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Heat tracing cable manufacturers make products in different types of heat tracing cables. The choice of which to use mainly depends on the intended application.
Constant wattage heat tracing cables
These cables emit a constant level of heat throughout the entire length. Therefore, they are suitable for a range of industrial applications where precise temperature control is mandatory. Certain uses are maintaining pipeline temperatures, preventing freezing in outdoor lines, and keeping storage tanks of viscous liquids at flowing consistency. These cables are very versatile and can be used in zones with both moderate and high temperatures.
Self-regulating heat tracing cables
These cables automatically adjust their heat output in response to surrounding temperatures. Thus, when it gets warmer, the cables reduce their heat output, and vice versa when it gets cooler. This feature helps avoid overheating and provides energy savings in less-demanding applications. Such cables are primarily used to maintain temperatures in pipes and tanks where the risk of freezing is possible.
Mineral insulated heat tracing cables
They are more rugged and durable than other types. Usually, these cables are made from copper and have a high level of heat tolerance. They are suitable for industrial applications that have extreme temperatures or are exposed to harsh environments. Such conditions can include petrochemical plants or offshore oil rigs.
Skin effect heat tracing cables
Usually, these cables are primarily used in pipelines carrying alternating current (AC). These cables heat up the pipe by utilizing the skin effect phenomenon, which causes electrical currents to concentrate near the pipe's surface. This type of heat tracing is commonly used in oil and gas industries to manage the viscosity of thickening substances like crude oil.
During installation, one must use heat tracing cable
Proper installation of heat tracing cables is mandatory for their efficient functioning and durability. Also, various factors like compatibility with the environment, energy efficiency, and the specific requirements of the maintained system determine the type one must select. In addition, professional installation ensures optimal performance throughout the cable's operational life, reducing the chances of failure or inefficient heating.
Maintaining process temperatures
In a lot of industries, heat tracing cables are widely used to maintain the ideal temperatures of various fluids. In chemical plants, for example, certain chemicals need to be kept at specific temperatures to maintain their desired properties and prevent solidification. In these places, heat tracing cables are installed on pipelines and vessels to ensure that the materials flowing through stay at the required temperatures. Without these cables, either the chemicals would become ineffective because of their solidifying or even breaking down, which is not good for business.
Preventing freeze in outdoor lines
In industries with outdoor installations like power plants or water treatment facilities, raw water lines, slurry lines, and other fluids need to be protected from freezing. Freezing can cause pipes to burst or gases to condense and cause blockages. To avoid this, heat tracing cables are installed on outdoor pipelines in cold climates to keep the contents above their freezing point. This is very important for keeping fluids moving reliably, especially in regions with extreme winter weather.
Keeping viscous liquids in motion
Many industrial liquids and chemicals have a high viscosity. These include materials like waxy crude oil, glycol, and slurry used in oil and gas and mining. If these products cool down too much, they become too thick to flow through pipelines. Heat tracing cables are installed on the pipelines to maintain the temperatures of these substances above their critical points. This ensures that they keep flowing smoothly from one place to another without blockages. After all, heat tracing cables prevent downtime during production and transportation and protect the infrastructure from damage due to solidified materials.
Providing reliable tank heating
Storage tanks in industries are often filled with materials that require consistent temperatures to maintain their effectiveness. These materials can include anything from oils and fats to chemicals and liquid gases. When tank temperatures drop, these substances may either solidify or separate, rendering them useless. In heat tracing cable installation, the cables wrap around these storage tanks to keep the contents at the right temperatures, thus ensuring easy retrieval at all times. This is important in sectors like food processing, petrochemicals, and pharmaceuticals, where temperature control is paramount in maintaining product quality.
Heat tracing cables protects against condensation
In industries where vapor is prevalent, such as in natural gas processing, heat tracing cables are installed on pipelines carrying these gases. This keeps the gases above their dew point temperature so they don’t condense into liquid. Condensation can cause blockages or even damage to the infrastructure. Therefore, by maintaining the pipeline temperatures with heat tracing, businesses can prevent condensation-related hazards.
For heat tracing cables to work efficiently, they must be built with quality materials and have a solid construction design. After all, factors like the level of heat output, durability, energy efficiency, and installation ease are influenced by these components.
The core conductors
Usually, heat tracing cables are made from copper or stainless steel, which serve as the core conductors. These conductors are responsible for distributing electricity throughout the length of the cable. While copper provides excellent conductivity and flexibility, making it easier for manufacturers to mold into shapes, stainless steel offers superior corrosion resistance in adverse heat environments. This is especially important for industries like oil and gas.
Insulation layers
To separate the electrical conductors from the environment, high-quality insulation materials must be added. In most cases, this is done with fluoropolymer, PVC, and rubber. Each type provides different benefits, such as temperature tolerance and chemical resistance. For example, fluoropolymer is highly resistant to extreme heat and harsh chemicals. On the other hand, PVC is more affordable and offers decent protection in less demanding environments.
Heating profile
This defines the amount of heat the cable outputs per foot or meter. Normally, two types of heating profiles are available: constant wattage and self-regulating.
Constant wattage cables maintain a steady level of heat along their entire length. In contrast, self-regulating cables automatically adjust their heat output based on the surrounding temperatures. This helps prevent overheating.
Outer jacketing materials
Only tough jacketing materials like silicone rubber, PVC, and thermoplastic elastomer are used to enclose heat tracing cables. These jackets protect against abrasions, impact, and chemical exposure. It also adds a layer of insulation, which improves energy efficiency.
Quality control practices
Manufacturers do it across multiple stages, from raw material sourcing to final testing. In addition, standardized procedures ensure consistency in performance. Common practices include monitoring the thickness of insulation and verifying the electrical resistance of conductors.
Selecting the right heat tracing cable for specific industrial needs requires careful consideration of several key factors. Doing this will ensure operational efficiency and safety.
Desired temperature maintenance
Constant wattage cableworks best where high temperatures are prevalent. Self-regulating cable, on the other hand, is ideal for situations that demand a low thermal need.
Environmental conditions
Heat tracing cable must be selected based on the operating environment. Consideration factors should include whether it will be exposed to hazardous chemicals, moisture, or outdoor weather elements. This exposure can lead to corrosion, chemical degradation, or premature cable failure. As a solution, go for mineral insulated or over-jacketed cables for heavier applications. At the same time, go for self-regulating cables in less extreme environments.
Pipe size and watt density
This is the amount of heat the cable releases per inch square on the pipe surface. It ensures that heat tracing cables can maintain the right temperatures without wasting energy. For large pipes, low watt density cables will be enough. They are more efficient. High-watt density cables suffice in small pipes. They provide the necessary temperature maintenance.
Ease of installation
Go for self-regulating heat tracing cables. They can be easily installed since they do not require any manual tuning. Constant wattage cables, though, require careful routing to avoid hotspots.
Smart systems
If the business plans to use smart technology in its operations, go for heat tracing cables with IoT capabilities. This will allow businesses to remotely monitor and control cable performance.
Inherent safety
Pick heat tracing cables with built-in over-temperature protection. They prevent hazardous situations like pipe damage or combustible exposure.
Self-regulating cables, which automatically decrease their heat output in warmer areas, are the most energy-efficient heat tracing cables. They, therefore, provide significant energy savings over constant wattage cables in less demanding applications. Also, using demand-controlled systems that only activate the heat tracing when necessary helps minimize energy wastage.
There is a need for yearly inspections of heat tracing cables to check for physical wear, testing the electrical continuity, and ensuring insulation integrity. It is also important to verify that the cables are not exposed to damaging chemicals or else they will wear out faster than expected. In addition, any damaged sections should be replaced before the start of the next operating season so as to avoid downtime.
Consulting with manufacturers can help businesses identify the electronic cables that will suit their needs. In addition, experts will consider factors like temperature ranges, pipe sizes, and materials to determine which cable will work best. After all, custom-built cables are more efficient and safer than standard ones.
The heating profile, cable length, and material used during manufacturing are major factors affecting the electrical resistance of heat tracing cables.
