Professional Documents
Culture Documents
PE43
Commissioning and Maintaining Electrical Resistance
Heat-Tracing System
Table of Contents
1. User guidance.......................................................................................................................................................2
1.1
Scope..........................................................................................................................................................2
1.2
Applicability .................................................................................................................................................2
1.3
Benefit.........................................................................................................................................................2
1.4
Principle ......................................................................................................................................................3
1.5
Definitions ...................................................................................................................................................3
1.6
References .................................................................................................................................................3
2. Commissioning the heat-tracing system ..........................................................................................................4
2.1
Cable testing after installation ....................................................................................................................4
2.2
Functional check and field documentation .................................................................................................6
3. Maintaining the heat-tracing system .................................................................................................................7
3.1
General requirements .................................................................................................................................7
3.2
Visual inspection.........................................................................................................................................7
3.3
Periodic operational check..........................................................................................................................8
3.4
Maintenance inspection checklist ...............................................................................................................8
3.5
Specific maintenance and repair procedure...............................................................................................8
3.6
Troubleshooting heat-tracing systems .......................................................................................................9
4. Safety considerations .........................................................................................................................................9
4.1
Process safety ............................................................................................................................................9
4.2
Electrical safety...........................................................................................................................................9
4.3
Thermal safety ..........................................................................................................................................11
5. Troubleshooting ................................................................................................................................................12
5.1
Common causes of failure ........................................................................................................................13
6. Record keeping ..................................................................................................................................................14
6.1
Recommended records for preventive maintenance................................................................................14
6.2
Hazardous chemical areas .......................................................................................................................14
List of Appendices
Appendix A. Commissioning inspection checklist for electrical resistance heat tracing ............................. 15
Appendix B. Maintenance inspection checklist for electrical resistance heat tracing .................................. 16
Appendix C. Troubleshooting guide for electrical resistance heat tracing..................................................... 17
Appendix D. Heater insulation resistance testing.............................................................................................. 19
Appendix E. Troubleshooting procedure for mineral insulated heating cables ............................................. 23
Red text indicates revisions made in the April 2008 issue.
Page 1 of 27
PE43
1. User guidance
1.1 Scope
The purpose of this procedure is to offer recommendations for commissioning electrical
resistance heat-tracing systems and to encourage the maintenance of the systems.
This recommended procedure includes the following types of electrical resistance heat-tracing
systems:
Flexible series resistance (one, two, or three conductor) thermoplastic insulated cable
Included in this document are checklists that may be used in the field for commissioning the heattracing system (Appendix A) and maintaining the system (Appendix B). Troubleshooting guides
are also included to help solve problems that might arise in the generic systems (Appendix C) as
well as Mineral Insulated systems (Appendix E). In addition, a procedure for testing heater
insulation resistance is outlined in Appendix D.
1.2 Applicability
This document is applicable to all DuPont facilities where electrical heat-tracing systems are
used. It is designed as a procedure for DuPont maintenance personnel and contractors. This
document provides recommended guidelines only, which can be used with properly installed and
documented systems. Because many heat-tracing systems are especially applicable for seasonal
use (e.g., freeze protection), preseason maintenance is especially recommended. Where heat
tracing protects critical processes, maintenance may be completed as allowed by the process
cycles.
1.3 Benefit
The proper commissioning of an electrical resistance heat-tracing system is very important to its
effective performance and can add years to the life of the system. Improper installation is often
realized only after problems occur. Freeze-ups and failure to attain design temperatures can often
be traced to improper installation.
The attention given to heat-tracing systems through proper periodic maintenance can prevent
frozen pipes, process failures, equipment damage, and even environmental incidents. In addition,
preventive maintenance applied to heat-tracing systems can increase personnel safety by
reducing exposure to electric shock and eliminating a source of fire. Reliability of emergency
eyewash and safety showers that are dependent on heat tracing is an additional safety
consideration.
Page 2 of 27
PE43
1.4 Principle
This recommended procedure is based on the principle that electrical resistance heat tracing
must be properly commissioned, tested, and maintained so that process, fluid, or material
temperatures allow electrical, thermal, and mechanical durability of the heat-tracing system. This
provision ensures that the performance of the system poses no danger to the user or
surroundings in normal use (see Section 4). In addition, this procedure recognizes that for the
heat-tracing commissioning to be successful, the system installation must also be properly
executed and documented.
1.5 Definitions
Arc blastenergy released by an electric arc initiated by partial breakdown of circuit impedance.
Electric arcing is the passage of substantial electric currents through what had previously been air
but becomes the vapor of the arc terminal material, usually a conductor metal or carbon.
Equipment protective device (EPD)a system intended to provide protection of equipment
from damaging line-to-ground fault currents by operating to cause a disconnecting means to open
all ungrounded conductors of the faulted circuit. This protection is provided at current levels
(typically 30 mA) less than those required to protect conductors from damage through the
operation of a supply circuit overcurrent device.
Flash hazarda dangerous condition associated with the release of energy caused by an arc
that suddenly and violently changes material(s) into a vapor. Next to the laser, the electric arc is
the hottest thing on earthup to or beyond 19,582C (35,000F)four times as hot as the
surface of the sun. The hazard includes the possibility of radiation burn from the arc blast.
Highly hazardous chemicala substance possessing toxic, reactive, flammable, or explosive
properties.
Megohmmeteran instrument (megohm insulation tester, megohmmeter or megger1) used to
determine the insulation integrity of electrical equipment by impressing a test voltage, generally
limited to 5,000 V dc, on the equipment under test.
Note: See IEEE-515 or IEEE-515.1 for a more comprehensive set of definitions.
1.6 References
Corporate Engineering Standards
DE1H
E7K
E10K
PE42
Commissioning Checklist (Including Punch List) for Distribution Equipment and Large
Motors
Lockout/Tagout
Page 3 of 27
PE43
Other References
ANSI/ IEEE515
ANSI/ IEEE515.1
NEC Article
210-19, FPN
No. 4
NEC Article
426
NEC Article
427
NFPA 70E
2.
Heat-tracing cable
Before thermal insulation is applied to the heat-tracing cable, the insulation resistance is
measured. Insulation should be measured with at least a 500-V dc test voltage. However, it
is strongly recommended that higher test voltages be used1,000 V dc for mineralinsulated heaters and 2,500 V dc for polymeric heaters. Under normal dry conditions and
before connection of the device to the associated wiring or control equipment, the minimum
insulation resistance should be 20 M.
Document revised April 2008 / Entire document reaffirmed April 2008
Copyright 2001, 2008 E.I. du Pont de Nemours and Company. All Rights Reserved. Used under Copyright License.
Page 4 of 27
PE43
Note: Tracers installed or stored in locations with high humidity can sometimes assimilate
moisture during installation and exhibit low test values that rise when placed into
service.
2.1.2
Branch circuit
After the thermal insulation is complete, the insulation resistance of the entire branch circuit
should be 20 M, measured at 500 V dc. If required, each electric heating cable operation is
checked by applying rated voltage and recording current and pipe temperature at steadystate conditions. Time should be allowed for the current to stabilize, because the starting
current is sometimes higher than the steady state operating current.
Note: Disconnect wiring from heating controllers while using a megohmmeter to prevent
possibility of damaging solid-state components.
2.1.3
Thermal insulation
8. Give careful attention to expansion joints when installing thermal insulation on a hightemperature service.
9. Provide pipe supports outside of insulation whenever possible.
Page 5 of 27
PE43
Calibration check at the temperature controller set point performed and set at this value
Page 6 of 27
PE43
7. Tabulate final documentation on a circuit basis and include verified as-built drawings. If
possible, attach an engineering flow diagram that shows the location of each circuit, which
can help resolve abnormal conditions during operations and assist in equipment
maintenance.
8. Commission backup (redundant) systems one at a time. Start up the primary system,
commission it, then shut it down. Next, start up the backup system, then commission it.
3.
Qualified maintenance personnel to administer the program and sufficiently document all
portions
Establishing a preventive maintenance program helps ensure proper operation and long life
of a heat-tracing system. The preventive maintenance program should include a
documented plan for continuing inspection, reporting, and recording of the condition and
repair of all heat-tracing equipment.
3.1.2
Personnel training
Maintenance personnel should have a thorough knowledge of equipment in specific heattracing systems and have the ability to recognize defects in the system and repair all
components. Changes in personnel and equipment require that training be repeated
periodically.
Signs of overheating
Loose connections
Thermostats and control cabinets that are improperly sealed, contain moisture, or show
signs of corrosion
Page 7 of 27
PE43
Visual inspection should be done on a routine basis and when any mechanical maintenance is
completed. Inspections should be scheduled according to the manufacturers recommendations
and frequency of equipment use.
Thermostats.
Indicating lights.
Meters.
Controllers.
If the electrical heat tracing is used for maintaining normal temperatures or critical process
control, operational checks should be completed more frequently. After mechanical maintenance
has been performed on heat-traced pipelines, vessels, or equipment, the electrical insulation
resistance and heating cable continuity should be checked to ensure the integrity of the heat
cable before the equipment is reenergized. EPDs should be periodically tested before the heattracing system is energized and at each repair.
Page 8 of 27
PE43
Standard S14G and NFPA 70E that permit interaction with energized heating circuits should only
be done for specific activities that ensure personnel have an understanding and control of the
hazards involved. See SHE Standard S14G for a review of hazards involved.
Ground-fault trips
Pipe temperatures below design, although the power output appears correct
4.
Safety considerations
4.1 Process safety
4.1.1
A process hazards review for plant site processes should include the impact of abnormally
high or low temperatures due to malfunction of heat-tracing systems. If failure of the heattracing system can result in adverse reactions, such as at pressure-relief points, the integrity
of the system must be carefully considered.
4.1.2
Reliability of tracing
If plant or personnel safety depends on the reliability of the heat-tracing system, each circuit
should be designed for a Type III process (see IEEE-515). Tracing should include a narrowband temperature controller with RTD or thermocouple-type sensors and maximum
flexibility in the selection of alarm and monitoring functions. Redundant equipment may be
warranted (see IEEE-515).
4.1.3
Process leaks
Personnel interacting with the thermal insulation should be aware of the possible presence
of flammable or toxic material leaking into the thermal insulation.
Identification label
An energized electrical heat-tracing system can cause electrical shock hazard or electrical
fire if it is not installed in accordance with the manufacturers recommended procedures. The
presence of an electrically heated system must be identified on the outer surface of the
thermal insulated pipeline, vessel, or equipment (see NEC Article 427-13). This
requirement is intended to reduce the risk of shock or burn to those who must work on the
process system (see Figure 1 for sample label). Labels are also available from the
manufacturer.
Document revised April 2008 / Entire document reaffirmed April 2008
Copyright 2001, 2008 E.I. du Pont de Nemours and Company. All Rights Reserved. Used under Copyright License.
Page 9 of 27
PE43
For systems operating at greater than 120 V to ground, consider providing identification of
the system voltage in addition to the required caution label.
Figure 1.
4.2.2
Ground-fault protection
If the heating cable system is damaged or improperly installed, electric arcing may not be
stopped by a conventional circuit breaker, because the fault current may be too low to trip
the breaker. To minimize the danger of fire from sustained electrical arcing, ground-fault
equipment protection is required. (See NEC Article 427-22) This can be accomplished by
EPD circuit breaker, ground-fault relay, or a heating controller with integral ground-fault
protection. The rule-of-thumb for selection of ground-fault current is to choose a device or
setting that is 30 mA above the background value. A 5 mA ground-fault device is not
acceptable and will result in inadvertent tripping. Long branch circuit lengths and certain
types of heaters can require trip levels greater than 30 mA.
4.2.3
Lockout/tagout
Unqualified persons can interact with the heat-tracing system, creating the opportunity for
the system to be compromised or damaged. To lessen the exposure of individuals to
possible electric shock, the heat-tracing circuit should be deenergized and properly locked
out and tagged if the insulation is to be removed.
4.2.4
Using Megohmmeters
Megohmmeter test voltages of 500 V dc, 1,000 V dc, or 2,500 V dc are commonly used for
testing electrical heating cable. DuPont test procedures should be followed to prevent
inadvertent contact that could result in secondary injuries from shock sensation on contact.
Physical injuries have been known to result in falls from ladders or jerking motions that
cause physical contact with fixed objects.
In addition to the voltage present during testing, it is possible for a capacitance charge to
remain on cables after testing. Megohmmeters can be both self-charging and
nondischarging. For self-discharging meters, it is recommended that the Megohmmeter
remain connected to the circuit for 30 seconds or more to allow the charge to dissipate. If
the meter is nondischarging or if any question of a possible charge remains, the insulated
wires should be shunted to ground.
Page 10 of 27
PE43
4.2.5
Electric heat tracers are unique in that they are not normally enclosed within a cabinet or
raceway. Because both qualified and unqualified (in NEC and OSHA terms) persons may
be required to interact with traced systems, power should be removed from the circuits
before the thermal insulation is removed or when the tracer is handled during maintenance.
Handling of energized tracers by qualified personnel should only be permitted if
accompanied by procedures that check the cables to ensure good physical condition.
Tracers should be constantly checked for damage to the cable such as cracking of the
sheath or jacket that can result when old cables are handled.
Note: Certain types of installed cables, such as mineral-insulated and constant-wattage
(zone) cables are more prone to damage resulting from handling, due to hardness of
conductors and metal sheath materials.
4.2.6
Defective tracers
Damaged or defective heating cable or components can cause electrical shock, arcing, and
fire. If a failed electrical tracer proves to be the problem, the damaged section shall be
removed and replaced with a new length. A failed tracer should always be replaced, never
repaired.
4.2.7
Damaged bus wires can overheat or short to ground. Care should be taken not to break bus
wire strands when stripping the heating cable.
4.2.8
Grommets
Reusing heating cable grommets can cause leaks, cracked components, shock, or fire. New
grommets should be used whenever the heating cable is pulled out of the termination
enclosure.
Heat-tracing systems are deenergized and locked out before work is performed (before any
thermal insulation is removed).
At least 152 mm (6 in.) of nonheating leads are provided within the junction box [NEC,
Article 427-18(a)].
However, maintenance and operations personnel should be aware of the elevated temperatures
at which some wattage tracers operate. They should allow a cool-down period before removing
the thermal insulation from deenergized heat tracing.
Page 11 of 27
PE43
4.3.1
Direct contact with hot surfaces should be avoided. When handling tracers on hot pipes or
vessels below 60C (140F), a job lineup should require proper personal protective
equipment: suitable gloves, shirts, or jackets that prevent direct contact with the hot
surface. The tracer should be handled in a manner that minimizes direct contact with the
heated surface. Work on systems with temperatures above 60C (140F) (NEC and OSHA
limit for exposed surfaces) represents a greater hazard to personnel in the way of possible
scalding or burns and should be avoided whenever possible. When permitted by site safety
practices or by special permission, procedures should require clothing, personal protective
equipment, and a work procedure that are suitable for the elevated temperatures.
4.3.2
As discussed in Section 4.2.5, traced systems may require interaction by both qualified and
nonqualified personnel for maintenance and repair. The specific site procedure should
require circuits to be deenergized during maintenance activities that require pipefitters,
operating personnel, or thermal insulators to work near or handle energized heating cables
or cold-leads. See Figure 1 for an example of a pipeline surface label that recognizes OSHA
concerns. The following additional safety considerations involved in removing thermal
insulation should be addressed:
Personal protective equipment required for certain types of thermal insulation containing
respirable fibers
Thermal insulation saturated with flammable or toxic materials from leaking flanges or
pipes
For help with these hazards, refer to the specific site procedures or the DuPont-Engineering
Safety, Health, and Environmental (SHE) Manual for additional information.
5.
Troubleshooting
Heat-tracing problems are most often associated with the following symptoms:
A cold pipe
Circuit-breaker trips
Locating the probable cause of the failure can be frustrating and time-consuming. The information
in this section can help troubleshoot problems with heat-tracing systems. For new tracing or for
repairs, to prevent expensive rework, testing should be completed before the thermal insulation is
installed. In addition, the troubleshooting guide for electrical resistance heat tracing in Appendix C
provides a chart to help locate the probable causes of symptoms and outlines appropriate
corrective actions. The guide provides probable causes and corrective actions for the following:
Circuit-breaker trips
Ground-fault trips
Page 12 of 27
PE43
Note:
If a failed electrical tracer proves to be the problem, the damaged section should be
removed and replaced (see Section 4.2.6).
5.1.1
Wet insulation and failure of the thermal insulation system are the leading causes of freezeups and inability of the system to maintain the system temperature (see Appendix C).
5.1.2
The NEC (Article 210-19, FPN No. 4) defines a branch circuit voltage drop of 3 percent as a
reasonable design basis for conductor sizing on power, heating, and lighting loads. Rated
voltage is more critical for series-resistance and constant-wattage heating cables. Measured
voltage at the front end (power connection) to the heating cable should be within the design
basis. Because a 10 percent voltage drop at the end of the heating cable will result in only
80 percent of the rated wattage, front-end and end-of-circuit voltages should be measured
and compared to the design basis during commissioning and when heater performance is in
question.
Heating controllers using silicon controlled rectifier (SCR) and solid-state relay (SSR) output
have greater voltage drop than electromechanical relays. The power supply transformer tap
setting should be based on the voltage at the output terminals for a fully loaded circuit.
5.1.3
Page 13 of 27
PE43
5.1.4
6.
Recordkeeping
6.1 Recommended records for preventive maintenance
A good preventive maintenance program includes adequate records and other documentation of
electric heat-tracing systems. The basic records that follow are recommended for each system
(see IEEE-515).
6.1.1
Equipment record
Equipment records include drawings that contain basic information on the heating cable
itself. Drawings should include cable type, line size, thermal insulation type and thickness,
length, location, control type, watts per unit length at operating temperature, maximum
power, and power source for the heat-tracing system.
6.1.2
This file records the cost of maintaining the heat tracing, which helps to compare cost with
benefits of various systems.
6.1.3
Maintenance record
This record lists the points to be checked on a particular system and documents that the
checks have been completed. Completed copies of the maintenance inspection checklist for
electrical resistance heat tracing found in Appendix B can be used as log sheets and
maintenance records.
6.1.4
This record should include a complete listing of the duties of maintenance personnel for
various heat-traced equipment.
6.1.5
Inventory control
These records keep track of the parts on hand used to repair electric heat-traced systems.
The inventory control records may be combined with the cost record or maintained
separately.
Page 14 of 27
PE43
Appendix A.
For an electronic version of this form, click on the following link: PE43.Form
Circuit number
System
Project number
Reference drawing(s)
Line number
Heater number
Area classification
AIT/T-classification
Panel number
Location
Circuit number
Circuit amp/voltage
Heater manufacturer
Heater total design length
Heater model
Current in amperes
Field
1-phase
3-phase
Line
A-phase
B-phase
C-phase
Neutral
Start-up
After 10 minutes
After 4 hours
Ambient temperature at time of test
Pipe temperature at beginning of test
After 4 hours
After 4 hours
HEATING CONTROLLER
Heating controller
Ambient sensing
Pipe sensing
Type
Location
High setting
Low setting
Operation verified
Heater current
High setting
Low setting
Operation verified
Ground-fault current
Setting
Operation verified
Loss of voltage
Operation verified
Other
Operation verified
GROUND-FAULT PROTECTION
Type
Setting
Measured
TESTING
Performed by
Company
Date
Witnessed by
Company
Date
Accepted by
Company
Date
Approved by
Company
Date
Note:
Page 15 of 27
PE43
Appendix B.
For an electronic version of this form, click on the following link: PE43.Form
(Self-regulating, power-limiting, constant-wattage, series-resistance, MI cable)
Circuit number
System
Reference drawing(s)
Circuit length
Design voltage
Ground-fault protection type
Ground-fault trip rating
CIRCUIT INFORMATION
Breaker panel number
Breaker pole(s) number
VISUAL
Date
Initial
Thermal insulation
Damaged insulation/lagging
Poor water seal
Missing insulation/lagging
Moisture
Heating system components
Poorly sealed enclosures
Moisture
Corrosion
Heater lead discoloration/signs of overheating
Controller
Operating properly
Controller set point
ELECTRICAL
Insulation resistance testing
Test voltage
Megohmmeter value (500 V)
Megohmmeter value (1,000 V)
Megohmmeter value (2,500 V)
Heater supply voltage
Value at power source
Value at power connection
Heater circuit current reading
Amp reading at 2 to 5 min
Amp reading after 15 min
Comments and actions
Page 16 of 27
PE43
Appendix C.
Symptom
Circuit breaker
trips (standard
breaker)
Probable cause
1. The breaker is undersized.
Ground-fault trip
(breaker or
controller)
Power output is
zero or appears
low
Power output
appears correct,
but pipe
temperatures are
below design
SL/PL SR CW MI
X
X
X
X
X
X
X
X
X
X
X
X
Corrective action
1, 2, 6. Recircuit loads or resize circuit
breaker (check size of branch circuit
conductors).
X
X
X
X
X
X
X
X
3. Repair connections.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Notes:
(continued)
Page 17 of 27
PE43
Appendix C.
Symptom
E
Probable cause
2. Sensor location
1. Relocate sensor
Variations from
setpoint along
traced pipeline
Corrective action
SL/PL SR CW MI
Excessing
1. Temperature sensor located too close to
cycling of heating
heating cable or other heat source
controller
2. Ambient temperature near control setpoint
Notes:
1. SL indicates self-regulating heating cable.
SR indicates series-resistance, single or multiple-conductor heating cable.
CW indicates constant-wattage, zone-type heating cable.
PL indicates power-limiting heating cable
MI indicates mineral-insulated heating cable.
2. Refer to the body of this procedure for additional information related to using this troubleshooting guide.
Page 18 of 27
PE43
D.1 Safety
Follow site procedure for lockout/tagout and testing for presence of voltage before proceeding.
Because the potential of the megohmmeter is high enough to be dangerous, guard all
ungrounded terminals of the circuit being tested against accidental contact, and follow site
procedure for personal protective equipment. After completing the test, ground the cable
according to the procedure to allow the absorbed charge to dissipate.
20 M is the minimum acceptable test value for polymeric cable and MI cable.
Readings should not vary more than 25 percent when changing test voltages.
If unacceptable readings are obtained, stop the test and correct the problem. Do not proceed
with testing voltages unless readings are in the acceptable range.
Most MI cables are insulated with magnesium oxide, a hygroscopic material that attracts and
absorbs moisture. MI cables with low insulation resistance readings are most often due to
cracked sheaths, broken seals at the cold lead, or other damage and should not be used.
Page 19 of 27
PE43
Connect the negative lead (earth) to the heating cable metallic braid (see Figure D-1 for
polymeric cables and Figure D-2 for MI cables).
Connect the positive lead (line) to the heating cable bus wire if it is a single lead (MI). For
two-wire systems, connect to both bus wires simultaneously.
Set the voltage at 500 V dc, turn on the Megohmmeter, and apply voltage for a minimum of 1
minute until the reading reaches a constant value for 15 seconds. Record the value in the
commissioning or maintenance inspection checklist (see Appendices A and B). Do not
proceed to the next step unless readings are in the acceptable range.
If the test at 500 V is acceptable, increase the voltage to 1,000 V dc, turn on the
Megohmmeter, and apply voltage until the reading reaches a constant value for 15 seconds.
Record the value in the commissioning or maintenance inspection checklist (see Appendices
A and B).
If the test at 1,000 V is acceptable, increase the voltage to 2,500 V dc, turn on the
Megohmmeter, and apply voltage until the reading reaches a constant value for 15 seconds.
Record the value in the commissioning or maintenance inspection checklist (see Appendices
A and B). (Do not use 2,500 V dc for MI cable.)
Turn off the Megohmmeter and disconnect the leads. Discharge if required.
Turn off the Megohmmeter, disconnect the leads, and reconnect the circuit wiring. Discharge
if required.
Page 20 of 27
PE43
Lock out the circuit; proceed in compliance with site safety rules for working in a cabinet.
Connect the positive lead (line) to the two insulated branch circuit wires simultaneously.
Set the voltage at 500 V dc, turn on the Megohmmeter, and apply voltage until the reading
reaches a constant value for 15 seconds. Record the value in the commissioning or
maintenance inspection checklist (see Appendices A and B). Do not proceed to the next step
unless readings are in the acceptable range.
Set the voltage at 1,000 V dc, turn on the Megohmmeter, and apply voltage until the reading
reaches a constant value for 15 seconds. Record the value in the commissioning or
maintenance inspection checklist (see Appendices A and B).
Record the test values in the commissioning or maintenance inspection checklist (see
Appendices A and B).
Turn off the Megohmmeter, disconnect the leads, and reconnect the circuit wiring. Discharge
if required.
Figure D1.
Heater-to-braid test
Page 21 of 27
PE43
Figure D2.
Megohmmeter
Flexible leads
Note:
Terminal identification may vary. Plus and minus shown for illustration only.
Figure D3.
Braid-to-ground test
Megohmmeter
Heater leads
Overjacket
Metal braid
Ground
Note:
Terminal identification may vary. Plus and minus shown for illustration only.
Page 22 of 27
PE43
Temperature Probe
Ohmmeter
Volt Meter
Clip on Ammeter
For any of the problems listed below, before proceeding with other testing, it is useful to walk the line
looking for locations of obvious damage or where maintenance or repair work has been recently carried
out as the heater or thermal insulation may have been damaged during maintenance or repair
procedures.
How was the problem detected?
1. Many sites today use electronic temperature controllers that use alarms to communicate
problems. If the system has electronic control and an alarm has sounded to alert a problem,
what type of problem was it?
a) Ground Fault alarm. If the circuit has alarmed on ground fault, de-energize the circuit,
disconnect the heater from the branch circuit wiring in the junction box, and from one of the
tails of the heater check the insulation resistance to ground with a 500 or 1000 volt
Megohmmeter. The value should be compared to the Maintenance Inspection Checklist.
(See Annex B). If the insulation resistance of the heater is satisfactory, check the insulation
resistance of the branch circuit conductors:
If the heater has a value less than 5 megohms, it may require further action. The
exception is during periods of rain or very high humidity. Moisture can track along the
sleeving used to insulate the tails of the MI cold lead and across the face of the seal to
the pot causing the insulation resistance to temporarily decline until the weather
improves. If this is the cause of the low reading, wiping the tails and the face of the
compound with a clean dry cloth will often improve the reading. Electrical moisturedisplacement sprays can also be useful in improving insulation resistance due to surface
moisture.
If the insulation resistance of the heater did not improve, and if signs suggesting
maintenance work was done to the piping system were observed, remove the insulation
at those locations and look for physical damage to the heater.
Page 23 of 27
PE43
b) Low Voltage alarm. Check to see if the breaker has tripped. If the breaker has not tripped
and if the system is new, you may find that the heater is connected to the wrong supply
voltage or perhaps the alarm level has been set too close to the nominal value during
commissioning so that temporary voltage sag during the startup of motors causes an alarm.
c) Low Current alarm. MI. heaters are series type cables which usually result in a go or no
go condition, unless the low current alarm has been set too close to the nominal heater
current it is likely that the heater is open circuited. De-energize the circuit, disconnect the
heater from the branch circuit wiring in the junction box and test the heater for conductor
continuity with an ohmmeter connected between the tails of the heater. Compare the
resistance reading to the value recorded in the Maintenance Inspection Checklist (Annex
B) or Commissioning Checklist (Annex A) and if similar, check the continuity of the branch
circuit conductors:
If heater continuity does not exist, and if signs of maintenance work were observed,
remove the insulation at those locations and look for physical damage to the heater. If
none is observed, fault locating equipment will be required to locate the source of the
problem.
d) Low Temperature alarm. With a low temperature alarm, but no electrical alarm, a
temperature sensing probe can be used to check temperatures at various locations along
the pipe to find the location of the low temperature. Any holes made in the cladding should
be at the bottom so that rain does not enter the insulation.
Possible reasons for the problem include:
Wet or missing thermal insulation, inadequate thickness, or the wrong type of thermal
pipe insulation. If so, the insulation problem needs to be corrected.
The heater was under designed and does not provide the required wattage. Either
increase the thickness of the thermal insulation or replace the heating unit with one
having the needed power output.
The sensor is located at a fitting that has insufficient heating cable to compensate for the
additional heat loss of the fitting. Either rework the heater at the fitting to increase the
amount of cable or increase the insulation thickness in this area.
While the product in the line is flowing, cold product may be entering the line at a
temperature less than the setting of the low temperature alarm. The low temperature
alarm may have to be set lower or disabled.
2. When the system has electronic control with alarm, but low or no flow is observed without any of
the alarms in 1, or if the pump circuit tripped out, the cause may be a heat sink that has
insufficient heating cable to compensate for the additional heat loss, or missing or damaged
insulation at some point other than where the temperature sensor is located. As described in 1d
a temperature-sensing probe can be used to check temperatures to find the location of the low
temperature.
3. If the system has electro-mechanical control it is likely that the first sign of a problem will be low
or no flow or the pump circuit trips out because of low temperature. If the GFI or breaker has not
Page 24 of 27
PE43
tripped, walk the line looking for locations where maintenance work has been recently carried
out.
The circuit should then be checked for:
a) Ground fault trip was it a nuisance trip or does the GFI continue to trip? If it does the
heater should be tested with a Megohmmeter as in E.1.a).
b) Tripped breaker - was it a nuisance trip or does the breaker continue to trip? If it does,
check the insulation resistance as per E.1.a).
c) Low Current Use a clamp-on ammeter on one of the branch circuit conductors supplying
the heater, if necessary turn the temperature setting on the thermostat up until the
thermostat switch closes and measure the current. If no current is detected, de-energize the
circuit and check the heater for conductor continuity. If current is detected but it is more than
10% lower than the nominal value, check that the supply voltage is correct.
d) Low temperature with a probe, check the temperature at a section of pipe that has not
been subjected to maintenance work and is well away from any fittings that create additional
heat loss. If this test indicates the correct temperature then the problem is likely a fitting that
has insufficient heating cable to compensate for the additional heat loss of the fitting, or
missing or damaged insulation. On the other hand, if the temperature is too low, the cause
may be a thermostat setting that is too low, an inadequate thickness of insulation, the wrong
type of insulation, the heater was under designed and does not provide the required wattage
or if the product in the line is flowing slowly, cold product may be entering the line.
A TDR can be used for detecting either an open or a short circuit. It sends a signal along the cable
which is reflected back when it sees a change in impedance. By dialing in the Velocity of Propagation
(VP) for M.I. cable (about 0.39) the TDR will give a reading in feet so that distance along the heater can
be approximated without calculation. A more accurate fault location can be obtained by taking a reading
from each tail of a heater and adjusting the VP until the two readings added together equals the length
of the heater. Figure 1 shows a typical trace for a cable with an open circuit while Figure 2 is for a cable
with a short. The vertical line shows the distance to the open or short and is usually accompanied by a
reading in feet or meters.
M.I. heating units are often used on pipe tracing circuits that are over 300 meters (1000 feet) long.
Although fed from one supply, they are usually divided into series connected sections of 45 to 90
meters (150 to 300 feet) for ease of installation. Although TDRs are touted as being suitable for circuits
up to 5 KM (16,400 feet) be aware that stainless steel sheathed M.I. cable is very lossy and many
TDRs are not powerful enough for use with long lengths of M.I. cable. Therefore before purchasing a
TDR it is recommended that you try it first on a heater of a length similar to the longest series section
that your specifications will allow.
Page 25 of 27
PE43
Figure E2.
If the heater is open circuited and the insulation resistance is one megohm or more, a Capacitance
Meter could also be used. Take a reading from each tail of the heater. The distance to the fault from
Tail A is Ca/(Ca + Cb) x Heater Length where Ca and Cb are the capacitance readings from Tail A and
Tail B respectively.
For a cable with an insulation resistance of less than one megohm but continuity on the conductor, a
bridge can be used as per Figure 3. When the bridge is balanced, the potentiometer indicates the
percent of the distance from the positive lead. The positive and negative leads should then be
transposed at the bridge and the bridge again balanced. The two readings when added together should
total approximately 100%. The distance to the fault is Ra x Heater Length where Ra is the percent
shown on the potentiometer from the positive terminal on the bridge.
Page 26 of 27
PE43
If the heater is broken or cut, it may have a low insulation resistance AND an open circuit. If this is the
case, a capacitance meter or high resistance bridge will not find the location of the fault. In the case of
a low insulation resistance, to determine if the problem is in a hot-cold or end splice, before cutting out
and replacing the splice, connect one lead of the megohmmeter to one of the tails of the heater and the
other to ground or to the sheath of the cold lead. Lightly wipe the splice with a torch and if the problem
is moisture in the splice, the needle on the megohmmeter will flicker.
Page 27 of 27