800 Winterizing and Heat Tracing

Abstract
This section covers design and installation considerations for winterizing in general
and heat tracing in particular. Winterizing is the application of a general design
philosophy aimed at preventing the disabling of equipment due to the solidification
or viscosity increase of liquids, and the mechanical distortion that occurs at low
ambient temperatures.
Heat tracing is the most common method of accomplishing winterizing. This
section deals with electric, steam, glycol, and hot oil heat tracing systems.

Contents Page

810 General 800-3

811 Establishing the Need for Winterizing
812 General Principles of Winterizing
813 Specific Winterizing Techniques
814 Comparison of Steam and Electric Tracing
820 Electric Tracing of Piping and Equipment 800-9
821 Design of Electric Heat Tracing Systems
822 Electric Tracing Systems
823 Selection of Heat Tracing Cable
824 Selection of Heat Tracing Controls and Instruments
825 Installation of Electric Heat Tracing Systems
830 Steam Tracing of Piping and Equipment 800-22
831 Types of Steam Tracing Systems
832 Materials for External Steam Tracers
833 Selection of Steam Pressure
834 Selection of Steam Tracers
835 Calculations for Steam Tracing
836 Steam Trap Spacing

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837 Steam Header Size Selection

838 Sizing of Condensate Lines
839 Steam Tracing Design Guidelines
840 Glycol and Hot Oil Heat Tracing Systems 800-31
850 References 800-32
860 Tables for Selection of Steam Tracing 800-32

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810 General
This section discusses the need for, and methods of, heat tracing and winterizing
piping and equipment frequently requiring cold weather protection or process
temperature maintenance. Not included in this manual is the heat tracing of instru-
mentation, which is included in Section 1500 of the Instrumentation and Control
Manual. Insulation of equipment is covered in the Insulation and Refractory
Manual. For steam heat tracing only, the size and thickness of insulation is
discussed in Sub-section 834 of this manual.
The term winterizing is frequently substituted for the term heat tracing. They are
not equivalent. In this section, winterizing is defined to encompass all the design
considerations necessary to prevent freezing and includes consideration of liquid
pour point, burial, insulation, heat tracing, line routing, equipment layout and
design, process design, and operational methods. Heat tracing is a subset of winter-
izing, and this section deals extensively with its use as the main winterizing tool.
The following design and plant layout comments should not be construed as
applying to all fluids but only to those fluids for which temperature maintenance
would be required.

811 Establishing the Need for Winterizing

Fluid Considerations. Winterizing is required when ambient temperatures can
drop low enough for a sufficient period to result in solidification or excessive
viscosity of fluid in an insulated line or piece of equipment under stagnant condi-
tions, thus affecting the process design parameters or the functioning of instrumen-
tation. The criterion is applied even though the fluid is not stagnant under normal
operating conditions.
The need for winterizing depends on the duration and level of temperatures, wind
speeds, precipitation, the type of fluid involved, geometry, and insulation material.
These factors are seldom all well defined, so calculations need to be supplemented
by experience and engineering judgment. Environmental variables can be obtained
from the National Weather Service. General rules of thumb for process lines and
equipment are:
• All process lines and associated equipment, e.g., valves, pumps, containing
fluids with pour points more than 20°F above the coldest expected ambient
temperature should be winterized.
• In the case of water-contaminated fluids, it should be assumed that water will
settle out in low points and freeze. For such fluids, the winterizing criterion
will depend on the pour point, the point of maximum tolerable viscosity, or the
freezing point of water, whichever is higher.
• In some cases the formation of hydrates must be considered.
The preceding assumes that the systems will be insulated to protect the fluid in the
ambient temperature range from pour point (or water freezing) to the winterization
need point specified here.

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Mechanical Considerations. Winterizing is required when the expected tempera-

tures would cause enough mechanical distortion to result in malfunction or damage
to piping or mechanical equipment.

812 General Principles of Winterizing

To minimize winterization needs, the following general design guidelines should be
applied to all systems for which performance might be affected by cold ambient
conditions. This includes handling of high pour point fluid under temperate condi-
tions.
1. Design to eliminate or minimize the number of low points where water can
collect. This results in a system that is self-draining or requires few low point
drains to empty lines and equipment.
2. Design small fittings (such as drain valves) close to the pumps, lines, tanks, so
heat from the larger bodies keeps the fittings warm.
3. Keep water and high pour point liquids out of instrument systems by using
seals.
4. When practical, provide for draining stagnant lines and equipment or
displacing high pour point or freezing stock with a low pour point fluid or a
gas.

813 Specific Winterizing Techniques

The following winterizing techniques are specific to each type of equipment.

Air Intake Screens

Keep air intake screens, such as those found on air blowers, away from free steam
sources, cooling tower plumes, and other water vapor sources to prevent icing. Heat
trace, if required.

Burner Fuel Knockout Pots

To revaporize any hydrocarbon condensate, heat trace and insulate pots unless a
means of liquid draw-off has been provided. Winterize the piping to the burners,
unless the pots are sufficiently close to the burners that re-condensation will not
occur upstream of the burners.

Compressor Suction Lines

Heat trace and insulate suction lines downstream of suction knockout pots, and
pulsation dampers to keep pipe wall temperatures above the condensing tempera-
ture.

Fire Hydrants and Monitors

Locate on/off valve and a normally open drain valve for standpipe below frost line.
See Standard Drawing GD-S1007 in the Fire Protection Manual.

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Gas or Volatile Liquid Lines

Heat trace and insulate where plugging by hydrate formation is likely as a result of
autorefrigeration at a control or relief valve or because of high operating pressures.
Refer to the Pipeline Manual or the Gas Processors Suppliers Association (GPSA)
Engineering Data Book for guidance on hydrate prevention.

Heat Exchangers, Air Cooled

1. Provide a louver system so fresh air intake can be limited and tempered by
recirculated air to control the temperature of the air to the cooling coil. Control
this air temperature so it remains 20°F above the pour point of the process fluid
or above 52°F, whichever is higher.
2. Steam coils, used to heat the process fluid during shutdown, should be self
draining through steam traps. Air temperature controlled by steam coils may be
the economic alternative to recirculation (see a. above) when expected cold
ambient days are minimal.
3. Local temperature indicators should be located on the outlet headers of each
cooling coil in wet or high pour service. This will allow operators to detect
freezing in an individual coil.

Instrument Leads and Instruments

Instruments can require winterizing by sealing, and/or purging and/or heat tracing.
Refer to the Instrumentation and Control Manual for instrument tracing needs and
design.

Manifolds, Snuffing Steam (e.g., for furnaces)

1. Provide a means for free draining or air purging the lines leaving the manifold.
2. Provide a normally open drain valve on the manifold as a bleeder to prevent
steam from leaking into the distribution lines.
3. Provide a steam trap upstream of the activation valve to prevent collection (and
subsequent freezing) of condensate during periods of non-use.

Pressure Safety Valves (PSVs)

1. PSV outlet lines discharging to atmosphere in wet service should have weep
holes at low points to prevent water from accumulating.
2. Heat trace and insulate nonfree closed system PSV outlet lines in wet or high
pour point service.
3. PSV bypass lines should be self-draining. If not, they require winterization.

Process Lines and Valves

1. For continuously flowing lines during normal plant operation, provide means
to drain the lines or displace fluid with a low pour point fluid or a gas when the

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plant is shut down. If this is not practical or if a line has intermittent flow, it
should be winterized.
2. Avoid putting process valves in vertical lines: this creates a nondrainable
pocket above the valve gate.
3. In horizontal lines mount block valves with stems vertical so bonnets will not
collect water.
4. Provide large untraced valves in water service with body drains for protection
during shutdowns.
5. Branches should come off the tops or sides of lines so water will remain in the
main line.
6. Bypass lines should be self-draining, i.e., with their valves located in the
highest horizontal section of the bypass.

Pumps
1. In addition to other winterizing criteria, consider the need to prevent thermal
shock on standby pumps. Use heat tracing and/or recirculation warm-up lines
to keep pumps warm when not in use.
2. Pump vents routed to flare should be heat traced if condensation could occur or
water vapor is present.
3. Heavy oil pumps without mechanical seals may be steam purged to keep drains
open.
4. A glycol (or other low pour point fluid) cooling system for pumps is recom-
mended to avoid the freezing problems encountered with cooling water
systems.

Safety Showers
Refer to Sub-section 280 of this manual, Tempered Water Systems for Safety
Shower and Eyewash, for alternates to winterizing or for limits on installation of
winterizing.

Tanks and Vessels

1. Heat trace and insulate water draw-off lines and pots.
2. Overflow lines of small tanks can be traced and insulated to avoid fouling or
freezing.
3. Use internal heaters or heat trace and insulate high pour point stock storage.
Both steam and electric heating “pads” are available for small tank and vessel
surfaces.

Utility and Instrument Air Systems

Utility air as well as instrument air should be dried to eliminate winterizing prob-
lems.

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Utility Stations
1. Water and steam lines from supply headers to utility stations should be run
together and enclosed in the same insulation, logistics permitting.
2. Use a branch from the steam line to trace the valves at the station.
3. Locate a drain hub at each station so water dripping to grade will not form ice
patches.

Water and Drain Lines

1. Bury such piping below the frost line.
2. Heat trace and insulate aboveground water lines.
3. When not buried below frost line, heat trace and insulate underground lines
and risers. Foamed glass insulation is recommended.

Water Lines, CW Exchangers

Install block valves and a 1-inch bypass so that if a unit utilizing the cooling tower
water is shut down, the exchanger may be drained and its cooling water lines may
be circulated through the cooling tower and its piping.

814 Comparison of Steam and Electric Tracing

Heat tracing is commonly done with steam, electricity, or hot liquids. Steam and
electric tracing are by far the most common and are compared here. Hot oil and
glycol systems apply to special situations and are discussed in Sub-section 840. In
deciding which technique to use for a particular application, consider the
constraints that may dictate the method to be used.
For example, electric tracing is specified when:
• Accurate temperature control is required (such as for heat sensitive process
liquids subject to degradation) (obviates steam pressure letdown)
• The required temperature is lower or higher (hot oil is an option) than that of
available steam
• Overheating can be a hazard, such as water to safety showers and eyewashes
• Frequent on-off operation is desired or necessary
• Steam is not available or the supply is unreliable
• It is not possible or it is not economic to collect or treat steam condensate
Alternatively, steam tracing is the first consideration when:
• Steam is in abundant supply
• Electric circuitry is undesirable
• Power is not available or the supply is unreliable

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When the selection of steam or electric tracing is truly optional there is seldom a
clear cut choice based on economics. This is due to the variety of parameters that
must be analyzed involving costs of design, material, installation, operation and
maintenance, in addition to energy costs. Each situation should be individually
analyzed. The normal practices of the facility may govern.
Thermon Manufacturing Company, Chemelex (Raychem), Dekoron (Samuel
Moore Group) and other heat tracing manufacturers have developed computer
programs that can quickly make economical comparisons and recommendations,
and thus, provide an optimal heat tracing design to meet individual specifications.
Any Vendor’s design must be checked to ensure compliance with design specifica-
tions and that adequate design factors were used.
In addition to firms that provide economic analyses and detailed designs, there are
also firms that provide heat tracing installation and performance checks on a
turnkey basis. This approach should be considered where limited heat tracing expe-
rience is available or for large, complex projects.
The following discussion provides some general guidelines comparing capital,
energy, and maintenance costs for steam and electric tracing.

Capital costs
Electric tracing is generally cheaper than steam for short tracer lengths (less than
about 100 feet) providing the current is low enough for the thermostat to be used as
a contactor. On short runs most of the cost is in the branch circuits for electric
tracers, and for steam tracing, in the steam and condensate piping for steam tracing.
Branch circuits for electric tracers, however, are usually less expensive than steam
and condensate piping.
Most instrument tracing falls into the electric heat tracing category. This is
discussed in the Instrumentation and Control Manual.
Electric tracing is generally cheaper than steam tracing for water freeze protection
and similar low temperature applications in nonclassified areas.
For other applications, and assuming steam is available, steam tracing within a
process unit is generally cheaper than electric tracing.
For heat requirements greater than 20 to 30 watts/ft, an electric tracing system can
be more expensive than a steam tracing system because a greater number of electric
tracers per pipe will be required.
For off-plot applications, the cost of tracer systems depends on the availability of
steam or electricity. Electric power is usually more readily available.

Energy Costs
Electric energy tends to be cheaper than steam for lower temperatures such as is
required for freeze protection. Steam tracers greatly overheat the line when the
ambient temperature approaches or exceeds the required line temperature, while
electric tracers are thermostatically controlled to shut off when the required temper-
ature is reached. While low-pressure steam often appears to be cheap or free, its use

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impacts the overall steam balance and must be evaluated carefully. See
Sub-section 340.
Steam energy tends to be cheaper than electric energy for maintaining a product at
high temperatures.
Tracer systems designed to operate only in plant shutdowns, usually have annual
energy costs low enough to be ignored in economic comparisons.

Maintenance Costs
Meaningful comparative maintenance costs for steam and electric tracing are not
readily available. Studies indicate maintenance costs for steam are about twice as
much as for comparable electric tracing. This higher cost is due mainly to steam
trap wear.
Electric tracing maintenance costs are less than steam, providing the tracing is prop-
erly designed, installed, and operated. (Indeed, many steam tracing systems are so
poorly installed that maintenance costs are quite high.) Electric tracing is sensitive
to overheating from line steamout, loss of insulation, and mechanical damage, most
of which can be avoided. A properly designed and operated electric tracing system
should incur very low maintenance costs.
For comparison purposes, maintenance costs normally are only a small percentage
of total cost.

Total Costs
As previously stated, each installation should be assessed individually as to the
method of heat tracing used. However, several guidelines may be applied.
• Steam tracing is more economical than electric tracing for piping in large
process units.
• Electric tracing is more economical than steam tracing for short, low wattage
applications, e.g., instruments.
– Electric tracers required for short, low wattage applications have a lower
capital cost than steam tracers.
– Energy cost differences are generally negligible because of the short
length of the tracers and relatively low heat losses.
• For off-plot and remote area tracers, electric power is usually more readily
available but the lower capital and energy costs of steam tracers may justify
bringing a steamline into an area where a large amount of tracing is required at
high heat densities and at high temperatures.

820 Electric Tracing of Piping and Equipment

This subsection provides the general requirements for electric heat tracing of piping
and associated equipment.

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821 Design of Electric Heat Tracing Systems

Design by Cable Manufacturer
Cable manufacturers will provide a complete design of electric tracing systems for
a fee of about 10% of the cost of the materials that they supply. In most cases they
should be able to provide a better design at a lower cost than a design by the
Company or a contractor because they have design staffs that do nothing but heat
tracing work, and they have design aids such as computer programs readily avail-
able. (Thermon will provide PC programs free of charge.)
The vendor should provide drawings and schedules, for Company approval, that
completely define the tracing system to facilitate evaluation of the proposed designs
and subsequent troubleshooting. The designs should be reviewed carefully. Each
heater circuit should be shown on an isometric drawing to clearly indicate the
following:
1. Location of temperature sensing bulb and cold junction
2. Representation of all flanges, valves, branch lines, drains, pumps, instruments,
and pipe and tubing supports
3. Indication of heater style and interconnection of multiple heaters, i.e., heat
tracing systems, whether series, parallel, or combinations thereof

Design Considerations
The following are some important points that should be considered whether the
design is done by the Company, or the Company is checking the design work of
others.

General
• A preliminary design in sufficient detail to place orders for long lead time
items, such as transformers, may be necessary.
• The arrangement of circuits should be determined only after a careful study of
the process flow diagrams and the piping and instrument diagrams. This is
essential to a reliable design.
• Waiting until field measurements can be made to fabricate the cables will not
normally delay a job. Cables can be shipped by air and can be received at the
jobsite in less than a week if the order is placed against a prior commitment.
• Electric heat tracing routing and control layouts may be shown on transparen-
cies of piping drawings, but in most cases it is better to show them on isometric
sketches made especially for the tracing system.
• Heat tracing cables must be carefully selected to avoid overheating or under-
heating piping and equipment. Some catalogs also contain charts and tables
from which heating cables of various resistance values can be selected to
match the required heat input.

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• In the past, many electric heat tracing cables have been replaced or had their
voltage increased because they failed to maintain required pipe temperatures.
Such failures can result from a number of factors, for example:
a. Inadequate weather protection for insulation or poor insulation mainte-
nance
b. Inadequate allowance for insulation variables and lower than normal volt-
ages
c. Design wind conditions that are too low
d. Use of a design minimum ambient temperature that is too high
e. Inadequate allowance for heat sinks such as valves, flanges, pipe supports,
and exposed portions of equipment
• Metal jacketing, see Area Classification, this section.

Temperature
• For all operating conditions, the maximum surface temperature of the electric
heat tracing cable must be lower than the ignition temperature of the fluid in
the pipe being heat traced. The applicable temperature limits can be found in
Article 500 of NFPA 70, the National Electric Code.
• The cable temperature should always be checked at the worst energized or de-
energized conditions (such as for high temperature upsets or steamouts) so that
it does not exceed manufacturer’s rating.
• If the de-energized temperature is too high, select a cable with a higher temper-
ature rating.
• If the energized temperature is too high, also consider heat transfer cement to
reduce cable temperature or a greater number of cables operating at a lower
wattage per foot of cable.

Length
• If a cable is too short, either a field splice or a separate short section of cable
with its own transformer is required. If the cable is too long, it will have to be
cut off and a termination fitting will have to be field installed or else the cable
will have to be doubled back on the end of the pipe or spiral wrapped around
the pipe. (Spiral wrapping, if feasible, is preferable to doubling back.)
• Changes in length of series cables after the voltage of the power source is fixed
should be limited as the power per foot of cable is inversely proportional to the
square of the length. Doubling back should only be done after it is determined
that it will not result in overheating the line or cable. Spiral wrapping cannot be
done if heat transfer cement is required or if the cable is not flexible enough to
be maneuvered around the pipe in the space available.
• Heat tracing circuits longer than 250 feet should be fabricated in multiple
sections with cold junction splices being made in an accessible junction box.

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Underground
• When electric heat tracing is to be used underground, it should be designed to
allow maintenance without excavating the pipe. Use a 1/2- or 3/4-inch conduit
or similar steel raceway banded to the pipe. Have ground level pull points
every 300 feet maximum.

Individual Circuits
• Large and small pipes, pipes located indoors and outdoors, and pipes above
grade and buried, normally require separate tracers.
• Each cable must trace pipe that has uniform conditions (fluid flow and heat
loss) for the entire length of the heater.
• A single cable or cables in series should not be used to trace two or more lines
in different services.
• Use a single cable wherever possible. Use one tracer with heat transfer cement
instead of two or more tracers without heat transfer cement.

Power Supplies
• Power supply points to the cables and temperature sensors should be located so
as to minimize costs of the electrical wiring to the heater.

Control
• Thermostats must be installed in such a way that they sense a temperature that
is representative for the entire heating cable under all operating conditions. For
example, installing too close to hot or cold piping or equipment can result in
false signals.
• Optional fluid flow paths that may result in stagnant fluids and sections of pipe
with no flow, such as normally closed bypasses and dead end legs, normally
require separately controlled tracers.

Pumps
• Pumps should normally be traced with a separate section of heat tracing cable
which can be readily disconnected from any cables heating suction and
discharge lines. Valves can normally be traced with the same cable that is on
the line, with the cable installed in such a way that the valve can be removed
without cutting the cable. Alternately, valves that require frequent removal for
maintenance can be enclosed by a heated box.

Series Cables
• Series type cables should be factory fabricated to exact field dimensions of
erected pipe if at all possible to avoid the more costly and less reliable field
connections. A field check is usually necessary because piping is seldom
installed exactly as shown on the drawings.

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• For series type cables, try to select a cable with a resistance such that the
voltage drop for the required length of cable is equal to a standard voltage to
avoid use of a step-down transformer.

Self-Regulating
• Copper resistance wires and self-regulating cables draw considerably more
current when cold than when final design temperature has been reached. This
can result in larger transformers, feeders, and overcurrent protective devices
than would be required for cables with alloy resistance wires such as nichrome.

Insulation
• Using correct insulation factors for the calculations is very important.
Changing insulation type can increase heat loss by a factor of two or more.
• The Insulation and Refractory Manual and various manufacturers’ catalogs
contain tables from which the required heat input can be determined for
various temperature differences between pipe and ambient for various insula-
tion thicknesses and material.
• Heat loss should be based on insulation inside diameter rather than pipe size
when oversize insulation is required to fit over the cable. A safety factor of at
least 35% should be used to allow for insulation variables unless this factor is
included in manufacturer’s selection tables. Some manufacturers’ tables
require the addition of a wind factor for outdoor lines.
• For temperatures below 212°F, insulation should be a water repellent, low
hydroscopic type such as water repellent rigid mineral wool or cellular glass.
• Weather protection for insulation is very important because electric tracing
normally has insufficient heat output to dry wet insulation. Even if drying is
possible, some insulations will never regain their full efficiency after once
being wet.
• Service test tracing before insulation.

Area Classification
• Applications for classified and nonclassified areas should be considered.
Follow the manufacturer’s recommendations.
• When metal jacketing is used, it should be smooth (rather than corrugated) and
should be of formed-modified “S” longitudinal joints. The circumferential
joints should be sealed with closure bands with nonsetting sealer applied
between the band and the jacket on each outer edge. Jacketing that is over-
lapped or otherwise closed without sealant is worthless as a barrier to moisture.

822 Electric Tracing Systems

There are two types of electric heat tracing cables: series and parallel. Parallel are
more common.

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Series-Type Cables
In series-type cables, the heating elements are insulated resistance wires that are
connected together at the remote end to form a series path or loop for the electric
current. See Figure 800-1.

Fig. 800-1 Series Heat Tracing Cable

Advantages Disadvantages
Efficient Must be Factory Cut to Correct Length
Low Installation Cost Field Modifications Very Difficult
Accurate Temperature Control Restriction on Minimum Length Without Stepdown
Transformer
Very High Temperatures Possibility of Hot Spots
Long Circuits Possible

The required voltage for a given heat density (watts per foot of cable) is propor-
tional to the length. (For a fixed voltage, the heat density is inversely proportional
to the square of the length.) Therefore, for a given cable, different voltages are
required for different lengths. Field changes in length cannot be made without
substantially affecting the heat density unless the voltage can also be changed.
Mineral Insulated (MI) series-type cable consists of one or more copper or resis-
tance alloy conductors embedded in magnesium oxide electrical insulation and
enclosed in a copper, stainless steel or Inconel sheath. It is available from Nelson
Electric Company, Thermon, and Emerson-Chromalox. Nelson Cables are UL
approved for use in Class I, Group D, Division 2 areas when the heat density is
reduced to limit sheath temperature to a safe value.
Teflon Insulated series-type cable consists of one or more copper or resistance
alloy conductors insulated with Teflon and protected by braid. Thermon TEK cable
is the most common of this type of cable in refinery service. TEK “Sure-Flow”
cable, TEK cable with a heat transfer jacket extruded over it, can be used where
heat transfer cement is required.

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Parallel Cables
Constant Wattage. This type of cable consists of two parallel bus strips or wires
with heating elements connected electrically. See Figure 800-2.

Fig. 800-2 Parallel Heat Tracing Cable (Constant Wattage)

Advantages Disadvantages
Efficient Maximum Length Limitation
Low Installation Cost Possibility of Hot Spots
Can be Field Modified Easily Limited High Temperature Range
Cut to Length in Field
Uses Standard Voltages

Several suppliers make parallel-type heating cables in which the heating elements
are Nichrome wires wrapped around the two insulated bus wires and alternately
connected to them at 1- to 4-foot intervals. The assembly is enclosed in plastic insu-
lation and may be covered with a metallic braid.
The effective heating length of parallel heat tracing cable must be an integral
multiple of the distance between heating element connections to the bus wire. For
while standard voltages can be used for most applications and the cable can be
readily cut to length in the field without affecting heat density, no heat is produced
in the heating element between the last connection to the bus and the cut end.
Consideration of length also impacts in overly long runs where the bus wires set up
a resistance to current flow and, therefore, cause a voltage drop.
Self-regulating. These are also called “self-limiting” and are parallel type cables.
The resistance element is a blend of irradiated plastic and graphite particles. The
bus wires are in continuous contact, via the graphite mix, with the current flowing
between them. The entire assembly is insulated with plastic and may also be metal
jacketed. See Figure 800-3.
The resistance of the heat tracing graphitic material increases rapidly with tempera-
ture increases (and decreases with temperature decreases), making the cables self-

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Fig. 800-3 Parallel Heat Tracing Cable (Self-Regulating)

Advantages Disadvantages
Efficient Limited High Temperature Range
Low Installation Cost Maximum Length Limitation
Accurate Temperature Control Maximum Heat Density Less Than Series Type
Cable
Cut to Length in Field
Hot Spots Not a Problem
No Minimum Length
Uses Standard Voltages
Does Not Necessarily Require Thermostat

regulating. This feature minimizes the probability of burnouts, eliminates the need
for high- or low-temperature limit switches in most applications, and allows for the
use of a single cable on complex piping systems where heat loss may vary greatly
at different points or where doubling back and overlapping of the cable on itself is
necessary.
These cables are also flat enough to fit under standard size insulation. They give
good heat transfer without the use of cement, especially when used with aluminum
tape, and they are flexible enough to be easily wrapped (overlapped and doubled
back) around valves and equipment.
A more sophisticated type of self-regulating cable is available; utilizing four-wire,
480-volt power for use with long lines (several thousand feet). Power is supplied at
one end of the line and the heat duty is divided among the three phases and the
ground wire, at 270 volts, along the length of the line. Little Company experience is
currently available with this design.
Disadvantages of the self-regulating cables are that the maximum heat density is
less than for series-type cables.

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Internal Wire Impedance System

Another type of electric heat tracing is the Internal Wire Impedance System (IWIS).
This is also known as Skin Effect Current Tracing (SECT). In this system, a single
insulated conductor is enclosed in a steel tube or conduit and is grounded to the
tube at the remote end. Current flows through the insulated wire and returns
through the tube. See Figures 800-4 and 800-5.

Fig. 800-4 IWIS (SECT) Heat Tracing

Advantages Disadvantages
Efficient Limited Use for Shorter Circuits
Accurate Temperature Control More Difficult to Install
Very Long Circuits Must be Carefully Engineered
Can Usually be Replaced Without Removing Insulation

Fig. 800-5 SECT Heat Tracing Installation

Because the voltage drop due to current flow in the tube is approximately equal to
the voltage induced in the tube by current flow in the internal wire (by transformer
action), the net voltage on the tube is very small.

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The tube serves two purposes: as a conduit and as a heating element. At one end the
conductor is bonded to the cable and at the other, an alternating current supply is
connected across the heat tube and the cable, closing the electrical circuit. As power
is applied, the resistance of the heat tube and the cable produce heat within the heat
tube itself. This action generates about 90% of the total heat energy.
A phenomenon is then produced by an electromagnetic interaction between the
many small parallel elements of the alternating currents within the power cable,
heat tube, and flux linkage surrounding them. This interaction is called skin effect.
It causes current to concentrate on the inner surface of the heat tube wall, permit-
ting the heat tube to be welded to the carrier pipe, while giving an excellent heat
transfer from the heat tube to the product in the carrier pipe.
In addition to the heat generated by current flow in the wire and tube due to their
resistance, heat is generated in the tube by magnetic hysteresis and eddy currents
induced by the alternating current.
This system is especially applicable to long pipelines because it permits long
distances between feed points. For example, distances between feed points up to
8000 feet are practicable at 480 volts or up to 12 miles at 4000 volts.
It is especially suitable for underground pipelines because in the event of an elec-
trical failure, repairs and replacement can be made without digging up the pipeline.
Similarly, repairs can readily be made on insulated aboveground lines without need
to remove pipe insulation. This system can maintain line temperatures up to about
300°F, using Teflon insulated wire.
It is recommended that the Engineering and Technology Department (ETD)
Mechanical and Electrical Division be contacted for counsel and assistance if IWIS
heat tracing is being considered.
IWIS systems are generally used for pipelines, such as Carter Creek’s 21 mile
molten sulfur line. The system is designed to provide heat to the carrier pipe and
the product evenly along the full length of the pipe. Constant temperature is main-
tained by cycling the system on and off. A temperature sensor attached to the
carrier pipe is constantly monitored by a temperature controller.

823 Selection of Heat Tracing Cable

Most suppliers offer several types of cable, and suppliers’ catalogs should be
consulted before a final choice is made. Also, suppliers’ recommendations
regarding installation requirements for the particular application should be consid-
ered. Heat transfer cement is required for some types of cable at higher heat
outputs, and aluminum tape covering is recommended in other cases.
Cables can be supplied with ranges of output (typically 10 to 100 watts/foot),
maximum operating temperatures (up to 1000°F), voltage levels, and cable lengths.
On past projects satisfactory tracing materials and design assistance have been
provided by Thermon Manufacturing Co., Chemelex (Raychem), and Dekoron.
Refer to Sub-section 821 for a discussion of design considerations.

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824 Selection of Heat Tracing Controls and Instruments

Temperature controls should be kept as simple as possible. Elaborate control
systems cost more to design, purchase, and maintain and should be used only where
a definite process need exists or where an economic analysis has shown multiple
controls to be necessary.
The following discussion provides control selection guidelines.

Thermostats as Load Switching Devices

Thermostats can normally be used as load switching devices up to 480 volts,
provided the heater current does not exceed the rating of the thermostat.

Ambient Temperature Thermostats

Where protection against low atmospheric temperature (freeze protection) is
required, on-off thermostats sensing ambient temperature can be used to control
groups of heaters, i.e., steam, fluid, or electric.
Obviously, this system controls line temperature only indirectly and then only in
response to the ambient temperature. That is, if a given heater is installed to prevent
freezing at -20°F, the line will be hotter than necessary when the power is constant
and the ambient temperature is at 40°F (particularly if there is less heat loss from
the line than anticipated).
This higher temperature is unimportant on most water lines, but it must be consid-
ered where power conservation is important, where there is a danger of overheating
the heater cable, or where overheating of the line must be prevented, such as on
caustic, acid, or safety shower lines.

Line Temperature Thermostats

Where control of line temperature at a fixed point is required, an on-off thermostat
can be used with the sensing element.
There will usually be a 15- to 20-degree temperature differential between the on
and off switching points due to over- and undershoot.
This type of control is suitable for most heaters that cannot be group controlled by
an ambient temperature sensing thermostat.

Solid-State Temperature Controllers

Solid-state temperature controllers provide closer and more reliable on-off control
than conventional thermostats. Solid-state controllers are available with an accuracy
of 0.5% and an on-off differential of 0.1% of range.
They can be group mounted in centrally located panels and can be furnished with
high- and low-temperature alarms and circuit failure alarms. In some cases, the
actual installed cost may be competitive with line-mounted thermostats.

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Modulating Temperature Controllers

In cases where very close temperature control can be justified, modulating control-
lers can be used. These are usually silicon controlled rectifier (SCR) units with
sensing elements mounted on the pipe. They control the power output of the heater
in proportion to the heat demand and thus maintain close temperature control.
Ambient sensing SCR controllers can be used for group control where freeze
protection is required. This prevents overheating at temperatures slightly below the
maximum set point in systems designed for very low ambients.

High-Temperature Limit Switches

High-temperature limit switches should be used as a backup for any temperature
control in cases where there is a danger of overheating the line or overheating the
heating cable, if the primary control fails to function properly.

Temperature Sensing Elements

Bulb-type sensing elements with capillary tubing to the thermostat or high-limit
switch are commonly used for on-off control systems.
Resistance temperature detectors, thermocouples, or thermistors can be used when
it is desirable to mount the thermostat or limit switch at a greater distance from the
sensing element than possible with a capillary tube or where the temperature is too
high for bulb-type units.
These devices are also used with solid-state and modulating units.

Monitoring Devices
Monitoring devices to check heater operation should be provided in critical applica-
tions. High- and low-temperature alarms and ammeters or current relays activating
alarms to check current flow can be used. Ammeters are less costly than a relay-
alarm system, but must be manually read to check on current flow (and thus heater
operation).
With series cables, current is either 100% (heater operating) or zero (heater cable
open). Even if several series cables are connected in parallel to a single circuit,
current will change by relatively large increments as individual cables fail. Hence,
relatively insensitive and inexpensive meters or relays can be used.
With self-regulating parallel cables, the current is a function of heater temperature;
thus, current monitoring cannot be used to determine heater condition.
With resistance parallel cables, current will drop off as individual heater elements
fail. However, because a heater cable consists of many parallel elements, several
elements would have to fail to affect total current significantly. This means that a
segment of a traced line may already be frozen without any indication of failure via
current measurement. Voltage fluctuations also directly affect total current. Thus,
current monitoring is of limited usefulness with parallel-type cables.
The voltage between bus wires of a parallel-type cable can be monitored at the
remote end by a pilot light or voltage relay. This will indicate whether the entire

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Utilities Manual 800 Winterizing and Heat Tracing

cable is intact and energized. Voltage at the remote end will not positively ensure
that the cable is heating properly; anywhere from zero to all of the parallel elements
may have failed.
Major heating cable suppliers offer fairly sophisticated monitoring and alarm pack-
ages, and development work in this area is continuing. Suppliers should be
contacted for further details.

Fault Detection
If a fault occurs in a series-type cable, the fault current is limited by the resistance
of the cable up to the point of fault. If this is near the remote end, the fault current
may be only slightly greater than the normal current, and thus will not trip the over-
current protective device. There have been instances in which faults have occurred
and the resulting arcs have burned back along the cable toward the source until the
resistance was reduced sufficiently to permit the overcurrent device to trip.
In classified areas and in other critical installations, fault protection should be
considered. A ground fault circuit interrupter (GFCI) will provide the required
protection.

825 Installation of Electric Heat Tracing Systems

Details and Drawings
Drawings showing standard installation details will normally be supplied by the
cable manufacturer.
Manufacturers will supply installation details for electric heat tracing systems
including junctions (hot and cold) and splices, and method of installation on valves,
pipe branches, and other equipment. The most critical portion of electric heating is
at junctions, valves, pipe T’s, and for coverage of related equipment. In these areas
heat conductivity may be inadequate to avoid overheating of the electrical cable.
Standard drawings GD-J1220, GD-J1221 and GD-J1222, in the Instrumentation
and Control Manual, provide sizing information and installation details for electric
tracing.

Field Supervision
Proper installation of the tracer system is essential to prevent cable burnouts and to
obtain the required amount of heating. For this reason, very careful and thorough
field supervision is required.
In many cases, particularly where series-type cables are used, every inch of cable is
critical and should be inspected before the thermal insulation is installed. In addi-
tion, after installation each cable should be checked for continuity and meggered
(use of high voltage ohmmeter) to check resistance to ground.
The installation and checkout of an electric heat tracing system should be under the
direct supervision of an experienced construction engineer. If a qualified Company
engineer is not available, the services of a supplier’s factory trained man should be

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obtained at least at the start of installation work to assist the installation supervisor
and craftsmen in understanding product operation and installation.
Depending on the size of a job, additional services may be justified for taking accu-
rate field measurements of installed pipe, inspection of cable installation, and
startup of the system. For this, the service to consider is that of a turn-key design,
procure, and install contractor.

830 Steam Tracing of Piping and Equipment

This section establishes the general requirements for steam tracing of piping and
associated equipment. Tracing of instrumentation is covered in the Instrumentation
and Control Manual.
Standard Drawing GD-L1066 explains how to select tracers and illustrate their use
on drawings. Drawing GF-L99888, Sheets 1 and 2, show steam tracing installation
details. Drawing GD-L99596 illustrates trap manifold configurations.

831 Types of Steam Tracing Systems

External Steam Tracing Without Heat Transfer Cement is accomplished by
running tubing or pipe containing steam along the outside of the product line with
oversize insulation covering both the product line and the tracer.
Because of tubing flexibility and ease of installation, this method using tubing is
particularly suited for tracing irregular shapes such as flanges, fittings, valves, and
pumps.
Use of pipe tracers is very expensive but required for high pressure, high-tempera-
ture steam applications. Consideration of its use might be limited to straight run
applications and other means employed for tracing mechanical equipment and valve
manifolds.
External Steam Tracing With Heat Transfer Cement is similar to the system
described above except that heat transfer cement is applied to the tracer to increase
the heat transfer rate.
As a general rule, one tracer with cement can replace two or three tracers without
cement, providing both lower cost and faster heatup time. See Sub-section 834.
Integral Steam Traced Pipe is pipe that has a steam passage that is an integral part
of the pipe. A steam passage can either be extruded as a part of the pipe (available
in aluminum only), or formed by continuously welding a curved plate to the pipe.
Aluminum is not an acceptable material for most refinery uses, and neither the
aluminum nor the curved plate system are economically competitive with other
systems for most applications.
Jacketed Pipe Steam Tracing allows the product line to pass through the center of
a larger steamline. Because of its high cost, this system is used only where a very
high heat input is required or where the material in the traced line solidifies so

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Utilities Manual 800 Winterizing and Heat Tracing

easily that tracer tubes are inadequate to prevent solids buildup (for example lines
carrying liquid sulfur). An example of steam jacketed double wall pipe is shown in
Figure 800-6.

Fig. 800-6 Steam Jacketed, Double-Wall Pipe

Internal Steam Tracing uses a return bend or hairpin tracer inside the product line.
This system provides a high heat transfer rate and eliminates the oversize insulation
needed to fit over tracers that are external.
Internal tracing has application for long runs of large diameter pipe where a high
heat input per foot is required. For example, penetration asphalt handling systems.
In intermittent services such as loading lines, internal tracing can provide fast
startup because normally all that is required is to melt a small area around the tracer
for flow to begin.
Disadvantages are that pigs or scrapers cannot be used, cross contamination is
possible, flow area is reduced, and alloys are required to prevent corrosion by some
products. Contamination through leakage may be of serious concern and should not
be overlooked.

832 Materials for External Steam Tracers

Carbon steel tubing should not be used for steam tracing because it does not
provide adequate corrosion allowance.
For steam pressures to 175 psig and line temperatures to 400°F, ASTM B-88 Type
K copper water tubing should be used. Joints should be made with brass tubing

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compression fittings. On small jobs, if skilled craftsmen are available, 1150°F

melting point solder (silver solder) may be used as an alternate. Compression
fittings offer a large maintenance advantage over solder fittings.
For steam pressures above 175 psig and line temperatures to 400°F, stainless steel
tubing or Schedule 80 carbon steel pipe tracers can be used.
Stainless steel (SS) tubing should be used if heat transfer cement is required. SS
tubing should also be used in applications such as tracing instrument leads and
where a great deal of bending is required such as valve manifolds or pumping equip-
ment.
Schedule 80 carbon steel pipe tracers should be used where the tracer is welded to
the pipe. Its joints, under insulation, should be welded.
All tracing should be service tested before being insulated.
Tubing materials and applications are discussed in Section 300 of the Piping
Manual.
Minimum sizes are normally 3/8-inch nominal (1/2-inch OD) SS tube or 1/2-inch
Schedule 80 pipe because smaller sizes have a greater chance of plugging and can
only be run short distances between condensate drawoff points. If greater flexibility
is required, 3/8-inch OD tubing may be used for short tracers.
Formed channels should always be used over tracers on piping that require heat
transfer cement. The channels reduce installation costs because they can be filled
with cement and applied over the tracer to eliminate the laborious hand troweling of
cement around the tracer. The channel also helps to overcome the expansion forces
of the tubing and to keep the cement from breaking away from the pipe.

833 Selection of Steam Pressure

Lower pressure steam tracer systems will normally have higher capital and mainte-
nance costs than higher pressure systems because of the greater number of larger
tracers, greater number of traps, and larger headers.
The cost of high pressure steam should be balanced against the higher capital and
maintenance costs of a low pressure tracer system.
The pressure at the trap must be sufficient to force the condensate into the collec-
tion system (including pressure required for elevation head). Steam pressure at ≤15
psig may be used only where the condensate discharges to atmospheric pressure; it
is too low to operate traps against a closed condensate system.
The use of 15 psig steam is also not recommended for below freezing temperatures.
In addition to the danger of freezing in the lines, ice slicks will be created in loca-
tions where the condensate must be dumped to grade.
In cold climates, low pressure tracer systems are most likely to freeze. At -20°F
ambient and below, a steam pressure of at least 100 psig is recommended.

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Where low pressure steam will be required to prevent boiling or overheating of the
product in the line, particularly on small lines, electrical tracing should be consid-
ered. Use of insulating strips between a high pressure steam tracer and the pipe is
an alternative to low pressure steam use.

834 Selection of Steam Tracers

Figure 800-14 through 800-25 at the end of this section have been provided for
selecting the number and size of steam heat tracers; calculations are based on line
size for various minimum ambient temperatures, holding temperatures, and steam
pressures.
These figures show tabulations of the number and size of tracers using copper
tubing without heat transfer cement, Schedule 80 pipe without heat transfer cement,
and copper tubing with heat transfer cement.
Actual temperatures of material in the lines may be considerably higher than shown
in the tabulations. Calculations were made only to determine the number and size
of tracers required for a specific holding temperature and assumptions for the calcu-
lations are necessarily conservative to allow for uncertainties in the heat transfer
rate.
Sizes of Type K copper tubing shown in the tables are nominal sizes which are 1/8-
inch less than the outside diameter.
Insulation sizes and minimum thicknesses to be used with steam tracers are shown
in Figure 800-26, located at the end of this section.
Note With today's energy costs the insulation thicknesses listed in Figure 800-26
may not be economic for process lines. For hot lines, economic insulation thick-
nesses may be considerably greater than those values listed in the table. When this
is the case, the tabulations in the figures should not be used. Instead, the calcula-
tion procedure presented below should be utilized to determine the number and size
of the tracers required.

835 Calculations for Steam Tracing

If the calculations required are not contained in the referenced figures, and if the
services of a heat tracing system manufacturer are not readily available, the
following manual method can be used for temperature maintenance calculations:

Calculations for Tracing Without Heat Transfer Cement

The determination of the number and size of tracers involves the solution of two
heat transfer equations. A precise solution is not possible because of unknown
design conditions, particularly that of the separation of the tracer and the traced line.

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Assumptions
1. The tracer does not touch the traced line and all heat transfer is by convection
and radiation.
2. The inside surface of the insulation is at the product temperature.
3. The outside of the tracer is at the steam temperature.
4. The thermal resistance on the outside of insulation is negligible. This assump-
tion causes an error of less than 0.5% when wind velocities are 15 MPH or
higher or when a cold rain is falling.
5. Thermal equilibrium has been reached.

Equations

Q t = Q Convection + Q Radiation

T s – Tp
0.25
( T s + 460 ) 4 ( T p + 460 ) 4
= 0.131N t d t  ------------------  ( T s – T p ) + 0.0453N t d t F ---------------------------
- – -----------------------------
 dt  100 100

(Eq. 800-1)

0.524KS
Q i = --------------------------- ( T p – T a )
 di 
ln  ----------------- 
 d i – 2t i 
(Eq. 800-2)

Q
W s = -------i
Hv
(Eq. 800-3)
where:
di = Outside diameter of insulation, in.
dt = Outside diameter of tracers, in.
F = Factor for net radiation from the tracer. Use 0.5 for copper tubing
and carbon steel pipe tracers.
Hv = Heat of vaporization of the steam, Btu/lb
K = Conductivity of insulation Btu/hr-ft2 - °F/in. (If not listed, refer
to the Insulation and Refractory Manual for selection)
Nt = Number of tracers
Qt = Heat loss from tracer(s), Btu/hr per foot of pipe

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Qi = Heat loss through insulation, Btu/hr per foot of pipe

S = Safety Factor to allow for insulation variables, normally 1.25
ti = Thickness of insulation, in.
Ta = Ambient temperature, °F
Tp = Product temperature, °F
Ts = Steam temperature at inlet pressure minus pressure drop in tracer,
°F
Ws = Weight of steam condensed, lb/hr per foot of pipe (total for all
tracers on the pipe)

Methods of Solution
1. If the desired holding temperature, Tp, is known, solve by trial and error for the
smallest number and diameter of tracers that will cause Qt to be equal to or
greater than Qi.
2. If the number and diameter of tracers is known, solve by trial and error for the
product temperature that will cause Qt to equal Qi.
3. When a large number of calculations are required, a computer or a program-
mable calculator can easily be programmed to solve these equations.

Calculations for Tracers with Heat Transfer Cement

The Thermon Manufacturing Company and other major tracing system suppliers
publish design guides for sizing steam tracers when heat transfer cement is used.
Calculations not covered by the guides will typically be done on request. When
designing systems using heat transfer cement, the use of a single larger tube will be
more economical than two 1/2-inch OD tubes.

836 Steam Trap Spacing

Figures 800-7 through 800-12 allow selection of maximum tracer length between
steam traps excluding the supply pipe to the tracer and the condensate line from the
tracer to its trap. Tables included are for 3/8-, 5/8- and 1-inch nominal size tubing
and 1/2-, 3/4- and 1-inch Schedule 80 pipe with steam pressures of 15, 40, and 150
psig.
The tables are based on a pressure drop of 10% of the inlet psig or 10 psig, which-
ever is greater, with maximum length not to exceed 500 feet.
To use the tables in Figures 800-7 through 800-12, first find the lb/hr of steam per
100 feet of traced line from the steam tracer tables or calculations and divide by the
number of tracers on the line to get the lb/hr of steam per 100 feet of tracer. Then,
using the tabulation, find the tracer size being used at this steam rate and read the
maximum length under the correct steam pressure. Interpolate for steam rates that
fall between the values listed in the tables.

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Fig. 800-7 Maximum Tracer Length Between Traps 3/8-Inch Nominal (1/2-Inch OD) Tube
lb/hr Steam Length of Tracers, ft
per 100 ft 15 psig 40 psig 150 psig
Tracer Tube Steam Steam Steam
5 200 310 500
10 120 200 410
15 100 150 320
20 80 130 260
25 — 110 220
30 — 100 200
35 — — 180
40 — — 160
Note For explanation see Section 836.

Fig. 800-8 Maximum Tracer Length Between Traps 5/8-Inch Nominal (3/4-Inch OD) Tube
lb/hr Steam Length of Tracers, ft
per 100 ft 15 psig 40 psig 150 psig
Tracer Tube Steam Steam Steam
5 450 500 500
10 320 490 500
15 240 380 500
20 200 310 500
25 180 280 500
30 160 250 500
35 140 220 450
40 130 200 410
45 120 180 380
Note For explanation see Section 836.

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Utilities Manual 800 Winterizing and Heat Tracing

Fig. 800-9 Maximum Tracer Length Between Traps 1-Inch Nominal (1 1/8-Inch OD) Tube
lb/hr Steam Length of Tracers, ft
per 100 ft 15 psig 40 psig 150 psig
Tracer Tube Steam Steam Steam
5 500 500 500
10 500 500 500
15 500 500 500
20 500 500 500
25 500 500 500
30 450 500 500
35 410 500 500
40 360 500 500
45 300 500 500
Note For explanation see Section 836.

Fig. 800-10 Maximum Tracer Length Between Traps 1/2-Inch Schedule 80 Pipe
lb/hr Steam Length of Tracers, ft
per 100 ft 15 psig 40 psig 150 psig
Tracer Pipe Steam Steam Steam
5 270 420 500
10 170 270 500
15 130 200 440
20 110 180 350
25 — 150 300
30 — 130 270
Note For explanation see Section 836.

Fig. 800-11 Maximum Tracer Length Between Traps 3/4-Inch Schedule 80 Pipe
lb/hr Steam Length of Tracers, ft
per 100 ft 15 psig 40 psig 150 psig
Tracer Pipe Steam Steam Steam
5 460 500 500
10 320 490 500
15 240 380 500
20 200 310 500
25 — 280 500
30 — 250 500
Note For explanation see Section 836.

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Fig. 800-12 Maximum Tracer Length Between Traps 1-Inch Schedule 80 Pipe
lb/hr Steam Length of Tracers, ft
per 100 ft 15 psig 40 psig 150 psig
Tracer Pipe Steam Steam Steam
5 500 500 500
10 500 500 500
15 480 500 500
20 420 500 500
25 370 500 500
30 330 500 500
35 310 500 500
Note For explanation see Section 836.

837 Steam Header Size Selection

Figure 800-27 provides estimation calculations for the steam tracing header sizes
based on flow rate in pounds per hour.
To use the table, first determine the steam rate from the tracer tables or calculations
and adjust for length of tracer to determine the steam rate to each tracer. Then sum
the rates from each tracer on a header and select the header size listed for that flow
rate.
More exacting methods of economically sizing piping are covered in Subsection
340 of the Piping Manual.

838 Sizing of Condensate Lines

Condensate from steam tracing is collected and discharged from tracers through
steam traps. Each tracer should have a dedicated trap. Trap sizing and selection is
discussed in Section 300 of this manual.
Traps are typically grouped into manifolds as shown on Standard Drawing GD-
L99596 and discharge into a common condensate line or header.

Two-Phase Flashing—Caution
Some condensate flashes to steam as it discharges through the traps to a lower pres-
sure. More condensate flashes to steam as the pressure is reduced in flowing
through the condensate piping. This produces a propensity for 2-phase flow (liquid
and vapor) in the condensate return lines. Therefore, pressure drop calculations
should be based on two-phase flashing flow (discussed in Section 350 of this
manual).
When traps are grouped in a common manifold, all of the traps will occasionally
discharge simultaneously. Typically, lines from grouped traps to the branch collec-

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Utilities Manual 800 Winterizing and Heat Tracing

tion header are sized for the sum of the instantaneous rates of all traps on the mani-
fold. Lines serving steam tracers only, however, should be sized for half this load.
An allowance should be made for future additions to the system, for fouling of the
pipe with rust and scale, and for blowing of live steam through worn traps or traps
that have failed open.
Oversizing of the condensate return system may also promote excessive flashing
and subsequent restriction in condensate return. This will lead to inadequate tracer
functioning.

839 Steam Tracing Design Guidelines

Each tracer should have its own supply valve and trap. Split tracers (two tracers
controlled by the same supply valve) are only allowed when one branch is less than
20 feet long and only where isolation for maintenance can be done in the same
fashion as the process lines and equipment they serve. The following are general
steam tracing design guidelines.
• Arrange tracer supply valves and traps in logical groups according to the equip-
ment the tracers serve.
• Locate the supply valves and traps so they will be easily accessible for mainte-
nance.
• Identify seasonal tracers by color coding or tagging the supply valves and traps.
• To be self-draining, individual tracer supply valves should be located in hori-
zontal piping at a high point in the line.
• Tracers should slope continuously downward from supply to trap without
pockets where possible.
In a freezing climate provide a means of emptying tracers of condensate so they
will not freeze when shut down. If tracers slope continuously from supply to trap,
they will be self-draining and no special provision will be required.
In the event of failure to self-drain, provisions can be made for blowing the conden-
sate out with air. This requires a temporary air hose connection at the tracer source.
This method will not remove all water from the tracer but normally will not leave
enough to damage the line. As another option, high point vents and low point drains
may be provided for condensate removal on shutdown. This is a positive method of
draining condensate but may be impractical due to inaccessible vent and drain loca-
tions.
The choice between these two schemes should be made with input from operating
personnel.

840 Glycol and Hot Oil Heat Tracing Systems

Guidelines for design of glycol and hot oil heat tracing systems are not available for
this edition in this manual.

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850 References
Engineering Data Book, Gas Processors Suppliers Association (GPSA).

860 Tables for Selection of Steam Tracing

Figure 800-13 lists the tables used for selection of steam tracing. Listing is by
ambient temperature, steam psig, and related figure number. (For discussion, see
Sub-section 830.)

Fig. 800-13 Figure List

List of Tracer Sizing Tables
Figure Number Ambient, °F Steam, psig
800-14 –20 150
800-15 0 40
800-16 0 150
800-17 20 15
800-18 20 40
800-19 20 150
800-20 40 15
800-21 40 40
800-22 40 150
800-23 60 15
800-24 60 40
800-25 60 150
800-26 Insulation Size and Thickness for Traced Lines
List of Maximum Tracer Maximum Length Tables
Figure Number Nominal Size, In.
800-7 3/8 Tubing
800-8 5/8 Tubing
800-9 1 Tubing
800-10 1/2 Sch 80 Pipe
800-11 3/4 Sch 80 Pipe
800-12 1 Sch 80 Pipe
800-27 Steam Header Sizes

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Fig. 800-14 Steam Tracing Tables
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Fig. 800-15 Steam Tracing Tables
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 Utilities Manual 800 Winterizing and Heat Tracing
Fig. 800-16 Steam Tracing Tables
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Fig. 800-17 Steam Tracing Tables
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 Utilities Manual 800 Winterizing and Heat Tracing
Fig. 800-18 Steam Tracing Tables
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Fig. 800-19 Steam Tracing Tables
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 Utilities Manual 800 Winterizing and Heat Tracing
Fig. 800-20 Steam Tracing Tables
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Fig. 800-21 Steam Tracing Tables
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 Utilities Manual 800 Winterizing and Heat Tracing
Fig. 800-22 Steam Tracing Tables
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Fig. 800-23 Steam Tracing Tables
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 Utilities Manual 800 Winterizing and Heat Tracing
Fig. 800-24 Steam Tracing Tables
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Fig. 800-25 Steam Tracing Tables
December 1989 800-44 Chevron Corporation
Utilities Manual 800 Winterizing and Heat Tracing

Fig. 800-26 Insulation Size and Minimum Thickness for Traced Lines in Figures 800-14 through 800-25
Traced Insulation Insulation Insulation
Line Size, Thickness(1) Thickness(1)
Size Inside Diameter K = 0.3 to 0.4 K < 0.3
1 1 ½(2) 1 1
1½ 2(2) 1½ 1
2 3 1½ 1
3 4 1½ 1
4 6 2 1½
6 8 2 1½
8 10 2 1½
10 12 2 1½
12 14 2 1½
14 16 2 1½
16 18 2 1½
18 20 2 1½
20 22 2 1½
24 26 2 1½
Note Guidelines for selection of economic insulation thickness, are discussed in the Insulation and Refractory Manual, Section 300.

(1) Insulation thickness for K = 0.3 to 0.4 Btu/hr-ft2-×F/in. were based on economics for the United States in 1974. They may not be the most
economical thicknesses today. Fuel cost assumed was $5.00/EFO bbl. The insulation thicknesses for K less than 0.3 were selected to
give approximately the same heat loss at K = 0.3 as the thicker insulation at K = 0.4.
(2) Use 2-inch insulation size on 1-inch line and 3-inch insulation size on 1 ½-inch line when Schedule 80 pipe tracers are used.

Fig. 800-27 Steam Header Sizes for Steam Trace Systems

Maximum Flow Rate, lb/hr
Header
Size, In 15 psig 40 psig 150 psig
¾ 20 60 150
1 60 150 300
1½ 250 400 900
2 500 800 1700
3 1300 2000 4200
4 2000 3000 6500
Notes: 1. For explanation see Section 837.
2. Steam header sizes are based on economic pipe size as shown in Figure 3 of Design Practice l-13101, “Line Sizing for Process
Plants.”

Chevron Corporation 800-45 December 1989