Experts in industrial heat trace systems • eltherm
Installation and operation self-regulating & parallel heating cables
eltherm GmbH
Ernst-Heinkel-Strasse 6-10
57299 Burbach, Germany
P.: +49 2736 4413-0
F.: +49 2736 4413-50
info@eltherm.com
QAA 023 Rev.10
The trace heating systems ELSR-... and ELP-... are suitable for industrial use on pipelines, containers and associated equipment in non-classified (common) areas, outdoor areas, wet areas and areas where flammable gases, dust or fibres may be present.
⚠️ ATTENTION In order to fulfil the warranty conditions, the instructions of the respective product manuals must be followed. Please note that these instructions provide information on general installation methods. Always follow the project planning specifications and contact our project office if you have any queries.
⚠️ ATTENTION Ensure that the data sheet for the supplied heating cable is available in addition to these instructions. The information in the data sheet is required for safe installation. Installation must therefore not be carried out without the data sheet.
The max. allowable length of a heating circuit (according to the corresponding data sheet) for unilateral feed depends on the admissible voltage drop (we recommend not to exceed a voltage drop of 10%) and the utilisation of the circuit breaker (recommended: 16 A CB with „C“ characterisation, utilisation 80%).
⚠️ ATTENTION Mounting, testing and maintenance of electrical trace heating systems may only be carried out by qualified employees who have been trained in handling electrical equipment.
Strict compliance with the relevant standards and safety regulations is a prerequisite for the safety of persons, systems and devices.
The persons tasked with planning, installation and maintenance have a special responsibility and must be familiar with the exact details of the applicable regulations.
The instructions must be kept with the system documentation for later use (maintenance, servicing).
? DANGER Prior to installation and maintenance work the relevant heating circuits and plant sections need to be de-energized!
Prior to accessing plant sections (pipelines, vessels etc.) ensure sufficient cooling down to avoid burns.
The metallic screen (protective braid or aluminium foil with embedded earth wires) has to be connected to the potential earth.
Improper mounting or damage to the electrical trace heating can lead to a danger of short circuit and fire while the system is in operation.
To ensure safe and error-free operation of eltherm electrical trace heating, only the original initial and medial connecting sets and termination sets specially developed and tested for this purpose may be used.
Make certain that all mounting work is complete on the pipe system that will be heated.
All pressure and material tests as well as coating and painting work on the pipelines must be completed. The coat of paint on the pipes must feel dry to the touch.
Check the nature of the pipe surface. It must not have any sharp edges or burrs that could cause damage during installation. If necessary, remove any or cover them with suitable material.
Compare the design of the pipeline (dimensions, structure, nature and number of inserts) with the design data.
Check all materials required for heating to ensure they are complete and for any transport damage.
Compare the material list of the delivered components with the design documents.
Check whether there are any special mounting instructions and whether all the necessary material and tools are on hand.
Measure the electrical and the insulation resistance of the heating cable and write them down in the mounting protocols provided for this purpose. Compare the value with the data in the design documents and technical specifications of the heating cables.
⚠️ WARNING Do not use adhesive tape with emollients (i.e. PVC)! Install according to the min. bending radius and installation temperature stated on the data sheet.
ELP types: Make sure the tapes will not have contact with each other or cross after installation, this may lead to overheating and damage of the heating tapes and nearby placed objects!
ELSR types: An overlapping or contacting installation of the heating tape does not cause overheating due to the self-regulating heating characteristic.
A heating circuit should be installed as shown in the following diagrams using the original eltherm accessories.
Do not crush the heating cable or pull it over sharp edges.
Avoid stepping on or driving over the heating cable at all costs.
Never use the heating cable as a step loop.
Keep to the lengths specified in the project planning for the fixtures.
The installation must be carried out on the intended system components at the positions specified by the planner in order to prevent system components from overheating and the desired holding temperatures from not being reached.
The specified minimum bending radius must be observed and adhered to.
Remove all unevenness, such as sharp burrs or similar, from the surface to be heated and clean the surface of grease and oil.
Mark the installation distances required according to the projection on the surface to be heated.
Illustration showing preparation of a pipe surface for heating cable installation, showing cleaning and marking of installation distances.
Diagram showing correct (checkmark) and incorrect (cross mark) methods for unrolling a heating cable from a drum.
Use a stable holder to unwind the heating cable.
Ensure that the unwinding device runs smoothly to prevent damage to the heating cable due to excessive tensile force.
Unroll the heating cable straight over the edge of the drum, not off to the side.
Do not lay the heating cable on the lowest point of the horizontal pipeline.
Laying the heating cable on the top half of a horizontal pipeline is unfavourable for reasons of heat distribution and should only be done if the project planning calls for it.
⚠️ ATTENTION The electrical connection and termination of the heating cables must only be carried out using eltherm accessories in accordance with the relevant assembly instructions. Failure to do so will invalidate any warranty claims.
When making the electrical connection, it must be ensured that no tensile, shear or torsional forces can act on the connection. This is achieved by providing suitable support for the heating cable in the immediate vicinity of the connection.
Normally the heating cable is laid stretched out along the pipe. Lay heating cables in a spiral pattern only if the project planning explicitly calls for it.
Illustration of a heating cable laid along a pipe, secured with adhesive tape at 300mm intervals. Another diagram shows a temperature sensor on the pipe.
Fasten the heating cable at intervals of 300 mm.
Use only fastening materials that have been defined as suitable accessories by the manufacturer and that were selected in the design documents.
Make certain that the selected materials meet the requirements (for temperature, mechanical and chemical resistance).
Check whether the use of other elements (such as aluminium adhesive tape for better heat transfer) is required in the design documents.
Illustrations showing different configurations of heating cables on a pipe: one cable, two cables, three cables, and four cables, along with a temperature sensor.
ℹ️ NOTE We recommend covering the entire surface of the heating cable on plastic containers or pipes (PE/PP/PVC/GRP/GRP or similar) with aluminium foil.
To save energy and to keep process temperatures constant, the application of superior control units are recommended. Please ask our project engineers when in doubt.
⚠️ ATTENTION To avoid short circuit, do not connect the two bus wires of the heating tape to each other. Under all circumstances observe the termination and maintenance instructions for the connection and termination of the heating tapes.
Make sure that the trace heaters are never used at or exposed temperatures above the nominal exposure temperature ratings.
⚠️ WARNING Never use metal clips or binding wire for fastening as doing so could cause the heating cable to be damaged.
Heating cables must be able to move slightly in the fastenings (for expansion and contraction).
When using a pre-stamped stainless steel band, note that a burr is produced inside the tab due to punching. Follow the installation instructions in the drawing below. This is the only way to ensure that the burr cannot damage the heating cable.
Diagram showing a heating cable fastened to pipe supports using adhesive tape, with a note on minimum bending radius and looped installation at supports.
In areas of pipe supports, heating cables must be laid in a looped manner in order to be able to provide sufficient power at this point.
⚠️ ATTENTION Observe the specified length allowances in project planning or design (for example in eltherm Designer).
Illustrations demonstrating the correct fastening of heating cables around pipe bends (elbows) using adhesive tape.
When laying a heating cable around a pipe bend, the heating cable must be laid on the outside of the pipe bend. If it is laid on the inside, the flow medium may be deposited in the pipe due to the lower heat input to the pipe.
Illustrations demonstrating the correct fastening of heating cables around flanges using adhesive tape.
When laying a heating cable around a flange connection, it must be ensured that the heating cable is laid once around the pipe directly in front of the flange connection. More power must be applied to the pipe at this point due to higher thermal expansion.
Illustrations demonstrating the correct fastening of heating cables on fittings using adhesive tape.
Illustrations demonstrating the correct fastening of heating cables on level indicators using adhesive tape.
⚠️ ATTENTION Fittings and level indicators must be installed all round to ensure uniform thermal expansion.
Illustrations showing the fastening of heating cables on Plug-in discs using adhesive tape.
⚠️ ATTENTION Make certain the metal braiding has the best possible contact with the surface of the fitting.
Only fasten the heating cable with the fastening material provided by the manufacturer and follow the recommendations for fastenings.
Illustrations showing the fastening of heating cables on valves using adhesive tape.
In areas with large pipe diameters, heating cables must be laid in a loop.
A special mounting variant consists of fastening the heating cable onto metal braidings. This variant is used mainly for heating geometrically complex shapes. This variant is also used if fittings (such as valves and pumps) have to be heated and easy access to the fittings is especially important (for maintenance purpose, etc.). This ensures that the metal braiding will be easy to open and close again without having to remove the heating cable first.
Illustration showing a heating cable fastened onto metal braiding.
Cut the braid to size so that it fits exactly.
Fasten the braiding onto the fitting.
Illustration showing a heating cable fastened onto braiding.
? DANGER The max. operating temperature of the heated device as defined by the plant owner as well as the maximum heating cable temperatures as given on the label must not be exceeded. This may be achieved by use of an appropriate temperature control.
Make sure the heater has a good contact to the surface to be heated. In case of gaps, fill those with thermally conductive and temperature resistant materials.
To prevent the penetration of thermal insulation material between the heating cable and the surface to be heated and to keep the surface temperature of the heating cable as low as possible, the heating cable must be covered over its entire length with self-adhesive metal foil.
If thermal insulation with a sheet metal jacket is used, an insulation bushing must be used to protect the heating cable from mechanical damage when it is led out of the panelling.
After completion of the heating circuit, a weather-resistant, permanently legible identification plate with all relevant system details must be attached to the junction box or the connection pipe immediately at the entry to the junction box.
⚠️ ATTENTION Test voltage minimum 500 VDC, recommended 2500 VDC.
Independent of the heating circuit length, the insulation resistance must not be lower than 20 MΩ. In case of a lower insulation resistance, the source of defect has to be determined and eliminated.
Any damage that has occurred must be repaired immediately. For short heating circuits by replacing the heating cable and for longer heating cable lengths by cutting out the damaged area and inserting a new heating cable section (see assembly instructions for connection set).
Repeat the tests after the terminal insulation has been applied.
? DANGER Electrically heated parts have to be identified in reasonable distances with warning labels „Electrical heating" on the thermal insulation.
Approx. 5 m distance between each label on pipelines or at least 1 warning label per pipe-branch respectively.
ℹ️ NOTE Trace heaters ELSR-... and ELP-... generally operate maintenance-free. However, it is recommended that the system be checked by qualified personnel in regular intervals for visual damages and insulation resistance.
? DANGER Damaged heating circuits shall not be operated. This is the case when:
ℹ️ NOTE Customer-side labeling with an identification plate is possible.
⚠️ ATTENTION Installed trace heaters have to be protected against damage that may occur during repair work on heated components.
After completion of the repair, the heating circuit will once again need to be tested.
Readings of ohmic resistance and insulation resistance are to be taken from cold heaters only.
Temperature control units and controls must be checked annually by trained specialists.
File Info : application/pdf, 12 Pages, 993.71KB
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