Installation of self-regulating and power limiting cables

1. INSTALLATION OF SELF-REGULATING and POWER LIMITING CABLES

Private and Confidential

2. Why do we install heat tracing?

Private and Confidential
page 2

3. Purpose

This presentation is a supplement to
the Installation and Maintenance
Manual for Self-Regulating and
Power Limiting Heating Cable
Systems.
It outlines Pentair Thermal Controls
cable installation protocol.
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4. Outline

Types of Cables
Installation Preparation
EHT Components
Attaching Cables
Typical SR and VPL Installation
Installing the C25-100 Connection Kit
Installation Details
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5. Types of Cables

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6. Types of Cables

BTV
QTVR
XTV
KTV
SELF REGULATING CABLES
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VPL
POWER
LIMITING
page 6

7. Self-Regulating Cables

Power varies with temperature. As
pipe temperature increases the
power output decreases.
At high temperatures, the polymer
expands, reducing the number of
the conductive paths, and thus
reducing current flow.
At low temperatures, there are
many conductive paths, allowing
current to flow between the
conductors.
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8. Power-Limiting Cables

The most important thing to be aware of on
the VPL cable is the location of the node. It
regulates where the cable is to be cut.
Fluoropolymer
outer jacket
Metal Braid
Power-limiting heating element
Fluoropolymer inner jacket
Fluoropolymer conductor insulation
Nickel-plated, copper
conductors (3.3 mm²)
Node connection (zone length 0.5-1.2 m)
Fluoropolymer clear jacket
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9. Power-Limiting Cables

When power limiting
cable is cut between
nodes.
A portion of that cable
no longer heats up.
This is why it is
important to always
leave an extra loop at
terminations for power
limiting cable.
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10. Installation Preparation

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11. Pre-Installation Checks

Check installation documentation
Check materials
Check piping and/or equipment to be traced
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12. Check Installation Documentation

Upon receiving the construction
documentation, or Electrical Heat
Trace (EHT) work pack, the
installer is to inspect the
documents to confirm all
documents are included and the
correct.
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13. Check Installation Documentation

Size of Electrical Heat Trace
(EHT) work pack changes form
job to job, but the installer
receives at a minimum the
isometric drawing(s) of the circuit.
QUANTITY SHEET
WORK CARD
Private and Confidential
HEAT TRACE ISOMETRIC(S)
INSTALLATION
CHECKLIST
MATERIALS
LIST
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14. Check Installation Documentation

Confirm all isometric continuations are included
in the work pack.
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15. Check Installation Documentation

Ensure that all required
permits are in place for the
area in which the installation is
to take place.
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16. Check Materials

Inspect the heating cable and components to
ensure that there is no visual damage.
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17. Check Materials

Test the insulation resistance of the cable.
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18. Check Piping and/or Equipment

Ensure that the length, diameter, and the configuration of
the piping is the same as the design documents.
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19. Check Piping and/or Equipment

Ensure that there
is no piping or
equipment
missing.
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20. Check Piping and/or Equipment

Walk the entire line and plan
the routing of the heating
cable(s) on the pipe and the
heat sinks (valves, supports,
drains, etc.).
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21. Pulling and Laying Out of Cable

When pulling the SR or VPL
cable avoid:
Sharp edges
Excessive pulling force
Kinking or crushing
Walking on it or running over it
with equipment
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22. EHT Components

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23. Typical Integrated EHT System

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24. Typical Modular EHT System

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25. Integrated Power Connections

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26. Integrated Power Connections

JBS-100-E(P)
JBM-100-E(P)
C-150-E
(Under Insulation)
VPL
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27. Modular Power Connections

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28. Modular Power Connections

JBU-100-E(P)
JB-EX-25
JB-EX-27
JB-EX-28
JB-82
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29. Modular Power Connections

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30. Modular Power Connections

Applications
Instruments and analyzers
Vessels, pumps, and other
equipment
Off pipe installation required
Wall mounts
Customer preference
Replacement of existing EHT
systems
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31. Connection Kit

The C25-100 is the most commonly used connection kit
for both self-regulating and power limiting cables.
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32. Insulation Entry Kit

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33. Tee Connections

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34. Tee Connections

T-100
JBM-100-E(P)
S-150
(Under Insulation)
VPL
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35. End Seals

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36. End Seals

The E-100-E and the
E-100-L-E are both
high profile (above the
insulation) end seals.
The E-06 (for BTV &
QTVR), E-19 (for XTV
& KTV) , and the E-50
(for VPL) are low
profile heat applied
end seals.
The E-150 is a low
profile cold applied
end seals.
VPL
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37. Splice Kits

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38. Splice Kits

The T-100 is high profile
(above the insulation) splice
kit that can handle up to 3
cables.
The S-19 (for BTV), S-21 (for
QTV), and the S-69 (KTV
and XTV) are heat applied
low profile splices.
VPL
The S-150 is a cold applied
low profile splice.
VPL
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39. Temperature Sensors

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40. Temperature Sensors

AMBIENT CONTROL
MONI-PT100-EXEAMB
T-M-10-S/0+50C
AT-TS-13
RAYSTAT-EX-04
RAYSTAT-ECO-10
FOR HAZARDOUS AREAS
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41. Temperature Sensors

LINE SENSING
T-M-X-S/…C
AT-TS-14
MONI-PT100EXE
RAYSTAT-EX-03
RAYSTATEX-02
RAYSTATCONTROL-10
FOR HAZARDOUS AREAS
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42. Temperature Sensors

DUAL SENSING
(control and limiter)
T-M-X-S/+X+YC/EX
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43. Fixing SR and VPL Cables

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44. Fixing Cables

Cables are typically fixed at
an interval of 300mm and
additionally where
necessary (i.e.. Valves,
pumps, drains, electrical
devices, etc.)
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45. Fixing Cables

Glass tape is
EXCESSIVE TAPE
expensive and
should not be used
excessively.
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46. Fixing Cables

When approved by
engineering, aluminum tape
(AT-180) can be used to fix
cable and thermostat
sensors to piping and
equipment.
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47. Fixing Cables

DO NOT USE:
Metal Strapping,
Vinyl Electrical
Tape, or Duct
Tape
GT-66 or
GS-54
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48. Fixing Cables

If possible place the
cables at the 4 o’clock
and 8 o’clock positions.
For circuits with greater
than 2 passes evenly
space the cable on the
bottom half of the pipe.
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49. Fixing Cables

Minimum Bending Radius
BTV & QTV
XTV
KTV
VPL
at 20°C
15mm
15mm
25mm
20mm
at -60°C
35mm
50mm
50mm
20mm
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50. Bending Cables

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51. Fixing Cable

Do not install
trace so that it is
locked in place.
This trace was
wrapped around
the valve locking
it in place once
either side of the
valve is insulated.
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52. Fixing Cables

Installation on tanks typically requires additional prepunched strapping.
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53. Fixing Cables

Caution: The prepunched metal strap
has an extremely
sharp edge on the
bottom, thus it should
be folded back onto
the cable.
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54. Fixing Cables

Self regulating cables allow for multiple overlapping
of the cable on itself but due to the loss in heat output
this is to be avoided .
VPL cables can only overlap themselves once.
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55. Typical SR & VPL Installation

Typical SR & VPL
Installation
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56. Installation

On simple/straight the cable
can be pulled from a
stationary reel holder.
The meter marks on the
cable can be used to
indicate how much has been
reeled out.
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57. Installation

If absolutely certain of the
required length, the cable
could be cut from the reel.
CAUTION: This can lead to
the cable being too short
(requiring a splice or a new
cable) or being to long
(wastage).
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58. Installation

Tape down the
beginning
When piping is too
complex the reel
must be carried
alongside the
piping as it is
taped to the pipe.
Run the reel along the
pipe taping the trace as
you go.
Leaving allowances for
all the piping devices
and supports.
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59. Installation

Details
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60. Installation Details

Component Allowances
Always consult the
design specifications
(or Pentair Thermal
Controls product
literature if there is no
design spec.) for the
additional heating
cable lengths for
piping components.
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61. Component Allowances

Valves
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62. Valves

This drawing shows
the general
installation method.
Configurations will
change for different
valve shapes and
sizes and heating
cable lengths.
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63. Valves

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64. Valves

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65. Valves

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66. Valves

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67. Valves

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68. Valves

If it is physically
impossible to apply
the full recommended
cable allowance to the
body install the
excess on either side.
WELD
WELD
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69. Valves

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70. Valves

If it is physically
impossible to apply
the full recommended
cable allowance to the
body install the
excess on either side.
WELD
WELD
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71. Valves

For thin (butterfly)
valves install the
excess allowance on
either side of the
valve body.
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72. Valves

Elbows
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73. Elbows

Do not install EHT on an elbow’s heel (outside radius). This area
is especially vulnerable because insulators often drill pilot holes
for the screws that fasten the elbow cutouts together.
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74. Elbows

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75. Elbows

Flanges
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76. Flanges

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77. Flanges

Clamps
Sometimes clamps are used in place of flanges. Be
sure to install enough trace so that the clamp can be
removed without having to remove cable up and/or
downstream of the clamp.
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78. Clamps

Do not install cables
underneath anything
which clamps around
the pipe.
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79. Clamps

Pipe Hangers
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80. Pipe Hangers

Do not clamp heating cable
with support. Cable must be
over the support
An allowance is not
required for hangers, only
enough extra so that the
hangers clamp may be
removed without having to
remove a lot of cable up
and/or downstream of the
hanger.
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81. Pipe Hangers

Pipe Shoes
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82. Pipe Shoes

The typical pipe shoe
allowance is 1.2m but
always confirm with the
drawing or specifications
as to what is required.
The allowance loops
should always exceed the
length of the shoe so that
it can be easily fixed on
either side of the shoe.
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83. Pipe Shoes

Linear Length
Allowance (typically 1.2m)
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84. Pipe Shoes

Dummy Supports
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85. Dummy Supports

Dummy supports (or dummy
legs) are large heat sinks
which typically require 1.2m
of extra cable per pass.
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86. Dummy Supports

DUMMY LEG
PIPE SHOE
Linear Length
Adder (Typically 1.2m)
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87. Dummy Supports

Trunnions
Trunnions are basically just two dummy supports thus they
need twice as much allowance.
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88. Dummy Supports

Dead Legs
Dead legs are very rare but they are easily mistaken for a
dummy leg. Dead legs have “T” fittings with a short piece of
blocked off piping, where a dummy leg is just a support at an
elbow.
A dead leg fills with stagnant fluid thus it must be traced, the
dummy leg allowance will not do.
DEAD LEG
(MI cable shown)
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DUMMY LEG
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89. Dummy Supports

Pumps
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90. Pumps

Pumps vary in size, type, and shape
with various methods of being
mounted. This makes it difficult to
show a standard installation since
almost every pump configuration is
unique.
Plan the installation and have it
approved by the site supervisor or the
client.
Pumps often appear in pairs so be
sure to install the parallel pumps in the
same style.
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91. Pumps

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92. Pumps

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93. Pumps

Vessels
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94. Vessels

Larger vessels usually
require pre-punched
strapping to be
installed.
This helps keep
spacing and prevents
the cable from sagging
underneath the
insulation
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95. Vessels

The spacing of
the pre-punched
strapping should
be provided on
the vessel
drawing or
installation
details (typicals).
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96. Vessels

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97. Vessels

When approved by
engineering, aluminum tape
(AT-180) can be used to fix
cable to the vessel.
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98. Vessels

Install the SR (MI shown)
cable as per the
configuration shown on the
drawing And the spacing
specified by the drawing.
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99. Vessels

Vents and Drains
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100. Vents and Drains

Trace along the opposite
side of the vent/drain
valve handle.
Once the main pipe is
insulated the trace is
trapped in place by the
valve handle, obstructing
maintenance on the
vent/drain.
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101. Vents and Drains

Do not trace beyond the
body of the valve.
No fluid should be present
beyond the valve body thus it
does not require trace.
Tracing the end flange
obstructs maintenance.
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102. Vents and Drains

Thermal Wells
Do not
exceed the
flange on a
thermal well
installation.
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103. Thermal Wells

Post Installation Test
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104. Post Installation Test

Terminations
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105. Terminations

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106. Terminations

Installing the
C25-100
Connection Kit
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107. Installing the C25-100 Connection Kit

Installing the C25-100
The following slides are a supplement
to the C25-100 connection kit
installation instructions.
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108. Installing the C25-100

Materials:
C25-100 connection kit
Tools required
Cable to be connected
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109. Installing the C25-100

Slides with white backgrounds
apply to both SR and VPL
cables.
Slides with blue backgrounds
apply only to VPL cable.
Slides with yellow backgrounds
apply only to SR cables.
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110. Installing the C25-100

Select the correct grommet
for the heating cable being
used.
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111. Installing the C25-100

Position
gland
components
and
grommet on
the heating
cable in
order shown.
Ensure grommets tapered end is pointing into gland body.
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112. Installing the C25-100

For VPL be sure to
be 300mm from
the nearest node.
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113. Installing the C25-100

VPL
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114. Installing the C25-100

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115. Installing the C25-100

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116. Installing the C25-100

SR
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117. Installing the C25-100

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118. Installing the C25-100

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119. Installing the C25-100

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120. Installing the C25-100

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121. Installing the C25-100

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122. Installing the C25-100

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123. Installing the C25-100

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124. Installing the C25-100

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125. Installing the C25-100

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126. Installing the C25-100

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127. Installing the C25-100

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128. Installing the C25-100

Pass prepared
heating cable
end with core
sealer through
the box entry.
Screw gland
body into
junction box
(use locknut for
unthreaded
boxes.
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129. Installing the C25-100

Position grommet
in gland body,
ensuring it is
sealed squarely
and tighten back
nut securely.
Connect
conductors and
braid to the
appropriate
terminals.
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130. Installing the C25-100

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131. Installing the C25-100

The End
Thank You for Your
Attention
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132. The End Thank You for Your Attention

Sketch Options
DUMMY LEG
PIPE SHOE
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133. Sketch Options

Flange
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134. Flange

Valve
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135. Valve

Thin Valve
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136. Thin Valve

Dummy Support
DUMMY LEG
PIPE SHOE
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137. Dummy Support

Pipe Shoe
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138. Pipe Shoe

Blank
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