall be capable of passing a 2.5 kV dielectric test for one minute after
undergoing a 0.5 kg-m impact.

All connection components used to terminate self-regulating heating cables, including

power connectors, splices, tees, and connectors, shall be approved for the respective
area classification and approved as a system with the particular type of heating cable
in use. Under no circumstances shall terminations be used which are manufactured by
a vendor other than the cable manufacturer.

Each heat tracing circuit should be, controlled by a pipe temperature monitoring device
or a RTD temperature sensor. RTD’s should be 100 ohm platinum type (PT-100).

6.1 Panel Details

Each circuit shall be fitted with earth leakage circuit breaker (30 mA). At least one
spare circuit shall be installed for each section of piping. Easy inspection of supply
points shall be made possible.

Internal wiring within the panel shall be PVC insulated 600/1000V grade, stranded
copper conductors, minimum size 2.5 mm2.

Wiring shall be securely held in position (either loomed or run in conduit / trunking). If
wiring corridors, conduits and flexible conduits are used they shall be, adequately
sized to accommodate future additions (6 conductors minimum) by others.
Wiring identification shall be by numbered and/or lettered ferrules of insulating material
and located adjacent to the terminals.

GEN-SPC-ELC-6102 REV. B (ELEC.HEAT TRACING)

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ELECTRIC HEAT TRACING

DOCUMENT NO : GEN-SPC-ELC-6102 REV. : B PAGE 10 of 13

Wiring connections to door mounted equipment shall be loomed, wrapped at both ends
to prevent movement at terminations.

All wiring for external connections shall be brought out to individual terminals on a
readily accessible terminal block. Sufficient spare ways (4 minimum) shall be allowed
for future use.

Wires shall be terminated using compression type lugs or crimp sleeves.

Plug and socket connections shall be of robust construction and include a location pin
or similar device to prevent the interconnection being made incorrectly.

Incomers shall be provided with Voltmeters and Ammeters. Relays shall be flush
mounting and fitted on the front of the equipment. All meters shall be of square pattern
type 96 x 96mm and mounted at a suitable height for easy reading from the front.

Potential free “Normally Closed” contact shall be provided to indicate failure of the heat
tracing system. This shall also include tripping of individual circuit breaker feeders.

SUPPLIER shall provide a canopy for control panel to protect against direct sunrays
and rain.

7.0 INSTALLATION

The electric heat tracing system shall be installed in accordance with manufacturer’s
instructions and recommendation. The location of the main Electric Heat Tracing
Panel shall preferably be in the substation. The control panel based on the system
requirements and design can be located in field at suitable location. The panel shall
be either with IPW-65 ingress protection when kept in a safe area or Ex-d as per area
class, if located in an hazardous area (It is preferable to locate the panel in a safe area
as far as possible).

Cable sheaths shall not cross or touch one another.

RTD’s shall be located away from heating cable to obtain accurate measurement of
the fluid temperature, so as to avoid cold spots.

7.1 Heater Distribution

Heaters shall be distributed and grouped logically in order to minimize the number of
switches, thermostats and power cables.

Heater branch circuits shall be of maximum 32 A for single-phase circuits and 3 x 20 A

for three-phase circuits. Each circuit shall be loaded only up to 80% of its rated
capacity.

The branch circuit shall be controlled by MCB and contactor.

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ELECTRIC HEAT TRACING

DOCUMENT NO : GEN-SPC-ELC-6102 REV. : B PAGE 11 of 13

To prevent overloading of the heater conductors, the maximum length of a parallel

heating cable shall be limited in accordance with the specification of the Vendor.

Through connections or ‘Tee-offs’ shall not be made underneath the pipe insulation;
only end-seals and ‘cold-lead’ connections may be used. All other connections shall be
made in connection boxes. Sufficient heater capacity shall be installed to ensure that,
towards the end of the heating cable, the output does not drop below the minimum
design value owing to the voltage drop in the heater conductors.

7.2 Temperature Controller

Temperature controller shall be provided for each circuit in distribution panel. The
temperature controller shall be connected to the RTO and shall control the contactor
and its circuit.

Temperature controller shall make sure the temperature maintained in the pipe is the
true temperature or temperature listed in line list by switching on and off the contactor.

Short pipes carrying the same liquid can be grouped under one circuit and one
temperature controller shall be provided for this circuit. RTD for the same shall be
located at the biggest pipe.

7.3 Local Thermostats

Electronic Temperature Controller with PT-100 sensor should be used for temperature
control. The contacts of the controller used for direct switching shall have a minimum
rated capacity of 16 A.

7.4 Connection Boxes

Power Junction Boxes shall be used for connections between supply cable and heater
cables; The power Junction Box Should have two power cable entrances at least with
ingress protection IP65.

7.5 Heater Installation

Extreme care shall be taken to prevent heater cables and pads absorbing water during
transport as well as during and after installation. During transportation to the site, the
ends of the cables or the connection leads shall be suitably sealed by heat shrinkable
adhesive end-seals, which shall remain fitted until the final connection is made in the
junction box, switch. etc..

GEN-SPC-ELC-6102 REV. B (ELEC.HEAT TRACING)

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ELECTRIC HEAT TRACING

DOCUMENT NO : GEN-SPC-ELC-6102 REV. : B PAGE 12 of 13

The heater cables or the cold leads shall be terminated in the junction boxes, switches,
etc. in such a manner that any ingress of water through the cores, braiding or in
between insulation layers due to the capillary effect is excluded.

Heater shall be installed in accordance with the SUPPLIER’s instructions. All heaters
shall be fixed to ensure continuous and permanent contact with the surface to be
heated over the entire (hot) length.

Entry kits shall be used where heating cables, cold leads or temperature leads enter
the thermal insulation to prevent damage and to ensure weatherproofing. The entry
kits shall be fixed to the bottom part of the pipeline.

Heating cable fixed to pumps, valves, flanges etc. shall allow easy removal of the
equipment without damaging the cables. To obtain good contact between heater and
heated surface, additional metal tape or foil shall be provided on both sides of the
pumps, valves, flanges etc. to avoid loosening of the heater from the associated pipes.
Special measures shall be taken to prevent sharp edges or rough surfaces damaging
the heaters.

Fixing materials for heaters shall ensure continuous and permanent contact between
heater and heated surface. They shall be non-corrosive and suitable for the relevant
operating temperature, and shall not damage the heater mechanically or chemically.

Junction boxes and wiring devices shall not be attached to the insulation, but shall be
mounted on brackets fabricated of angle, channel or other material of sufficient
strength to support equipment mounted on them. Brackets shall not be mounted on
pipes but rather, on separate supports.

8.0 IDENTIFICATION

Electrically heat traced piping and equipment shall be clearly identified with suitable
durable weatherproof caution signs, to read “Electrically Traced”, visible from all sides.
Signs on traced pipelines shall not be more than 5 metres apart and positioned on
alternate sides of the sheathing/ cladding.

Traced branch pipes, instruments, etc. shall carry individual signs.

The elements of a circuit such as local switches, thermostats, connection boxes and
heaters shall be provided with permanent labels, which shall consistently indicate the
number of the circuit to which the elements are connected.

The labels shall be fixed on a non-removable part; for heaters the labels shall be fixed
on the sheathing of the associated pipelines or equipment.

9.0 TESTING AND COMMISSIONING

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ELECTRIC HEAT TRACING

DOCUMENT NO : GEN-SPC-ELC-6102 REV. : B PAGE 13 of 13

9.1 Factory Testing

The “Type” testing of the trace heaters shall be done in accordance with section 5.1 of
IEC 62086-1.

The “Routine” testing of the trace heater shall be done in accordance with section 5.2
of IEC 62086-1.

Before leaving the SUPPLIER’s works, each length of cable or panel shall be subject
to inspection, dielectric testing and verification of rated output. Results shall be
recorded in test reports, which shall be distributed as specified in the purchasing
documents.

9.2 Commissioning

Heating cables and surface heaters should be visually checked for damage incurred
during shipping and handling. Continuity and insulation tests may be made as a final
quality check.

Prior to the application of thermal insulation, the insulation resistance of the heating
cable shall be measured under normal dry conditions and before associated wiring or
control equipment is connected. The measured value should not be less than 20 MΩ
AT 500 V (dc).

For heating devices provided with a non-metallic over jacket, an insulation resistance
test should be performed between the metallic covering and ground at 500V (dc) after:

Installation of the heating device on the pipe/ vessel, and Installation of the thermal
insulation. These tests are used to detect damage to the over jacket during the
installation process. It is recommended that the insulation resistance of the entire
branch circuit, after the thermal insulation is complete, should not be less than 10 MΩ
measured at 500V (dc).

GEN-SPC-ELC-6102 REV. B (ELEC.HEAT TRACING)