FAQs
What is Heat Tracing?
Heat Tracing (or Trace Heating, or Surface Heating) is the method of applying heat to a body, or to a product (liquid, powder, or gas) contained within a system (pipework, vessel or equipment) for storage or transportation, in order to avoid processing problems or difficulties.
Heat may be applied to:-
Liquids
- to prevent freezing
- to enable pumping by reducing the viscosity of the liquid
- Powders
- to eliminate condensation from the walls of equipment that could result in ‘clogging’of the product
- Gases
- to prevent hydration due to a drop in gas pressure across pipework fittings such as valves
The two main types of heat tracing employed in industry today
Electric Surface Heating
Heaters that use electrical power, either single or three phase
Steam Surface Heating
Heating that utilises steam from the plant either as a by-product or is created solely for the purpose of heating
Electric heat tracing is governed by a number of International and National Standards covering Industrial (Safe) and Industrial (Hazardous) locations
Steam Trace Heating
A typical steam heating system utilises, as the name suggest, steam that is either created for the purpose of heating, or steam that is a by-product of the process used on the plant.
Advantages of Steam
Steam does not produce electrical arcs and therefore is a useful option in explosive areas to prevent gases and dusts in the atmosphere igniting
Steam is considered ‘free’energy, although maintenance reduces the advantage of steam somewhat
Disadvantages of Steam
Steam is high temperature and;
It is very difficult to control without expensive valve arrangements.
Labour intensive to install to equipment.
Expensive to produce, use and maintain.
The system is prone to leaks, especially on high pressure steam systems.
Is very dangerous to personnel
Is very inefficient mainly due to the lack of control
Electric Trace Heating
Parallel Heating Cables
Self-Regulating Cables
Zoned Power-Limiting Cables
Zoned Constant Wattage Heating Cables
Series Heating Cables
Single Phase Series Cables
Three Phase Series Cables
Mineral Insulated
Self-Regulating Cables
These are one of the most common types of heating cables available on the market today.
The general construction is that there are two bus-wires (Live and Neutral) carrying the supply voltage.
A conductive matrix is extruded over the bus-wires. This is actually the heating element and not an insulating layer.
To provide electrical insulation, a layer of thermoplastic is then extruded over the matrix and conductors.
As an option, a further layer of metallic braiding is normally applied to the cable. This layer provides both mechanical protection and also an earth path for earth leakage detection.
As a final option, a layer of thermoplastic or fluoropolymer is extruded over the final cable. This final layer provides UV and further mechanical protection.
Zoned power limiting cables
These types of cables differ in the construction to self-regulating cables. In this construction the two bus-wires are extruded with an insulating layer over each conductor.
At pre-determined distances, the insulation is removed from alternate conductors, exposing the base conductor. A heating wire (or element) is wrapped around the two conductors, and where the wire meets these two areas, a heating ‘zone’ is created.
Sometimes the heating element is strengthened with fiberglass thread to absorb the high stresses created (especially at higher voltages) in the relatively thin heating wire.
A layer of insulation is then extruded over the cable. Similar to the self-regulating cable, a further optional layer of metallic braid and a final thermoplastic or fluoropolymer insulation can be extruded over the cable to provide a finished product.
Series Constant Wattage Cables
These cables are either provided as a flexible, cut-to-length version, or as a mineral insulated type cable.
The design of the cable relies on insulated conductors which are wired in series (for single phase supplies) or connected in a star connection at the remote end (for three phase supplies).
Principles of Heat Loss
All pipes/equipment that are above the ambient temperature will experience heat loss.
Heat loss is the loss of heat to the environment.
If no heating is applied to the pipe/equipment it will eventually equal the ambient temperature, at which point the heat loss will be zero.
The heat loss can be delayed by the application of thermal insulation. However, over a period of time, without heating the equipment will eventually match that of the ambient.
To keep equipment above the ambient, it is essential to add heatingand insulationto offset the heat loss.
Heat Loss from a Pipe
Q = 2π x K x (Tp-Ta)+ sf
ln(d2/d1)
Q Heat Loss (Watts/m)
K ‘k’-factor for the insulation at Mean Temperature Tm (W/m°K)
Tp Process Temperature (°C)
Ta Ambient Temperature (°C)
d2 Outer diameter of insulation
d1 Inner diameter of insulation
sf Safety Factor (typically an extra 10%)
Selecting a Cable
Heating cables come in a variety of ranges and outputs.
Check the Pipe Maximum Temperature
Check the Hazardous Area T-Rating
Adjust for the Voltage
Match the Heat Loss
The Design Checklist
Is this Maintain or Raise and Maintain?
What are the material(s) to be heated
Hazardous Location information.
Pipe/tank/vessel dimensions
Temperature to be held
Insulation type and thickness
Voltage available
Minimum Ambient temperature
Maximum permissible pipe temperature
Links
www.therenewableenergycentre.co.uk
www.electricalsafetyfirst.org.uk/guides-and-advice/around-the-home/
www.electricalsafetyfirst.org.uk/guides-and-advice/around-the-home/
www.cia.org.uk/Portals/0/Winterisation%20Nov%202011.pdf
www.networkrail.co.uk/timetables-and-travel/delays-explained/snow-and-ice/
www.rspb.org.uk/forprofessionals/farming/advice/species.aspx
www.rhs.org.uk/advice/profile?PID=159
www.nhs.uk/livewell/winterhealth/Pages/Winterhealthhome.aspx
www.gov.uk/government/news/winter-weather-uk-government-response
www.rspca-bristol.org.uk/uploads/documents/1329298413_WinterCareAdvice.pdf
www.healthandsafetyatwork.com/hsw/winter-weather-ppe
HTUK Services Ltd Specializes in the Following Areas
Market Areas – Industrial EX and None Ex Areas
- Chemical & Pharmaceutical
- Offshore
- Oil and Gas
- Power Generation
- Water
- Aerospace
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Applications
- Pipe Freeze Protection
- Temperature Maintenance
- Long Line Heating
- Tank Heating
- Frost Heave Prevention
- Hopper Heating
- Floor Heating
- Antenna de icing
- Surface Ice Prevention
- Instrument Heating
Market Areas – Life Sciences
As your life science partner, Watlow offers worldwide manufacturing and distribution, as well as superior application support.
Scientific discoveries and new technologies play an instrumental role in how the industry has changed and is changing for you and your instrumentation requirements. We understand that technology changes and all our design and developments of thermal solutions keep this in mind.
We Provide Products and Services to the Following Life Science Segments
Medical: Patient Care and Surgical Devices
Since patient safety is a top priority, Watlow provides thermal solutions that include flexible, cartridge, cable and ULTRAMIC® advanced ceramic heaters, along with Watlow safety limit controllers that are designed and manufactured to the equipment’s mechanical and electrical isolation characteristics.
Analytical Instrumentation
Because analytical instruments vary in type and in the material analysed, the process temperatures can vary a great deal. Watlow offers an array of product solutions such as ULTRAMIC 600 advanced ceramic, cartridge, tubular and ceramic fibre heaters combined with temperature sensors and controllers to provide turnkey solutions.
Biotechnology Research and Clinical Diagnostic Instrumentation
With all of the changing technology requirements in the industry, Watlow has developed precision heater and controller solutions that are based on modular design concepts. Watlow works one-on-one with you to develop thermal assemblies, while improving design times, cost and logistic support.
Laboratory and Sterilization Equipment
Because Watlow manufactures temperature controllers with advanced control algorithms to provide stable and repeatable temperature performance along with user-friendly interfaces, Watlow has been the preferred supplier in providing temperature control systems for laboratory equipment.
Custom Control Platform
Watlow has a unique approach to providing fast and cost-effective prototype services for custom controllers in clinical diagnostic and analytical instrumentation applications.
Market Areas – Transportation
We understand the challenges and requirements unique to the transportation industry. With applications covering virtually every as pet of applied heat our application experience, manufacturing and technical skill allow us to design and engineer the right product for your application.
- Rail
- Air
- Sea
- Automotive – Diesel
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Applications
- Switch Point Heating
- Third Rail Heating
- Pipe Freeze Protection
- Floor Heating
- Snow & Ice melting – Roof & Gutter
- Snow & Ice melting – Ramps & Stairs
- Snow & Ice prevention – Tunnels
- Diesel Line freeze prevention
- Add Blue freeze prevention
Products
- Self-Regulating Heating Cables
- Constant Wattage Heating Cables
- Series Heating Cables
- Skin Effect Systems
- Heating Mats
- Formed Heaters
- Thermostatic controllers
- Terminations
- Insulated & Heated Valve covers
- Distribution boards
- Heated silicone pads
- Control & Distribution Panels
- Thermal Insulation
- IBC jackets
- Plug and Play kits
System Solutions Designed to Fit your Diesel Application Needs
Our partner Watlow has more than 25 years’ experience as a diesel solutions partner, delivering global support wherever needed. For more than 85 years, they have designed, developed and manufactured complete thermal system assemblies—heaters, sensors and controllers—for leading industrial companies throughout the world.
Our diesel application solutions support original equipment manufacturers (OEMs), after treatment system integrators, retrofitters of over-the-road, medium and heavy-duty vehicles, and off-road construction, mining, agriculture, marine and locomotive equipment. We design application-specific sensors, controllers and heater components that can be integrated into your thermal management system for diesel exhaust after treatment and engine control.
On-Engine
Whether your application requires temperature sensing for fluids, cylinder heads, turbo inlets and outlets, or electric heating systems for fluids or intake air pre-heating burner systems—we can customize an on-engine solution that fits your application needs.
Watlow’s temperature sensors communicate with the engine control unit (ECU) using CAN, LIN, PWM or analogue outputs. Sensors are engineered to handle harsh diesel environmental demands including vibration, contamination and temperature extremes. Durability has been proven with over one million sensors operating in diesel applications.
After treatment
Watlow sensor solutions maximize diesel oxidation catalyst (DOC) performance, enable efficient and controlled DPF regeneration and provide for optimized selective catalytic reduction (SCR) system efficiency. We proudly manufacture sensors from our TS 16949, ISO 9001 and ISO 14001 sensor certified facility.
Does your application require additional heat for after treatment optimization or DPF regeneration? We offer a wide range of heater, temperature sensor and controller technologies that integrate with your system to facilitate an optimized after treatment system.
Watlow’s application-specific heater technologies and controllers solve problems including diesel exhaust fluid (DEF) thawing and freeze prevention and urea re-crystallization at the doser and SCR inlet.
Aerospace companies are looking for a partner to provide products and services that reduce weight, increase strength, reduce drag and lower part count. Watlow offers decades of experience in applying innovative products and services to the market. Watlow provides tried and true products such as thermocouple and RTD temperature sensors, silicone rubber blanket heaters, cartridge, cable and polyimide electric heaters to name just a few. Watlow also helps OEMs reengineer sensor products and controller systems.
Watlow utilizes its experience in the aerospace industry, as well as the experience it gathers from working in other high tech industries such as semiconductor processing, medical device and analytical equipment to provide the best solution for application requirements. Watlow can help engineer heating and temperature sensing solutions for the following aerospace-related applications. Please click on the links to see related product sections and literature.
Aircraft and Aircraft Engine Production and Test
- Titanium and exotic metal superplastic forming equipment
- Heat treating ovens, baths and chambers
- Wind tunnels
- Engine test stands
Civil and Military Aircraft
- In flight probes and detectors
- Water and waste water lines and tanks
- Drain masts
- Galley water systems and rethermalizing systems
- Cockpit, cabin and cargo hold heating panels and systems
- Rotorcraft electro-thermal de-ice systems
- Brake temperature sensors
Aircraft Engines
- Engine inlet electro-thermal de-ice systems
- Turbine inlet temperature sensors
- Exhaust gas temperature (EGT) sensors
- Piston engine inlet, cylinder head temperature (CHT) and EGT sensors
- Piston engine heaters
- Battery heaters
Spacecraft and Satellites
- Rocket engine temperature sensors
- Satellite thruster heating
- Satellite thermal management
- Satellite deployment systems
- Space cameras
Market Areas – Food Services / Refrigeration
Watlow has been heating up the foodservice equipment industry for decades. As the leader in thermal system design, we have supplied solutions for griddles, ovens, dishwashers, fryers and warming units in restaurant equipment all over the world. Watlow offers the broadest array of cooking computers, heaters, temperature sensors and software for your foodservice equipment.
We bring together over 80 years of heating expertise and technical knowledge, which translates into energy efficient cooking, lower maintenance, easy operation, consistent, reliable food quality and innovative offerings to your customers.
Market Areas – Manufacturing
Serving the Energy Process Industries for More than 20 Years
For more than 60 years, Watlow has been a preferred and trusted partner in designing electric process heaters; thermocouples; temperature, process and power controllers, and complete thermal systems. Watlow supports process industry end users, process original equipment manufacturers (OEMs) and system integrators. Our expert technical support team serves engineering and procurement construction (EPC) firms by providing excellent service and agency-approved products.
Expertise and leadership enables us to define and produce solutions for your demanding applications. We supply engineering design and support services and products for many applications including catalytic cracking and regeneration, gas dehydration, gas sweetening and others requiring technical thermal expertise and application design knowledge.
Watlow is the global leader in providing innovative thermal solutions for semiconductor.
Watlow is the global leader in providing innovative thermal solutions for semiconductor applications ranging from crystal growth through front-end wafer process to back-end assembly.
Ever since the first semiconductor diode, temperature has played an important role in semiconductor manufacturing processes. Watlow was there at the beginning and continues to provide proven results to the industry’s processes including in-situ deposition, etch and photolithography.
Watlow’s solutions are based on an understanding of the semiconductor technology roadmap. Temperature, as a critical process variable, increases in importance for equipment and process engineers as dimensions shrink. Watlow meets the ongoing demands of the industry and the thermal challenges of the semiconductor technology roadmap. Watlow continues to invest in R&D, global manufacturing and sourcing and introductions of new thermal technologies and solutions.
To better serve the semiconductor industry, Watlow has design, manufacturing, sales and technical support facilities in Asia, Europe and North America which provides the support of international design guidelines and agency approvals. Watlow has also developed new thermal technologies for deposition, dry and wet etch, photolithography, test and back-end assembly.
We Provide Thermal Solutions for the Following Applications:
Deposition and Etch Vacuum Chamber
- Wafer Chuck Assemblies
- Thick Film Heaters on Ceramic Substrates
- Temperature Sensor Technologies
- High Performance Metal Sheath Heaters Gas Delivery and Pump Line
- ASSURANT™ Pump Line Heaters
- High Uniformity Gas Delivery Line Heaters
- SERIES EHG Temperature Controllers
The solution is more than just the cost of heaters, temperature sensors or temperature and power controllers; it’s performance that counts. With Watlow’s thermal components processors can count on less downtime due to increased heater reliability; and a reduction in operating costs due to energy conservation – both of which help achieve greater output.
We provide plastic processors with product innovations for injection molding, thermoforming and extrusion operations, for years. Quality, innovation and reliability are the hallmarks of Watlow’s family of heaters, sensors and controllers. Watlow provides not only traditional thermal solutions, but also innovative, high-performance technologies to meet the specific processing demands of plastics industries.
Injection moulding
Watlow provides a broad range of heaters, sensors and controllers for applications including products like barrel heaters. These heaters are ideal for highly engineered or filled resins that require higher temperatures and tighter tolerances. Regardless of the machine tonnage, Watlow has the product to fit your need.
Hot Runner Systems
In hot runner systems, temperature uniformity is critical to insure balanced melt flow delivery for part-to-part consistency as well as preventing runner obstructions and material degradation. Watlow’s history is highlighted with numerous innovations for hot runner systems. The first to patent the cartridge-style heater, the tradition continues with a broad offering of both traditional and high-end products to meet the demands of this plastics processing segment.
Extrusion
Regardless of the extrusion system, Watlow’s family of thermal solutions provides the high-performance, reliability and accuracy needed to optimize processes. Watlow’s products provide overall product quality, assure process repeatability and shorten overall startup time.
Some applications where Watlow can provide thermal solutions for extrusion include:
- Larger diameter band heaters for single- or multi-layer blown film dies
- High- and low-watt density cartridge heaters for a variety profile and shape dies
- Strip heaters for versatile surface die and former heating
- A comprehensive offering of mercury-free power controllers
- Temperature sensors
Thermoforming
Watlow can provide an array of products and engineering services to help optimize thermoforming processes. Whether a customer requires a ‘sealed face’ heater to keep sheet/roll contaminants away from the element while offering ease-of-cleaning and longer life, or overall precise process control, Watlow’s family of heaters, temperature sensors and controllers can meet these demands.
Regardless of the application, Watlow has the solution to meet the need:
- Heaters – radiant, strip and tubular
- Control system
- Controllers – EZ-ZONE®
- Power controllers – DIN-A-MITE®, E-SAFE® II, SERIES CZR and solid state relays (SSRs)
- Temperature sensors
Blow Moulding
Regardless of your resin choice or final part shape, Watlow has an extensive offering of heaters, temperature sensors, and temperature and power controllers to meet the application requirements.
Serving the Energy Process
Serving the Energy Process Industries for More than 20 Years
For more than 60 years, Watlow has been a preferred and trusted partner in designing electric process heaters; thermocouples; temperature, process and power controllers, and complete thermal systems. Watlow supports process industry end users, process original equipment manufacturers (OEMs) and system integrators. Our expert technical support team serves engineering and procurement construction (EPC) firms by providing excellent service and agency-approved products.
Expertise and leadership enables us to define and produce solutions for your demanding applications. We supply engineering design and support services and products for many applications including catalytic cracking and regeneration, gas dehydration, gas sweetening and others requiring technical thermal expertise and application design knowledge.
Watlow is the global leader in providing innovative thermal solutions for semiconductor.
Watlow is the global leader in providing innovative thermal solutions for semiconductor applications ranging from crystal growth through front-end wafer process to back-end assembly.
Ever since the first semiconductor diode, temperature has played an important role in semiconductor manufacturing processes. Watlow was there at the beginning and continues to provide proven results to the industry’s processes including in-situ deposition, etch and photolithography.
Watlow’s solutions are based on an understanding of the semiconductor technology roadmap. Temperature, as a critical process variable, increases in importance for equipment and process engineers as dimensions shrink. Watlow meets the ongoing demands of the industry and the thermal challenges of the semiconductor technology roadmap. Watlow continues to invest in R&D, global manufacturing and sourcing and introductions of new thermal technologies and solutions.
To better serve the semiconductor industry, Watlow has design, manufacturing, sales and technical support facilities in Asia, Europe and North America which provides the support of international design guidelines and agency approvals. Watlow has also developed new thermal technologies for deposition, dry and wet etch, photolithography, test and back-end assembly.
We Provide Thermal Solutions for the Following Applications:
Deposition and Etch Vacuum Chamber
- Wafer Chuck Assemblies
- Thick Film Heaters on Ceramic Substrates
- Temperature Sensor Technologies
- High Performance Metal Sheath Heaters Gas Delivery and Pump Line
- ASSURANT™ Pump Line Heaters
- High Uniformity Gas Delivery Line Heaters
- SERIES EHG Temperature Controllers
The solution is more than just the cost of heaters, temperature sensors or temperature and power controllers; it’s performance that counts. With Watlow’s thermal components processors can count on less downtime due to increased heater reliability; and a reduction in operating costs due to energy conservation – both of which help achieve greater output.
We provide plastic processors with product innovations for injection molding, thermoforming and extrusion operations, for years. Quality, innovation and reliability are the hallmarks of Watlow’s family of heaters, sensors and controllers. Watlow provides not only traditional thermal solutions, but also innovative, high-performance technologies to meet the specific processing demands of plastics industries.
Injection moulding
Watlow provides a broad range of heaters, sensors and controllers for applications including products like barrel heaters. These heaters are ideal for highly engineered or filled resins that require higher temperatures and tighter tolerances. Regardless of the machine tonnage, Watlow has the product to fit your need.
Hot Runner Systems
In hot runner systems, temperature uniformity is critical to insure balanced melt flow delivery for part-to-part consistency as well as preventing runner obstructions and material degradation. Watlow’s history is highlighted with numerous innovations for hot runner systems. The first to patent the cartridge-style heater, the tradition continues with a broad offering of both traditional and high-end products to meet the demands of this plastics processing segment.
Extrusion
Regardless of the extrusion system, Watlow’s family of thermal solutions provides the high-performance, reliability and accuracy needed to optimize processes. Watlow’s products provide overall product quality, assure process repeatability and shorten overall startup time.
Some applications where Watlow can provide thermal solutions for extrusion include:
- Larger diameter band heaters for single- or multi-layer blown film dies
- High- and low-watt density cartridge heaters for a variety profile and shape dies
- Strip heaters for versatile surface die and former heating
- A comprehensive offering of mercury-free power controllers
- Temperature sensors
Thermoforming
Watlow can provide an array of products and engineering services to help optimize thermoforming processes. Whether a customer requires a ‘sealed face’ heater to keep sheet/roll contaminants away from the element while offering ease-of-cleaning and longer life, or overall precise process control, Watlow’s family of heaters, temperature sensors and controllers can meet these demands.
Regardless of the application, Watlow has the solution to meet the need:
- Heaters – radiant, strip and tubular
- Control system
- Controllers – EZ-ZONE®
- Power controllers – DIN-A-MITE®, E-SAFE® II, SERIES CZR and solid state relays (SSRs)
- Temperature sensors
Blow Moulding
Regardless of your resin choice or final part shape, Watlow has an extensive offering of heaters, temperature sensors, and temperature and power controllers to meet the application requirements.