INSTALLATION OF SELF-REGULATING and POWER LIMITING CABLES
Why do we install heat tracing?
Purpose
Outline
Types of Cables
Types of Cables
Self-Regulating Cables
Power-Limiting Cables
Power-Limiting Cables
Installation Preparation
Pre-Installation Checks
Check Installation Documentation
Check Installation Documentation
Check Installation Documentation
Check Installation Documentation
Check Materials
Check Materials
Check Piping and/or Equipment
Check Piping and/or Equipment
Check Piping and/or Equipment
Pulling and Laying Out of Cable
EHT Components
Typical Integrated EHT System
Typical Modular EHT System
Integrated Power Connections
Integrated Power Connections
Modular Power Connections
Modular Power Connections
Modular Power Connections
Modular Power Connections
Connection Kit
Insulation Entry Kit
Tee Connections
Tee Connections
End Seals
End Seals
Splice Kits
Splice Kits
Temperature Sensors
Temperature Sensors
Temperature Sensors
Temperature Sensors
Fixing SR and VPL Cables
Fixing Cables
Fixing Cables
Fixing Cables
Fixing Cables
Fixing Cables
Fixing Cables
Bending Cables
Fixing Cable
Fixing Cables
Fixing Cables
Fixing Cables
Typical SR & VPL Installation
Installation
Installation
Installation
Installation
Installation Details
Component Allowances
Valves
Valves
Valves
Valves
Valves
Valves
Valves
Valves
Valves
Valves
Valves
Elbows
Elbows
Elbows
Flanges
Flanges
Clamps
Clamps
Pipe Hangers
Pipe Hangers
Pipe Shoes
Pipe Shoes
Pipe Shoes
Dummy Supports
Dummy Supports
Dummy Supports
Dummy Supports
Dummy Supports
Pumps
Pumps
Pumps
Pumps
Vessels
Vessels
Vessels
Vessels
Vessels
Vessels
Vents and Drains
Vents and Drains
Vents and Drains
Thermal Wells
Post Installation Test
Terminations
Terminations
Installing the C25-100 Connection Kit
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
Installing the C25-100
The End Thank You for Your Attention
Sketch Options
Flange
Valve
Thin Valve
Dummy Support
Pipe Shoe
22.25M
Category: electronicselectronics

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.
Private and Confidential
page 3

4. Outline

Types of Cables
Installation Preparation
EHT Components
Attaching Cables
Typical SR and VPL Installation
Installing the C25-100 Connection Kit
Installation Details
Private and Confidential
page 4

5. Types of Cables

Private and Confidential

6. Types of Cables

BTV
QTVR
XTV
KTV
SELF REGULATING CABLES
Private and Confidential
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.
Private and Confidential
page 7

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
Private and Confidential
page 8

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.
Private and Confidential
page 9

10. Installation Preparation

Private and Confidential

11. Pre-Installation Checks

Check installation documentation
Check materials
Check piping and/or equipment to be traced
Private and Confidential
page 11

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.
Private and Confidential
page 12

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
page 13

14. Check Installation Documentation

Confirm all isometric continuations are included
in the work pack.
Private and Confidential
page 14

15. Check Installation Documentation

Ensure that all required
permits are in place for the
area in which the installation is
to take place.
Private and Confidential
page 15

16. Check Materials

Inspect the heating cable and components to
ensure that there is no visual damage.
Private and Confidential
page 16

17. Check Materials

Test the insulation resistance of the cable.
Private and Confidential
page 17

18. Check Piping and/or Equipment

Ensure that the length, diameter, and the configuration of
the piping is the same as the design documents.
Private and Confidential
page 18

19. Check Piping and/or Equipment

Ensure that there
is no piping or
equipment
missing.
Private and Confidential
page 19

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.).
Private and Confidential
page 20

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
Private and Confidential
page 21

22. EHT Components

Private and Confidential

23. Typical Integrated EHT System

Private and Confidential
page 23

24. Typical Modular EHT System

Private and Confidential
page 24

25. Integrated Power Connections

Private and Confidential
page 25

26. Integrated Power Connections

JBS-100-E(P)
JBM-100-E(P)
C-150-E
(Under Insulation)
VPL
Private and Confidential
page 26

27. Modular Power Connections

Private and Confidential
page 27

28. Modular Power Connections

JBU-100-E(P)
JB-EX-25
JB-EX-27
JB-EX-28
JB-82
Private and Confidential
page 28

29. Modular Power Connections

Private and Confidential
page 29

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
Private and Confidential
page 30

31. Connection Kit

The C25-100 is the most commonly used connection kit
for both self-regulating and power limiting cables.
Private and Confidential
page 31

32. Insulation Entry Kit

Private and Confidential
page 32

33. Tee Connections

Private and Confidential
page 33

34. Tee Connections

T-100
JBM-100-E(P)
S-150
(Under Insulation)
VPL
Private and Confidential
page 34

35. End Seals

Private and Confidential
page 35

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
Private and Confidential
page 36

37. Splice Kits

Private and Confidential
page 37

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
Private and Confidential
page 38

39. Temperature Sensors

Private and Confidential
page 39

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
Private and Confidential
page 40

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
Private and Confidential
page 41

42. Temperature Sensors

DUAL SENSING
(control and limiter)
T-M-X-S/+X+YC/EX
Private and Confidential
page 42

43. Fixing SR and VPL Cables

Private and Confidential

44. Fixing Cables

Cables are typically fixed at
an interval of 300mm and
additionally where
necessary (i.e.. Valves,
pumps, drains, electrical
devices, etc.)
Private and Confidential
page 44

45. Fixing Cables

Glass tape is
EXCESSIVE TAPE
expensive and
should not be used
excessively.
Private and Confidential
page 45

46. Fixing Cables

When approved by
engineering, aluminum tape
(AT-180) can be used to fix
cable and thermostat
sensors to piping and
equipment.
Private and Confidential
page 46

47. Fixing Cables

DO NOT USE:
Metal Strapping,
Vinyl Electrical
Tape, or Duct
Tape
GT-66 or
GS-54
Private and Confidential
page 47

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.
Private and Confidential
page 48

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
Private and Confidential
page 49

50. Bending Cables

Private and Confidential
page 50

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.
Private and Confidential
page 51

52. Fixing Cables

Installation on tanks typically requires additional prepunched strapping.
Private and Confidential
page 52

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.
Private and Confidential
page 53

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.
Private and Confidential
page 54

55. Typical SR & VPL Installation

Typical SR & VPL
Installation
Private and Confidential

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.
Private and Confidential
page 56

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).
Private and Confidential
page 57

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.
Private and Confidential
page 59

59. Installation

Details
Private and Confidential

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.
Private and Confidential
page 61

61. Component Allowances

Valves
Private and Confidential
page 62

62. Valves

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

63. Valves

Private and Confidential
page 64

64. Valves

Private and Confidential
page 65

65. Valves

Private and Confidential
page 66

66. Valves

Private and Confidential
page 67

67. Valves

Private and Confidential
page 68

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
Private and Confidential
page 69

69. Valves

Private and Confidential
page 70

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
Private and Confidential
page 71

71. Valves

For thin (butterfly)
valves install the
excess allowance on
either side of the
valve body.
Private and Confidential
page 72

72. Valves

Elbows
Private and Confidential
page 73

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.
Private and Confidential
page 74

74. Elbows

Private and Confidential
page 75

75. Elbows

Flanges
Private and Confidential
page 76

76. Flanges

Private and Confidential
page 77

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.
Private and Confidential
page 78

78. Clamps

Do not install cables
underneath anything
which clamps around
the pipe.
Private and Confidential
page 79

79. Clamps

Pipe Hangers
Private and Confidential
page 80

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.
Private and Confidential
page 81

81. Pipe Hangers

Pipe Shoes
Private and Confidential
page 82

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.
Private and Confidential
page 83

83. Pipe Shoes

Linear Length
Allowance (typically 1.2m)
Private and Confidential
page 84

84. Pipe Shoes

Dummy Supports
Private and Confidential
page 85

85. Dummy Supports

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

86. Dummy Supports

DUMMY LEG
PIPE SHOE
Linear Length
Adder (Typically 1.2m)
Private and Confidential
page 87

87. Dummy Supports

Trunnions
Trunnions are basically just two dummy supports thus they
need twice as much allowance.
Private and Confidential
page 88

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)
Private and Confidential
DUMMY LEG
page 89

89. Dummy Supports

Pumps
Private and Confidential
page 90

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.
Private and Confidential
page 91

91. Pumps

Private and Confidential
page 92

92. Pumps

Private and Confidential
page 93

93. Pumps

Vessels
Private and Confidential
page 94

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
Private and Confidential
page 95

95. Vessels

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

96. Vessels

Private and Confidential
page 97

97. Vessels

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

98. Vessels

Install the SR (MI shown)
cable as per the
configuration shown on the
drawing And the spacing
specified by the drawing.
Private and Confidential
page 99

99. Vessels

Vents and Drains
Private and Confidential
page 100

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.
Private and Confidential
page 101

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.
Private and Confidential
page 102

102. Vents and Drains

Thermal Wells
Do not
exceed the
flange on a
thermal well
installation.
Private and Confidential
page 103

103. Thermal Wells

Post Installation Test
Private and Confidential
page 104

104. Post Installation Test

Terminations
Private and Confidential
page 105

105. Terminations

Private and Confidential
page 106

106. Terminations

Installing the
C25-100
Connection Kit
Private and Confidential

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.
Private and Confidential
page 108

108. Installing the C25-100

Materials:
C25-100 connection kit
Tools required
Cable to be connected
Private and Confidential
page 109

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.
Private and Confidential
page 110

110. Installing the C25-100

Select the correct grommet
for the heating cable being
used.
Private and Confidential
page 111

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.
Private and Confidential
page 112

112. Installing the C25-100

For VPL be sure to
be 300mm from
the nearest node.
Private and Confidential
page 113

113. Installing the C25-100

VPL
Private and Confidential
page 114

114. Installing the C25-100

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page 115

115. Installing the C25-100

Private and Confidential
page 116

116. Installing the C25-100

SR
Private and Confidential
page 117

117. Installing the C25-100

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page 118

118. Installing the C25-100

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page 119

119. Installing the C25-100

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page 120

120. Installing the C25-100

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121. Installing the C25-100

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page 122

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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page 125

125. Installing the C25-100

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page 126

126. Installing the C25-100

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page 127

127. Installing the C25-100

Private and Confidential
page 128

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.
Private and Confidential
page 129

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.
Private and Confidential
page 130

130. Installing the C25-100

Private and Confidential
page 131

131. Installing the C25-100

The End
Thank You for Your
Attention
Private and Confidential

132. The End Thank You for Your Attention

Sketch Options
DUMMY LEG
PIPE SHOE
Private and Confidential
page 133

133. Sketch Options

Flange
Private and Confidential
page 134

134. Flange

Valve
Private and Confidential
page 135

135. Valve

Thin Valve
Private and Confidential
page 136

136. Thin Valve

Dummy Support
DUMMY LEG
PIPE SHOE
Private and Confidential
page 137

137. Dummy Support

Pipe Shoe
Private and Confidential
page 138

138. Pipe Shoe

Blank
Private and Confidential
page 139
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