ATEX Trace Heating Project | Compressor Seal Gas
Project Overview
Powertherm’s Trace Heating division successfully designed, supplied, installed and commissioned a bespoke ATEX trace heating system to protect a compressor seal gas network. The project involved the installation of approximately 115 linear metres of self-regulating electrical trace heating cable, ensuring the seal gas pipework maintained a consistent operating temperature of 90°C to prevent condensation and preserve gas quality.
Designed for use within a hazardous area, the complete ATEX trace heating system incorporated certified components and was engineered in accordance with BS EN 62395-2:2013 and BS EN 60079-30-2:2017, providing a safe, compliant and reliable temperature maintenance solution for this critical process application.
Technical Summary
| Sector | Oil & Gas |
| Application | Compressor Seal Gas Pipework |
| Service Provided | Design, Supply, Installation & Commissioning |
| System Type | ATEX Trace Heating System |
| Heating Cable | Self-Regulating Electrical Trace Heating Cable |
| Installed Length | Approximately 115 linear metres |
| Design Temperature | 90°C |
| Environment | Hazardous Area (ATEX) |
| Standards Compliance | BS EN 62395-2:2013 & BS EN 60079-30-2:2017 |
The Challenge
Compressor seal gas systems play a vital role in protecting rotating equipment by maintaining a clean, dry gas supply to the compressor seals. If the temperature of the seal gas pipework falls below the required operating temperature, condensation can form within the system.
The presence of moisture can adversely affect gas quality, interfere with seal performance, increase maintenance requirements and, in severe cases, lead to reduced compressor reliability, costly unplanned downtime and increased operational risk.
Maintaining the seal gas pipework at its design temperature was therefore essential to preserve the integrity of the seal gas system, protect valuable rotating equipment and ensure dependable compressor operation throughout the year.
Powertherm’s Solution
Following a detailed assessment of the operating conditions, Powertherm designed a bespoke ATEX trace heating solution specifically to maintain the seal gas pipework at 90°C and prevent condensation under all operating conditions.
Self-regulating heating cable was selected to automatically adjust its heat output in response to local pipe temperature, improving energy efficiency while reducing the risk of localised overheating.
The installation included:
- Design and supply of a complete ATEX trace heating solution.
- Installation of approximately 115 linear metres of self-regulating heating cable.
- ATEX-certified heating cable and accessories suitable for hazardous environments.
- Secure fixing of the heating cable using glass fibre fixing tape in accordance with industry best practice.
- Full termination, power connection, testing and commissioning.
All installation works were completed in accordance with:
- BS EN 62395-2:2013 – Electrical resistance trace heating systems for industrial applications.
- BS EN 60079-30-2:2017 – Electrical resistance trace heating for explosive atmospheres.
Inspection, Testing and Commissioning
Following installation, the system underwent comprehensive inspection, electrical testing and commissioning to verify safe operation, compliance and long-term reliability.
This included:
- Visual inspection of the complete installation.
- Verification of cable integrity and the absence of mechanical damage.
- Electrical resistance and insulation resistance testing.
- Confirmation that all terminations and electrical connections were correctly installed and secure.
- Final commissioning checks to verify the system achieved the required design temperature
Key Project Benefits
By maintaining the seal gas pipework at a constant operating temperature, the ATEX trace heating system delivers several operational benefits:
- Prevents condensation from forming within the seal gas system.
- Maintains the required gas properties for reliable compressor seal performance.
- Reduces the risk of moisture-related equipment failures.
- Supports reliable, continuous compressor operation.
- Improves long-term equipment reliability while helping to reduce maintenance requirements.
- Provides a fully compliant ATEX trace heating solution for hazardous environments.
The Result
The completed installation provides dependable temperature maintenance for a critical section of the compressor system, helping to ensure the seal gas remains dry and stable under all operating conditions.
By combining compliant design, quality installation, rigorous testing and commissioning, Powertherm delivered a robust ATEX trace heating solution that enhances process reliability, protects valuable rotating equipment and supports safe, efficient plant operation.
