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Abstract - Methods to measure and predict maximum approval agencies, such as CSA, FM and UL. In addition,
sheath temperatures of mineral insulated (MI) heating cable from a practical standpoint, the industry also needs MI heat
vary by testing agency, standards writing body and tracing designs to be cost-effective and easy to install and
manufacturer. This has resulted in confusion in the industry maintain. This paper proposes an improved test method to
about the best approach to predict sheath temperatures of accurately predict the maximum sheath temperature as well
MI heat tracing cables. This paper presents an analysis of as strategies to optimize the designs with MI heat tracing
two different test methods for sheath temperature prediction. cables.
The test methods studied are commonly known in the Investigations into improved methods for predicting MI
industry as the 'pipe test' and the 'plate test'. The paper cable sheath temperatures began in 2001 when it was
demonstrates that the pipe test has significant variation in recognized that different manufacturers were predicting
the measured sheath temperatures in successive test runs different temperatures for similar cables (Figure 1), which is
while the plate test produces a much more repeatable and contrary to what the principles of thermal heat transfer would
accurate result. The paper proposes the use of the plate test predict. The lack of consistency suggested that there was no
as a preferred method to measure and predict maximum industry-wide consensus as to the method that should be
sheath temperature. As a related topic, the paper also used to reliably and consistently predict the sheath
presents general considerations for optimizing designs that temperature of MI heating cables under various conditions or
will reduce costs and improve constructability of electrical that the existing methods did not produce consistent results.
heat tracing designs using MI heat tracing cables. A case Some of the factors suspected of contributing to this
study is presented to demonstrate application of these situation were:
design optimization techniques. 1. the data was based on limited measurements that
were made over 30 years ago,
Index Terms - Mineral insulated (MI) heating cable, 2. the tools and equipment used to generate the data
sheath temperature, pipe test, plate test, electric heat were no longer state-of-the-art, and
tracing, electric trace heating, AIT 3. the data existed only in the form of tables and graphs
and was limited to a small subset of the conditions
I. INTRODUCTION that were of interest.
5hNIh TemperabJre tor 511&- (1.9 mm) M' cable on Pipe at 15O"C (300F)
In North America, the heat tracing industry has been 500
customers for freeze protection and for process temperature Manufadu irA. ----�
-- ----
0� V-- Manufac urer Manufadu
maintenance applications for more than 50 years. It is well Eurooe �
Manufact rerC
canada
known that because MI cables are constant wattage cables,
they produce the same amount of heat regardless of the
��...- ---�
temperature of the pipe on which they are installed. When MI --- .---
/. :::.---'
heating cables are used in classified areas, the Canadian ��
and US electrical codes require that the surface temperature
150 l/""
of electrical equipment, including MI heat tracing cables,
100
operate below the auto-ignition temperature of flammable
fluids or dusts in the area. Therefore, it is important to be 50
• , . 30 50 60 70 80
temperature the heating cable sheath will reach in any
particular installation. For this reason, having the capability to
Fig 1 - MI Cable Sheath Temperatures Predictions by Manufacturer
accurately predict sheath temperatures is also required by
Fig 5 - Valve and Insulation Fig 6 - AI-tape to plug the insulation gaps.
2
3.2 mm diameter MI Cable Sheath Temperatures at 300·C pipe
To further illustrate the lack of consistency in the pipe test
temperatura methodology, data was plotted in an "Isoplot" format. In this
MO r-------. plot, data is measured twice, by taking data from the same point
on a cable installed on two pipes. In an ideal, repeatable test,
these duplicate temperature measurements would be the same,
and the plot would give a straight diagonal line. It can be seen
soo , in Figure 8 that the data points do not fall on the line, but rather
indicate an unacceptably large measurement error of over
1OO°C. Figure 9 also shows that the variation in the sheath
temperature measurement in the pipe test increases at higher
400 sheath temperatures i.e. at higher wattages and higher pipe
10Wift temperatures. Under these conditions, it is believed that the
fIIt:N::M:."'.""':.""'� variation in the insulation installation and cable installation plays
ODD
x
x
• T1 • T2 T3
1-
•
. T17 - T18
Sculpture 3V$. Sculpture 2
TIM
200
Fig 7 - Pipe Sculpture Sheath Temperature Measurements
100 �����----�
Similar results were obtained when the pipe temperature was
not controlled using the internal heater and controller. The
sample heating cable was powered at various wattages and the
entire system was allowed to stabilize. For example, figure 8
shows that the pipe temperature at six different locations varies Fig 9 - Pipe Sculpture Repeatabiliity
by 80aC at 30 W/ft.
3,2 mm dlarnet.r MI Cable 8haath Tltmperalu ... at YOriou.
poww Iwv•• on a "IPI! ,...t
OOO r-------.
Recognizing that it was going to be difficult to generate
40
reproducible sheath temperatures using the pipe test, a second
522
sheath temperature test method was evaluated. This test,
ooo t-------��--1 which is a modified version of the test described in BS 6351
"Electric Surface Heating. Code of Practice for the Installation,
oT1 Testing and Maintenance of Electrical Surface Heating
oJ2
T3 Systems" [2], is commonly referred to as the "plate test". This
T4 test uses a 600 mm x 600 mm x 50 mm metal plate which is air
>T5
cooled, electrically heated and well insulated. In the procedure,
+T7
oTe
10W/ft ·T8
the cable is laid on the plate over a trough to simulate the field
condition where the heating cable is not in direct contact with
the pipe. Figure 10 illustrates a typical plate test set up, with the
heating cable in place, and the plate surrounded by thermal
200
insulation, but left uncovered to illustrate the location of the
cable and thermocouples. After many trials, it was determined
156
-T17
-T18
that deeper troughs produce higher sheath temperatures up to
.T19 a 5-mm trough depth with no additional effect beyond a 5-mm
100 T20
104 100 depth.
3
332SA2600 (3.2 mm, Incoloy Sheath, Plate Test and Pipe Test Results
600
500 �
400
�1 c
§
�
r 8
@
Plate Test JOO"C
I I
c __
100
.. ..
Pow_tWfmI
2D 40 .00 .40
4
experimental results since the agreement between the two data the applications where the desired temperature to be
sets was excellent. The graphical output for one experimental maintained is relatively high and the area temperature rating is
condition is illustrated in Figure 13, confirming the temperature relatively low. In these cases, the standard heat tracing designs
range over the length of the modeled heating cable. Figure 14 would require multiple passes of MI cables with lower wattage
shows good agreement between the data predicted by the FEA in order to keep the maximum sheath temperatures below the
for cables at 50°C and 300°C and the data obtained area temperature rating. The design techniques listed below are
experimentally on the plate test. used to improve constructability by reducing the number of
The experimental results show that the plate test is a more passes while still ensuring reliable performance of the heat
repeatable and accurate method of predicting maximum sheath tracing systems. These methods have been proven effective for
temperatures for MI heat tracing cables. various real life applications and are continuing to be employed
in improving electrical heat tracing system designs:
462.46 Max
422.99 a) Investigate use of polymeric heating cables - Use of a
383.51 self-regulating, power-limiting or other heating cable
344.04
technology may be a suitable alternative since polymeric
304.57
265.09 heating cables do not have similar sheath temperature
225.62 considerations as MI cables. However, the user must
186.14 ensure that the alternate technology is applicable for the
146.67 given maintain and exposure temperatures as well as
107.19111in
ensure that the alternate technology provides a benefit in
reducing the number of heating cable passes as
compared to the MI cable design.
b) Review the area T-rating- Engineering assumptions for
establishing T-Ratings are often generalized for entire
facilities instead of considering the actual materials in a
y
specific section of the facility. Considering the AIT of the
specific hazards in the area may allow raising the
0 000 0.200 (m) acceptable equipment temperature, thus allowing higher
I outputs for a given cable and reducing the number of
0.100
Fig 13
cable runs required.
- MI Cable FEA Model of Sheath Temperature
c) Review the minimum ambient temperature assumption-
Heat loss calculations are based on a certain minimum
Comparison of Plate Test and FEA Results ambient temperature assumption. This minimum
ambient temperature may be increased based on the
600 actual history at the location which will potentially reduce
Q
OJ
Ii
550
500
,-�
/--.;.-� I d)
the calculated heat loss and number of passes of
heating cable.
Review the required maintain temperature assumption-
l"
450
""�.;;>:::-:;;.;;-� /<_-0
.Ie] I The heat input to maintain a pipe at a certain
/vJ
OJ
E
a.
400
.. / /� I temperature can be reduced if the required temperature
f!!. //' /";/
.. -;;;.//
I at which the pipe is to be maintained can be lowered
.s 350 //
/"
'"
r---� based on the actual fluid characteristics.
6 Exp_300C Plate
OJ
300 /
..c
Vl e) Rationalize the safety factor - As in any engineering
6 FEf,_300C PIGte
/ff""
-'
::?: design, safety factors are used in EHT system design to
E 250
o Ex�_50C PI.te ensure that design assumptions made can withstand a
/:/5.1
=>
o FEA_SOC 'late
E 200
'x certain level of variation from assumed values as actual
I
'"
::?: 150
g/ operating conditions change. Often the safety factors
I used can be rationalized for practical considerations. In
100
particular, as the Nominal Pipe Size (NPS) increases,
a so 100 150 200 the safety factor (SF) for the EHT design can be reduced
Cable Power Density [W/m) without adversely affecting system performance given
that larger thermal mass will exist in a pipe as the
Fig 14 - Comparison of Plate Test and FEA
diameter increases. As the safety factor is reduced, the
calculated heat loss is reduced which may reduce the
III. DESIGN OPTIMIZATION TECHNIQUES
number of passes of MI heating cables. The decision to
reduce the safety factor will also depend on the durability
After addressing the industry need to reliably and accurately
of the insulation and cladding material as well as the
predict the MI sheath temperatures, it was decided to develop
quality of the insulation installation. These factors must
design optimization techniques to further improve and optimize
carefully be considered before proceeding with a safety
the electrical heat tracing designs using MI heating cables. The
factor reduction.
driver behind this initiative was the industry need for simple,
cost effective, constructible, and easy to install and maintain f) Use insulation with improved K-Factor - Improving the
thermal resistance of the insulation has the same effect
electrical heat tracing designs using MI cables. There are many
as increasing the insulation thickness, thereby reducing
opportunities to optimize designs and reduce costs especially in
5
the heat loss to ambient. There are several alternative The technique in Figure 3 uses the design from Figure 2 (T
insulations available beyond the standard mineral wool rating change) and rationalizes the safety factor. H ere the
and calcium silicate insulation that are available for use, safety factor has been rationalized from 25% to 15%. This
with a potential to reduce the number of passes of MI results in the removal of one more pass of cable from 5
heating cables. passes in the Figure 2 design down to 4 passes in the Figure
g) Use a larger diameter MI heating cable- Under identical 3 design.
conditions, the sheath temperature for a larger diameter Finally in Figure 4 the designer has re-zoned the area and
MI cable will be lower than that of a smaller diameter limited the zone to a single flow path and has calculated the
cable. Thus use of a larger diameter MI cable may sheath temperature as a control limited design instead of a
enable higher wattage cables thereby reducing the stabilized design. This results in an EHT design using only 3
number of passes. passes of cable, down from the original base design of 7
h) Limit design to a single flow path where 'control limited' passes.
methods can be used - The sheath temperature of the
MI cable can be limited using controllers if a single flow V. CONCLUSIONS
path design is used rather than multiple flow paths under
a single heat tracing circuit. The current IEEE 515 contains a pipe test to predict MI
i) Increase insulation thickness - Increasing the insulation heating cable sheath temperatures which can lead to
thickness will reduce the heat loss thereby reducing the inaccurate and varied sheath temperature predictions
number of passes of heating cables. However this could throughout the industry. The plate test method has proven to be
be a potentially expensive option and should be used if a much more repeatable, cost-effective and accurate method of
and only if the standard design is not acceptable. predicting and verifying sheath temperatures. Maximum sheath
j) Consider the use of small, step-down low voltage temperatures measured using the plate test are in agreement
transformers - Using a step-down transformer will with the maximum sheath temperatures measured on the pipe
reduce the voltage supplied to an MI heating cable and test, with the plate test having the significant advantage of
consequently reduce the sheath temperature and being able to easily capture the hottest temperature along the
number of cable passes. Typically a 10 kVA transformer cable sheath. Due to the variability in the cable and insulation
will have 120 V primary supply with tap-selectable installation in the pipe test, the location where the maximum
secondary supplies of 10, 20, 30, 40, 50 and 60 V. This sheath temperature is measured varies from one set-up to the
can often be a cost effective method to reduce the other and cannot be recorded reliably. The plate test should be
number of passes of heating cable. considered as the method of choice to verify and predict the
maximum sheath temperatures in future releases of the IEEE
IV. CASE STUDY 515 standard, with the goal of entirely phasing out the pipe test
method. The paper also presents optimization strategies to
In order to demonstrate these design optimization reduce costs and improve installation and maintenance of the
techniques, an actual installation was chosen and selected electrical heat tracing designs while ensuring reliable system
techniques were applied from the base design to show how performance. These methods have proven effective for various
the techniques can assist in developing EHT designs that are real life applications and are continuing to be employed in EHT
constructible and maintainable while using the higher sheath system design.
temperatures as measured on the plate test.
The case study is illustrated in Appendix A, showing four VI. ACKNOWLEDGEMENTS
variations of an EHT design of a particular pipe segment.
Figure 1 is the base design where the designer has chosen to The authors would like to acknowledge the technical
use multiple passes of a lower wattage cable, thereby contributions of Latif Ahmadyar, P.Eng, Tyco Thermal
lowering the sheath temperature to meet the area temperature Controls Engineering Supervisor who developed the case
rating of 260°C. This design results in 7 passes of cable study for this paper.
along the main section of the pipe segment. Although this The authors would like to acknowledge the technical
technique of using more passes of a lower wattage cable contributions of Ningli Liu, Tyco Thermal Controls Product
achieves a design that meets the area temperature rating, it Development Engineer, who developed the FEA simulation for
has the significant drawback of having too much cable to this paper.
actually physically assemble on the pipe, along with the
associated problems with maintenance of valves or pumps VII. REFERENCES
and having to disassemble and re-assemble the multiple
passes. Further steps are needed here in order to optimize [1] IEEE 515, May 2004, IEEE Standard for the Testing,
the design and reduce the number of passes of cable. Design, Installation, and Maintenance of Electrical
The next technique applied to the base design is shown in Resistance H eat Tracing for Industrial Applications, New
Figure 2. In this design, the T-rating of the hazardous location York, NY: IEEE.
was T2 (300°C) based on the auto-ignition temperatures of [2] BS 6351-3, November 1983, Electric Surface Heating.
flammable fluids in the area. With the new T-rating, 7 passes Code of Practice for the Installation, Testing and
in the base design are reduced to 5 passes in the Figure 2 Maintenance of Electrical Surface Heating Systems: BSI
design. Although 5 passes is more manageable from an
installation and maintenance standpoint, some further VIII. VITA
optimization can still be performed.
Ron Jurchuk has a 1975 Electronic Technology diploma from
6
Fanshawe College and a 1981 Bachelor of Applied Science
Degree in Electrical Engineering from the University of
Waterloo. Ron has 20 years' experience with Imperial Oil and
Suncor in the petroleum refining and oil sands industries. He is
currently employed by Tyco Thermal Controls in Fort
McMurray, Alberta. He has been with Tyco Thermal Controls
for 9 years. Ron is a Certified Engineering Technologist in
Alberta as well as a registered Professional Engineer in the
provinces of Ontario & Alberta. He is a 35-year member of the
IEEE and has authored 2 IEEE PCIC conference papers.
7
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