Trace Heating Design Services
Engineered Trace Heating Solutions Designed for Performance, Efficiency and Compliance
The effectiveness of any trace heating system is determined long before installation begins. Accurate design is critical to ensuring systems deliver the required thermal performance, maintain process temperatures, prevent freezing, and operate efficiently throughout their service life.
At Powertherm, our experienced design engineers provide specialist trace heating design services for industrial applications across the UK. Combining extensive industry knowledge with proven engineering methodologies, we develop bespoke solutions tailored to the operational requirements of each asset and environment.
From process temperature maintenance and frost protection systems to hazardous area installations, our designs are developed to maximise reliability, minimise energy consumption, and reduce long-term operating costs.
Designed in Accordance with Industry Standards
Our in-depth understanding of electrical trace heating systems and the factors that influence their performance ensures every design is developed in accordance with recognised industry standards, including:
- BS EN 62395-2:2013 – Electrical resistance trace heating systems for industrial and commercial applications
- BS EN 60079-30-2:2017 – Electrical resistance trace heating for explosive atmospheres (ATEX)
By following these standards, we ensure systems are designed to achieve safe, reliable, and compliant operation throughout their lifecycle.
Comprehensive Trace Heating Design Capability
Every project begins with a detailed assessment of the process requirements, operating conditions, and environmental factors that will influence system performance.
Our design engineers consider:
- Process operating temperatures
- Ambient temperature conditions
- Pipework and equipment geometry
- Insulation specifications
- Hazardous area classifications
- Power supply requirements
- Operational and maintenance considerations
This allows us to develop a trace heating solution that is fully optimised for the application.
Detailed Engineering & Technical Deliverables
Powertherm provides a complete design package to support successful project delivery and long-term system operation.
Our design deliverables can include:
- Heat loss calculations
- Trace heating circuit schedules
- Electrical load calculations
- Cable selection and sizing
- Material specifications
- Technical design reports
- Detailed CAD drawings
- Installation guidance and supporting documentation
Upon completion, clients receive a comprehensive engineering package that provides full confidence in the suitability and performance of the proposed system.
The Importance of Correct System Design
Trace heating systems are not a one-size-fits-all solution.
An incorrectly designed system can result in:
- Insufficient heat output
- Excessive energy consumption
- Reduced system reliability
- Increased maintenance requirements
- Premature component failure
- Higher operating costs
By investing in a properly engineered design from the outset, operators can significantly reduce project risk while improving long-term system efficiency and performance.
Design for Frost Protection and Temperature Maintenance
We design trace heating systems for a wide range of industrial applications, including:
Frost Protection
Protecting critical pipework, tanks, vessels, and equipment from freezing temperatures and associated damage.
Temperature Maintenance
Maintaining specific process temperatures to ensure product quality, operational consistency, and process efficiency.
Process Heating
Supporting industrial processes where controlled temperatures are essential for production or material handling.
Hazardous Area Applications
Designing systems suitable for potentially explosive atmospheres in accordance with ATEX requirements and industry best practice.
Integrated Trace Heating and Insulation Expertise
As specialists in both industrial insulation and trace heating, Powertherm is uniquely positioned to optimise the performance of complete thermal management systems.
By considering insulation performance alongside heating requirements during the design stage, we can improve energy efficiency, reduce heat losses, and lower operational costs throughout the life of the installation.
Why Choose Powertherm?
- Experienced trace heating design engineers
- Designs developed in accordance with BS EN 62395 and BS EN 60079 standards
- Detailed technical calculations and CAD drawings
- Expertise in hazardous and non-hazardous environments
- Integrated insulation and trace heating solutions
- Complete design, installation, commissioning and maintenance support
Discuss Your Trace Heating Design Requirements
Whether you are planning a new installation, upgrading an existing system, or seeking specialist engineering support, Powertherm can provide a trace heating design solution tailored to your operational requirements.
Contact our team today to discuss your project and discover how a professionally engineered trace heating system can improve reliability, efficiency and long-term performance.