Self-regulating

Heat Trace

PSD 179
Systems

Continuing Education from Plumbing Systems & Design

JULY/AUGUST 2011

PSDMAGAZINE.ORG

INTRODUCTION
A hot water self-regulating heat trace system can be used for prompt
delivery of hot water at the fixtures. A heating cable system is one of
several accepted methods of providing prompt delivery of hot water.
(See Chapter 14.)
Today’s buildings are more architecturally complex than those built
a decade ago and make ever increasing demands on the interstitial
space occupied by HVAC ductwork, mechanical piping, communica-
tion wiring, and electrical conduits. This, combined with the need to
conserve energy and water, challenge engineers to provide cost-ef-
fective, energy-efficient domestic hot water systems. Maintaining the
temperature of a domestic hot water system may entail establishing
a means to continuously recirculate the water via pumps, valves, and
additional piping. An alternative method is to use self-regulating heat
trace systems.
Water conservation has become a major concern in the past few
years. The need to conserve water has led to requirements for the use
of low-flow fixtures, including faucets, showers, and water closets. The
water wastage that occurs when cooled water is dumped down the
drain while the user is waiting for hot water to flow can no longer be tol-
erated. In addition to wasting a precious resource, this practice incurs
extra energy costs to heat the water and waste treatment costs to pro-
cess the wasted water. The ability to keep a pipe warm close to the point
of use is of particular interest with the low-flow fixtures used today.
Variables affecting the performance of a heat trace system include:
the system temperature range, time to tap, water wastage, and energy
efficiency. Designers should consider these factors along with instal-
lation and life-cycle costs when selecting the proper hot water self-
regulating heat trace system for a particular building.
SYSTEM DESCRIPTION
Electric heat tracing systems replace heat lost through the thermal
insulation on hot water supply piping to maintain the water at desired
nominal temperatures, eliminating the need for insulated recirculation
lines, pumps, and balancing valves. Preventing the hot water from cool-
ing also ensures that hot water is readily available when it is needed.
An electrical heat tracing system is not a substitute for a complete,
efficient domestic hot water system. It does not eliminate the need for
an efficient water heater. What a heat tracing system does is provide
another approach to the design and installation of a hot water system.
It does this by simplifying the hot water distribution system, thereby
minimizing the amount of piping required. Items such as additional
piping and balancing valves are unnecessary.
In a heat trace system, a self-regulating heating cable is attached
directly to the hot water supply piping and insulated. A self-regulating
heating cable adjusts its power at each point along its length to main-
tain nominal temperature throughout the piping system. Electrical
energy input is controlled by the cable’s construction to maintain the
required water temperature at the fixtures. No return piping or circula-
tion pump is required.
Successful installation of a heat tracing system requires coordina-
tion among the various tradespeople involved. Plumbers and electrical
Note: All decimal equivalencies in the metric calculations are rounded. Therefore, the metric conversions shown in the text may vary slightly from the
answers shown in the metric equations.
2 Plumbing Systems & Design JULY/AUGUST 2011
CONTINUING EDUCATION
and insulation contractors must be made aware of the specific require-
ments affecting each other’s work.
The information in this chapter will help the designer understand
electric heat tracing as it applies to hot water systems. With this infor-
mation, a designer should be able to:
1. Compare the merits of heat tracing and a recirculation system
based on the requirements of a specific project.
2. Identify the extent of piping requiring heat tracing.
3. Understand the role of thermal insulation in hot water heat tracing.
4. In coordination with an electrical engineer, determine the circuit
breaker/power requirements based on the estimated heat tracing
circuit lengths.
5. Translate the design requirements into a complete design for a
project.
All examples and descriptions in this chapter are based on copper
water piping with fiberglass thermal insulation and other typical
design conditions. While design parameters may differ and pipe and
insulation materials other than those discussed can be and frequently
are equipped with heat tracing, such jobs should be undertaken with
the design assistance of a qualified manufacturer’s representative.
PRODUCT DESCRIPTION
Only Underwriters Laboratories, Inc., listed electric heat tracing systems
for hot water temperature maintenance should be used. (Note: Thirty
mA ground fault equipment protection is to be used for all hot water
heat tracing circuits.) These tested and approved systems are based
on self-regulating heating cables that are specifically designed for hot
water temperature maintenance. (See Figure 15.1.) Heat is delivered
through a carbon matrix heating element that responds to temperature
changes. Whenever the temperature in the heat traced piping begins to
rise, the cable automatically reduces its heat output. Conversely, when
the water temperature begins to drop the cable reacts by increasing its
heat output. This self-regulating feature occurs along the entire length
of a heat tracing circuit to ensure that each point receives the amount
of heat necessary to maintain thermal equilibrium.
Heating cables, self-regulating or otherwise, intended for pipe freeze
protection or general temperature maintenance should not be used for
hot water temperature maintenance, since their performance has not
been matched to the requirements of hot water applications.
SYSTEM COMPONENTS
A hot water temperature maintenance system (such as the one shown
in Figure 15.2) typically includes the following components:
1. Self-regulating heating cable.
2. Power connection kit.1
3. Tee/inline splice kit (permits 2 or 3 cables to be spliced together).
4. Cable end termination.
5. Attachment tape (secures cable to pipe, use at 12 to 24 in. [305 to
610 mm] intervals).
6. Electric heat tracing label (peel and stick label that attaches to
insulation vapor barrier at 10 ft [3.05 m] intervals, or as required
by code or specification).
7. Fiberglass thermal insulation and vapor barrier.2
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 IDENTIFYING THE PIPING REQUIRING HEAT TRACING
Typically, main and branch lines that are ¾ inch (DN22) and larger
are the primary locations for the application of a hot water heat trac-
ing system. A heat traced line can maintain hot water to every point of
use. Systems with different pressure or temperature zones can easily be
accommodated in the design and layout of heating circuits.
Deciding how close to the point of use the heat tracing should be
installed depends on the following conditions:
1. The gallons per minute (liters per second) of the fixture.
2. The diameter of the runout line.
3. The number of times per day the fixture will be used.
4. The acceptable period of time to wait for hot water.
5. The acceptable level of water waste per fixture per use.
6. Any special requirements at the point of use.
Most new facilities require fixtures that limit the gpm (L/sec) used by
lavatories and showers. As a result, the length of uncirculated, non-heat
traced piping has become increasingly important. Table 15.1 shows the
correlation of time to get hot water (in seconds), to fixture flow rate, to
length of ¾ in. (DN22) diameter runout piping that is not temperature
maintained.

Table 15.1 Time for Hot Water to Reach Fixture (sec)

Fixture Distance from End of Heat Tracing Circuit to Point of Use (ft)
Flow Rate
(gpm) 15 20 25 30 40
1 23 30 38 45 60
1.5 15 20 25 30 40
2 11 15 19 23 30
2.5 9 12 15 18 24
3 8 10 13 15 20
3.5 6 9 11 13 17
4 6 8 9 11 15
Source: Courtesy of Thermon Manufacturing Co.
Figure 15.1 Construction of a Typical Heating Cable for Note: Numbers based on use of ¾ in. nominal diameter type L copper tubing.
Hot Water Temperature Maintenance. Calculations are based on the heat loss from the piping and do not include
the amount of heat required to heat the piping or the water in the piping. See
Source: Courtesy of Raychem Corporation. Chapter 14 for these values.

Table 15.1(M) Time for Hot Water to Reach Fixture (sec)

Fixture Distance from End of Heat Tracing Circuit to Point of Use (m)
Flow Rate
(L/sec) 4.6 6.1 7.6 9.1 12.2
0.06 23 30 38 45 60
0.1 15 20 25 30 40
0.13 11 15 19 23 30
0.16 9 12 15 18 24
0.19 8 10 13 15 20
0.22 6 9 11 13 17
0.25 6 8 9 11 15
Source: Courtesy of Thermon Manufacturing Co.
Note: Numbers based on use of DN22 nominal diameter type L copper
tubing. Calculations are based on the heat loss from the piping and do not
include the amount of heat required to heat the piping or the water in the
piping. See Chapter 14 for these values.
Figure 15.2 Components of a Hot Water Temperature
Maintenance System. While considering the time factor may be important for the purposes
Source: Courtesy of Thermon Manufacturing Co. of keeping users satisfied, there is a more critical issue. Even with low-
Note: See “System Components,” above, for identification of flow fixtures, the amount of water wasted by dumping water until the
numbered parts. desired temperature is reached can be significant. (See Table 15.2.)
1
Power connection kits do not include electrical junction boxes.
2
All heat traced lines are to be thermally insulated with fiberglass.
Refer to the manufacturer’s insulation schedule for insulation
information.
JULY/UGUST 2011 Plumbing Systems & Design 3
 CONTINUING EDUCATION: Self-regulating Heat Trace Systems
Table 15.2 Water Wasted While Waiting for Hot Water to Reach Fixture
(oz)
Nom. Diam. Distance from End of Temperature Maintenance to Point of Use
Type L (ft)
Copper (in.)
15 20 25 30 40
¾ 48 64 80 97 129
Source: Courtesy of Thermon Manufacturing Co.
Notes:
1. Remember to add up all the fixtures in a facility and to multiply by both the
waste number shown and the expected number of usages per day.
2. Numbers based on line diameter and distance from end of temperature
maintenance.

Table 15.2(M) Water Wasted While Waiting for Hot Water to Reach
Fixture (mL)
Nom. Diam. Distance from End of Temperature Maintenance to Point of Use
Type L (m)
Copper
4.6 6.1 7.6 9.1 12.2
DN22 1420 1895 2365 2870 3815
Source: Courtesy of Thermon Manufacturing Co. Figure 15.3 Symbols Used to Indicate Components of a
Notes: Heat Traced Hot Water Supply System.
1. Remember to add up all the fixtures in a facility and to multiply by both the
waste number shown and the expected number of usages per day. Source: Courtesy of Thermon Manufacturing Co.
2. Numbers based on line diameter and distance from end of temperature Note: The numerals inside the symbols refer to circuit numbers.
maintenance.

Table 15.3 Nominal Maintenance Temperatures, °F (°C)

DESIGN CONSIDERATIONS Ambient Range, Hospitals, Hospitals, Kitchens,
°F (°C) Nursing Homes, Hotels, Condos, Laundries
Heating cable systems do not require system balancing. Often they are Prisons Prisons, Schools
used in buildings with significant lengths of return piping relative to
75–80 105 (42)
the lengths of supply piping or in hot water systems requiring multiple
circulation loops. (24–27)
Heating cable systems may not be economical in buildings with 72–80 120 (49) 140 (60)
doughnut configurations and small amounts of return piping. Such
(22–27)
systems still may be selected, however, if the designer wishes to elimi-
nate flow balancing. Source: Courtesy of Thermon Manufacturing Co.

Multiple Temperature Systems
For systems requiring multiple temperatures, heating cable can be
installed on the supply piping after the mixing valve to maintain the
different temperatures independently.
Remodels and Additions
For buildings with existing return systems, heating cable systems can be
installed in the additions so that hot water temperature is maintained
in the new piping without affecting the performance of the existing hot
water systems.
COORDINATING DESIGN INFORMATION
To get the most from each heat tracing circuit, the designer should
establish the maximum circuit length based on the number of circuit
breakers available for the project. (Note: Maximum circuit lengths
vary according to the voltage and temperature selection.) Regardless
of a building’s shape and size, it is recommended that the heat tracing
circuits be organized to follow the layout of the cable. For ease of iden-
tification during the layout process and for effective communication,
the designer should identify the piping requiring heat tracing on the
plumbing drawings. While indication of the heating cable, power con-
nection, end termination, and tee splice kits is given on the plumbing
drawings, only the power connection points need to be referenced on
the electrical drawings.
The symbols shown in Figure 15.3 are routinely used to indicate
components of a heat traced hot water supply system.
DETERMINING THE TEMPERATURE TO MAINTAIN
The desired temperatures for most applications are given in Table 15.3
along with the ambient temperature ranges of the space surrounding
the insulated pipe. The appropriate self-regulating cable is chosen
based on the desired maintenance temperature. If temperatures differ
from those shown, contact the manufacturer.
CHOOSING THE RIGHT CABLE
After determining the extent of the hot water supply piping to be heat
traced, the designer should decide the lengths to be maintained at 105,
120, and/or 140°F (42, 49, and/or 60°C). At this point, the total length
of each type of heating cable can be determined. Using the manufac-
turer’s published maximum circuit length for the desired temperature
cable, the designer can figure the required number of circuits. These
maximum circuit lengths should not be exceeded; otherwise, there will
be excessive electrical currents in the bus wires of the heating cable.
The maximum circuit length is the total length of cable that can be fed
from a single power connection point, inclusive of all splices, includ-
ing tees. Note that circuit lengths that are longer than these maximum
lengths may require larger circuit breakers. The designer must be sure
to check with the electrical engineer the available amperages of the
branch circuit breakers supplying power to the heat tracing. After the
required number of circuits is determined, that information should
also be checked with the electrical engineer. This will ensure that the
proper number of circuits has been allotted in the power distribution
system.
THERMAL INSULATION
While frequently overlooked, thermal insulation plays a critical role in
ensuring that hot water is available at the point of use. This is true for
both recirculation and heat traced hot water systems.
The standard design for heat traced piping (the design that manufac-
turers’ design guides are based on) utilizes fiberglass thermal insula-
tion with a kraft paper vapor barrier. Thicknesses range from 1 to 2 in.
(25.4 to 50.8 mm) based on line diameter. If a heat traced hot water

4 Plumbing Systems & Design JULY/AUGUST 2011 WWW.PSDMAGAZINE.ORG

 four-story facilities, such as hospitals, research labs, correctional facili-
ties, and campus dormitories.
In this example, the supply main is located in the interstitial space
between the first-story ceiling and the second-story floor. Because each
story has roughly the same layout and water use points are stacked, a
riser and drop are used to supply water at each plumbing location.
Electric heat tracing is installed on the horizontal mains and the
risers. Since the distance between the horizontal piping and the first-
story runouts is minimal (less than 15 ft [4.57 m]), heating cable is not
required beyond the horizontal line connecting the main to the riser.
Since this example is of a four-story facility, it is recommended that
heating cable be installed up to the feed point for the third story. The
line feeding from level three to level four again is less than 15 ft (4.57
m), and under most conditions a line of this length does not require
heat tracing. Untraced lines should be installed so as to prevent rapid
heat loss between uses. While this example is somewhat simplistic, the
design principles it demonstrates can be applied to a project of any
size.

Figure 15.4 Partial Simplified System Typical of Hospitals, Correc- HOT WATER HEAT TRACING TERMS
The following terms apply to all hot water heat tracing systems and
tional Facilities, and Hotels.
may aid in the selection of the appropriate system for each project.
Source: Courtesy of Thermon Manufacturing Co. 1. System temperature range. For a return system, this is the
system is designed to use only one cable for each temperature range, allowable temperature drop to the end of the system plus any
the thickness of the insulation will vary. additional variability caused by improper system balancing. With
Manufacturers of hot water heat tracing systems have established return systems, there is a trade-off between desired system per-
insulation schedules that outline the thicknesses required to keep the formance and the life-cycle cost of the system. For a heating cable
heat loss within the desired range. Note that in these schedules the system, the system temperature range is the range around the
insulation on piping 1 ¼ in. (DN35) in diameter and smaller is over- nominal maintenance temperature.
sized to allow space for the heating cable. 2. Unheated distance. This is the distance in feet (meters) between
After the installation of the heating cable and thermal insulation the last maintained leg of hot water piping and the point of use.
is completed, the piping is identified with stick-on labels to note the For example, if hot water temperature is maintained only for the
presence of electric heat tracing. This labeling gives notice to facility main run, the distance from the main to the point of use is the
maintenance workers that heating cable has been installed under the unheated distance.
insulation should any pipe maintenance or renovations be required. 3. Time to tap. This is the time required for hot water to reach the
fixture when the fixture is turned on. If the hot water temperature
HEAT TRACING HOT WATER PIPING
is not maintained all the way to the fixture, the cold water in the
The design of a heat tracing temperature maintenance system for mains
pipe must be drawn out before the user gets hot water. The length
and branch lines can be done on the plumbing drawings. (See Figure
of the wait is called time to tap. It is a function of the unheated
15.4.) By referring to the manufacturer’s heating cable selection chart
distance, the gpm (L/sec) flow rate, and the diameter of the pipe.
for the desired maintenance temperature, the designer can determine
the maximum heating cable circuit length for circuit break-
ers of different sizes. Taking this information into account
when laying out the hot water lines will ensure optimum
use of the circuit lengths.
Note, in Figure 15.4, that the main and branch lines are
heat traced and insulated while the short runouts are only
insulated. (Runouts that feed individual points of use typi-
cally contain less than ½ gal [1.89 L] of water. If the faucet
flow rate is above 1½ gpm [0.1 L/sec], hot water will reach
the point of use within 10 sec.) If the distance between the
branch line and the point of use is much longer than 40 ft
(12.19 m) or the flow rate is lower, the potential for water
wastage and the time required for hot water to reach the
point of use may be beyond the levels considered accept-
able for the facility. To remedy this situation, simply heat
trace closer to the point of use.
COMBINING HORIZONTAL MAINS WITH
SUPPLY RISERS
Designers of multilevel facilities often duplicate floor
plans over several levels, which simplifies the layout of
electrical, HVAC, and mechanical equipment. This practice
Figure 15.5 Typical Layout for 2 to 4-Story Hos-
also simplifies the layout of hot water supply lines, unless
there is a maze of recirculation piping and balancing valves
pitals, Research Labs, Correctional Facilities, and
are required. Figure 15.5 shows a layout typical of two to Dormitories.
Source: Courtesy of Thermon Manufacturing Co.

JULY/UGUST 2011 Plumbing Systems & Design 5

 CONTINUING EDUCATION: Self-regulating Heat Trace Systems

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The July/August 2011 continuing education article is
“Self-regulating Heat Trace Systems.”
Now Online! A hot water self-regulating heat trace system is one of
several accepted methods of providing prompt delivery of
The technical article you must read to complete the exam is located at
www.psdmagazine.org. Just click on “Continuing Education” at the top hot water to fixtures. Electric heat tracing systems replace
of the page. The following exam and application form also may be down- heat lost through the thermal insulation on hot water
loaded from the website. Reading the article and completing the form will supply piping to maintain the water at desired nominal
allow you to apply to ASPE for CEU credit. If you earn a grade of 90 percent temperatures. The information in this chapter will help
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SD 179
CE Questions — “Self-regulating Heat Trace Systems” (PSD 179)
1. A designer should consider ________ when selecting the proper 7. Using ¾-inch Type L copper pipe, how much water is wasted in
self-regulating heat trace system for a particular application. the time it takes hot water to reach a fixture that is 25 feet from
a. life-cycle costs the end of the temperature maintenance?
b. energy efficiency a. 48 ounces
c. time to tap b. 64 ounces
d. all of the above c. 80 ounces
d. 97 ounces
2. Electric heat trace systems eliminate the need for ________.
a. a water heater 8. Which of the following should be referenced on both the
b. balancing valves plumbing and the electrical drawings?
c. pumps a. power connection
d. both b and c b. end termination
c. tee splice kits
3. A typical heating cable consists of which of the following?
d. heating cable
a. insulating jacket
b. power source 9. A _______ is used to indicate a power connection point on
c. nonconductive core plumbing drawings.
d. none of the above a. triangle
b. square
4. Which of the following is part of a hot water temperature
c. diamond
maintenance system?
d. circle
a. power connection kit
b. electrical junction box 10. The desired nominal maintenance temperature for a school is
c. self-regulating heating cable what?
d. both a and c a. 105°F
b. 120°F
5. Heat-traced lines should be thermally insulated with _______.
c. 140°F
a. copper
d. none of the above
b. foam
c. fiberglass 11. The standard vapor barrier for heat trace piping is made of
d. kraft paper _______.
a. copper
6. How long will it take hot water to reach a 1.5-gpm fixture if the
b. fiberglass
end of the heat-tracing circuit is 30 feet from the fixture?
c. kraft paper
a. 18 seconds
d. foam
b. 23 seconds
c. 30 seconds 12. For a heating cable system, _______ is the range around the
d. 45 seconds nominal maintenance temperature.
a. time to tap
b. unheated distance
c. system temperature range
d. none of the above

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Self-regulating Heat Trace Systems (PSD 179)
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