Heat trace is a term that refers to the use of specific cables that have been designed to assist in regulating the heat of substances that flow through a pipe. Even though the original design was implemented to help in the regulation of water, as well as other types of liquids in a tube, these systems are now used for other purposes as well, such as de-icing and the prevention of snow building up on a driveway in residential areas.

Different types of heat trace cable systems have been developed to provide more specialized functions. While industrial facilities and setups have initially made use of heat trace cables and heat tracing systems in cases where freeze protection, temperature maintenance, and the prevention of cavitation was needed, commercial and residential systems have also been developed in more recent years.

Today, there are also different ways that heat trace systems can be installed, ranging from DIY installation systems to more professional systems that need to be established by individuals who are highly trained and experienced in the field of heat trace cable management.

Properties Of Heat Trace Cables

Heat trace cable systems are somewhat different than your traditional thermal insulation systems. It is crucial to understand these differences to know when a heat trace cable will be a more appropriate solution for a setup where heat regulation features are needed within pipes, as well as in other applications where heat trace cables may be utilized.

The properties of a heat trace cable tend to depend on the specific type of cable system that will be used. To determine the most appropriate cable type that should be utilized, a variety of factors will need to be taken into consideration. The purpose of the system’s installation would be the primary factor that should be accounted for in cases where you wish to determine the best heat trace solution for your setup.

When freeze protection is required, a different setup will be needed than cases where you would like to utilize a heat trace setup for reducing the risk of gas condensation, or when requiring a temperature regulation in a system where certain chemicals are transferred through pipes, such as phosphoric acid or sulfur.

In cases where a custom system is developed for tracing pipes and vessels, the first step would be to consider the current loss of heat suffered by the system. This would have an impact on the specific properties that the heat trace cable will present.

Generally, a heat trace system will include an appropriate heat cable, which can be constructed with a tinned copper grounding braid, a polyolefin overjacket, or a fluoropolymer over jacket. Insulation will be applied to areas where the heat trace cable will be utilized – this will help to prevent a loss of heat during operations further.

The cable may feature different types of insulation materials, depending on the specifications of the system and the kind of heat regulation features that are required. In some cases, a standard pipe strap system is used. In other cases, however, fiberglass tape, nylon cable ties for interlocking, and aluminum tape may be used instead.

A heat trace cable system will also feature a control system that will ensure appropriate heat regulation is achieved with the cable and the entire setup. The control system plays a crucial role as it provides the temperature does not rise too high but also ensures the temperature does not become too low, which would ultimately void the actual function of the heat trace system that was installed.

The control system may sometimes include a thermostat as well, allowing for the temperature to be detected and monitored at all times. The thermostat can also provide the added functionality of temperature control to the system. Modern control systems, such as the IntelliTRACE Control modules, allow for more precision in terms of controlling the heat trace cable, due to the inclusion of a microprocessor.

Advantages Of Heat Trace Cables

Several advantages are provided to specific applications over other options that may be available for heat regulation. Business owners, homeowners, and individuals in charge of setting up systems within manufacturing plants are advised to be aware of the potential advantages that are offered by heat trace cables to make a more informed decision in terms of the specific system that should be installed.

To truly understand the advantages of heat trace cables, you would have to consider the different types of these cables that are available on the market. Each has specific properties that should be taken into account that will ultimately add to the list of benefits that can be achieved.

For example, with a constant wattage heat trace cable, you get the advantage of having a single power input, along with the fact that the cable can be cut off at an appropriate point without any issues. These systems also offer an extended life cycle compared to some other thermal insulation systems, and they come with built-in UV resistance. They are also able to resistant high and robust chemical substances, and they are appropriate for heating pipes in hazardous areas.

Over the last few decades, different types of heat trace cables have been designed to provide more specific functionality in specific sectors. While some of the more traditional options that were used in the 1900s are still available, more advanced systems have been developed to assist in the heating of pipes, tanks, vessels, and other objects where a heat trace system can be implemented.

Three of the most common heat trace systems that are used in the modern-day include:

• Self-regulating heat trace cable
• Series constant wattage heat tracing cable
• Parallel constant wattage heat trace

In this chapter, we are going to take a look at the most common kinds of heat trace cables and systems that are used today, and also consider the most appropriate applications and uses for each type. When it comes to implementing such a system, whether in a residential, commercial, or industrial setting, it becomes crucial to understand how each model operates thoroughly, the pros and cons of each type, and what the most appropriate uses for each heat trace system would be. This way, a business or property owner can be sure that they will choose the most suitable option for the setup that they require, whether it is to melt ice on the driveway or to heat asphalt.

2.1 Self-Regulating Heat Trace

In the modern-day, self-regulating heat trace systems have become one of the more commonly used options in terms of producing heat in a variety of settings. Thus, we will start by looking at what a self-regulating heat trace cable is and how such a system work, as well as the different practical uses for this type of heat trace system.

2.1.1 What Is Self-Regulating Heat Trace?

The term “self-regulating heat trace cable” was given to these systems by the original inventor. The term is really used to describe how the cable works – a self-regulating heat trace cable can regulate the power running through the bus wires to produce an appropriate heat, based on factors such as external temperature that affects the cable. In some cases, a thermostat and control system may also be added to self-regulating heat trace cable system to help the user gain more accurate control over the temperature of the cable.  In the majority of cases, such additions are added to a heat trace cable system when used in industrial settings. The majority of residential and commercial policies do not necessarily require such accessories.

Temperature limitation helps to prevent the cable and the entire system from reaching a certain temperature. The specific maximum temperature that each wire is capable of depends on the specifications of the cable and the whole system. The idea behind this limitation that is placed on temperature is to help avoid the heat trace cable from overheating – in cases where a heat trace cable overheats, it may become damaged. By limiting the temperature to a heat level that will not cause damage to the cable, the risk of damaged cables due to overheating can be effectively prevented.

These cables can achieve this goal by regulating the flow of electricity through the system. While the cable is heating up and while it remains at a specific temperature, power will continue to flow through the cable. At the point where the temperature becomes too high, the flow of electricity is halted. This occurs before the cable reaches a temperature that is hot enough to cause damage to any part of the heat trace system.

2.1.2 Structure Of Self-Regulating Heat Trace

A standard self-regulating heat trace cable consists of four essential components and, in some cases, an additional fifth material that provides added protection and helps to prevent moisture, which could interfere with the functionality of the cable.

The four primary materials that need to be part of a self-regulating heat trace cable include bus wires in the center, surrounded by a conductive core, plastic insulation, and metal braid. In addition to these four essential materials, some of the self-regulating heat trace cables that are available on the market tend to include an addition outer lawyer, which is often referred to as the plastic outer jacket.

Each of these layers plays a different part in ensuring the cable can function normally and provide the adequate temperature limiting features that are required from a self-regulating heat cable; thus preventing overheating and potential complications from occurring due to such an event.

https://oemheaters.com/topic/self-regulating

Let’s take a look at each of these layers to understand better how a self-regulating is constructed and how exactly such a system tend to function.

• Bus Wires: The bus wires are located at the center of a heat trace cable and are an essential part of such a system, as these wires are what connects the heat trace cable to a power source, ensuring that electricity can run through the cable to produce the required heat.
• Conductive Core: The conductive core surrounds the bus wires and plays a crucial part in the functionality of any self-regulating heat trace cable. This particular layer is what contributes to the “self-regulating” features that this type of trace heating system offers. The conductive core is made from a specific kind of plastic material that is known to be electrically conductive when the surrounding temperature is low, but when temperatures rise too high, it becomes an insulating material. The material is sometimes referred to as PTC, also known as “Positive Temperature Coefficient.” Basically, with this type of material, resistance increases along with the temperature. As temperature rises, less electricity is conducted through the cable.

Apart from the bus wires and the conductive core, the rest of the layers that make up a self-regulating heat trace cable are added for protection. The plastic insulation that is located between the conductive core and the metal braid, for example, helps to provide insulation between the outside of the cable and the live-current that is constantly running through the cable.

2.1.3 Practical Uses For Self-Regulating Heat Trace

There are several types of applications and scenarios where a self-regulating heat trace cable would be the ideal type of heat tracing system to be used. As with any setup that requires a heat trace cable, it is essential to consider the pros and cons of each type and to match a specific type to the functions that need to be performed by the system.

In case of a self-regulating heat trace cable, one particular factor about these systems are very beneficial – and that would be the fact that these cables tend to become more conductive in colder temperatures – remember the fact that the conductive core can adjust according to the heat?

One of the ideal uses for self-regulating heat trace cables is in environments where freeze protection is required. Many scenarios may require freeze protection – in residential and commercial