Electrical Trace Heating

Delivering Process Improvement and Optimisation

Electrical trace heating can ultimately be the difference between the smooth running of a process and detrimental operational issues.  Poorly installed or low-quality trace heating could result in total – and costly – production downtime.

We provide Electrical Trace Heating Services to a vast range of industries for both hazardous and non-hazardous environments, from food processing, pharmaceutical manufacture and power generation, to water treatment, petrochemical and chemical plants.


Powertherm Electrical Trace Heating Services include:

Temperature Maintenance

When working with potentially explosive materials, by-products of a heated process, or temperature-sensitive substances, it’s vital that the temperature is controlled and maintained.  We provide innovative solutions for the following:

  • Process equipment: including boilers, balance of plant
  • Process pipework: including transfer lines
  • Fuel oil and gas lines
  • Storage equipment: including vessels, tanks, and silos
  • Instrumentation: pumps, valves, nozzles etc
  • Ash handling: for hoppers, cyclones and associated equipment.

Frost Protection

Installing trace heating for frost protection can be the difference between protecting the life of assets and costly damage or, worse, complete and costly failure.  Frost protection systems can also reduce the risk of injury to both personnel and the wider general public.  We have applied our solutions to the following:

  • Water supplies: including chilled water supply (CWS), fire water circuits
  • Process equipment
  • Storage equipment: including vessels, tanks, and silos
  • Instrumentation: including pumps and valves
  • External decontamination showers
  • Process piping: for condensation / frost prevention
  • Footpaths and walkways.
  • Trace heating temperature maintenance vessel
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Trace Heated Flexible Insulation Products

Trace heating cable can be sewn into pockets on the inside face of a flexible insulation cover to add temperature maintenance capabilities to the product.  Junction boxes and thermostats can also be incorporated into the jacket to provide a total heated solution in both hazardous and non-hazardous areas.  Covers can be individually tailored to suit: gas bottles, oil drums, critical valves, instrumentation, and IBC containers.


Winterisation

The integrity of pipework during freezing temperatures is something that most facilities don’t consider until it’s too late and they face the unwanted costs of downtime and maintenance due to equipment failures.  We offer the expertise and experience to carryout Winterisation Services in any industry which has trace heating installed for frost protection purposes.

Winterisation is an inspection of trace heating frost protection systems.  Our service is split into two parts: a visual inspection and electrical testing:

 

Visual Inspection Electrical Testing
  • Check cable and cable gland condition
  • Test continuity and record results (checking for open circuit or low resistance) and compare with previous year’s results.
  • Remove junction box lid and check for moisture ingress
  • Test insulation resistance (cores to earth, checking for low IR readings) and compare with last year’s results.
  • Check terminals for tightness and correct connection
  • Checking against previous results can identify any malfunctions in heating elements before they occur.

After the Winterisation Inspection is complete, a schedule of the circuits tested, and corresponding results are issued with a list of remedial works.  Undertaking these remedial works helps prevent a potentially costly future problem, reducing the risk of downtime or total asset failure.

 

Winterisation frozen pipes

 


Advanced Service Delivery

With over 30 years’ experience in industry and a team of CompEx trained engineers, the knowledge and processes we have developed in the more hazardous sectors are now applied to all projects to ensure the highest level of safety at all times.  In addition to safety, this approach ensures that the most suitable product is chosen, the most experienced personnel are employed to perform the job, and the right solution is provided for the client.

We have successfully completed projects ranging from bespoke temperature maintenance systems, to frost protection systems installed across whole power plants for both new installations and on-going maintenance contracts.  We work in partnership with the client to deliver a full turnkey service: consultations, design, material specifications, installation, testing, commissioning, and maintenance.  All projects are provided with design drawings and supporting documentation to ensure plant operators understand the system installed and where key parts are situated.

We offer a full range of trace heating tapes, from constant wattage to self-regulating and mineral insulated elements.  Our range of control solutions covers basic control thermostats through to remote control panels with digital temperature readouts.  We also understand that insulation is a vitally important contribution to the efficiency of trace heating systems and having this service available in-house for our clients allows them to use the cost, time, and project management benefits associated with dealing with a single contractor.

Our service doesn’t end after an installation is commissioned.  We know that trace heating systems need to be consistently monitored and maintained for optimisation.  As such, we offer additional surveys and testing of systems, and winterisation services, to provide a diagnostic report.  This identifies potential future issues and allows proactive maintenance and repair to minimise the risk of costly downtime.

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