Pipe Freeze Protection

Design/Install Guide

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HD100707-1 Rev0
Pipe Freeze Protection
Design / Install Guide
CONTENTS

Introduction Page 3

STEP 1 – Information Required Page 4

STEP 2 – Design Considerations Page 5

STEP 3 – Electrical Requirements Page 6

STEP 4 – Selecting Cable Page 6

STEP 5 – Cable Components Page 10

STEP 6 – Monitoring and Control Page 12

Installing Self Regulating Cable Page 13

Testing Self Regulating Cable Page 14

Cable Test Report Template Page 15

Troubleshooting Self Regulating Cable Page 16

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HD100707-1 Rev0
INTRODUCTION
Drexan HeatTracer products are designed to serve the most demanding environments including
hazardous and non-hazardous areas, as well as areas where corrosive exposure may be of
concern.
PipeGuard® is certified to; CSA (CUS) standards for use throughout North America, ATEX for
Europe, and is suitable for both metal and non-metal pipes, tanks and vessels.
The integrity of a heat tracing system depends upon on how accurately the cable is selected and
how well it is installed. An improperly designed and installed heat tracing system could result in
cable failure and possible physical injury.
The following instructions will provide you with a step-by-step procedure for determining the best
solution for your freeze protection applications.
Drexan HeatTracer web-based design program is available at www.pro-trace.com

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HD100707-1 Rev0
STEP 1 – INFORMATION REQUIRED
 Pipe diameter
 Pipe length
 Minimum ambient temperature
This is the minimum temperature expected (worst case) throughout the winter months.
 Maintain temperature
For freeze protection a typical maintain temperature of 5˚C (40˚F) is sufficient.
For process temperatures ensure the temperature rating of the cable is suitable.
Cable ratings: Refer to the respective cable data sheets available at
www.drexanheattracer.com.
 Start-up temperature
This temperature will have a direct effect on the maximum circuit length and the breaker
size required. You should select the temperature at which the cable will normally become
energized, not necessarily the coldest temperature.
 Metal or non-metallic Pipe
Some materials have superior heat transfer compared to others. Metal for example will
conduct heat better than a polymeric material. For this reason we recommend the use of
aluminum foil tape (part # TAPE-AL) on polymeric pipes applied over the pipe under the
cable.
 Pipe hardware (valves, shoes, flanges etc.)
When measuring the total length of the pipe to be heat-traced remember to allow extra
cable for the pipe hardware.
 Thermal Insulation type & thickness
All pipes, equipment and pipe hardware must be thermally insulated.
Measurement: Metric? Imperial? Temperature: Celsius? Fahrenheit?
Voltage: (include if 3 phase) _____________
Applications
Pipe Tracing: Metal? Other? (specify) _______
Pipe Length: Diameter: Insulation Type:
Insulation Thickness: Not Yet Determined:
Low Ambient Temp: Max. Pipe Temp: Maintain Temp:
Area Classification: Class Div. Group
Number of Supports Valves Hangers

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HD100707-1 Rev0
STEP 2 – DESIGN CONSIDERATIONS
 When a pipe enters a building it is important that the cable extends into the building
approximately 12” to ensure the pipe temperature is maintained above freezing.
 When a pipe enters the ground to below the frost line it is important to run the cable well
below the frost line to ensure the pipe temperature is maintained above freezing.
 When a main pipe has a short branch line connected to it, the branch line may be double
traced (down & back) to eliminate the need for a Tee Splice Kit.
 Heating cable should not pass through the air. When crossing from one pipe to another,
the cable should run through a Flexible Extension (part # FLEX-E)
 Select the cable wattage output to suit the application. A conservative design will allow a
slightly higher wattage output, per foot of cable, than required.
 Insulate all heat sinks in the heat tracing system. Allow sufficient cable to trace additional
heat sinks. See Table 4
 DO NOT expose heating cables to temperatures higher than their temperature ratings.
 For valves, install the heating cable so that the valves can be conveniently removed for
servicing.
 The type and thickness of thermal insulation will have a direct effect on the amount of heat
required. Longer circuit lengths may be achieved by increasing the insulating thermal value
to lower the cable wattage output required. Refer to Table 3
 Multiple runs of cable may be required on larger pipes with high heat loss.
 When using a spray-on insulation it is recommended that a layer of aluminum foil tape be
placed over the cable to prevent embedding of the cable in the thermal insulation, thereby
resulting in poor heat transfer from the cable to the pipe.
 If lines are steam cleaned, pay particular attention to the maximum exposure temperature,
even if the heating application is freeze protection. Standard freeze protection cables will
fail if exposed to low pressure steam. Specify either PipeGuard Hot or PipeGuard CMH
cables in these applications.

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HD100707-1 Rev0
STEP 3 – ELECTRICAL REQUIREMENTS
Design the heat tracing system using the most commonly expected start-up temperature.
Be practical. If you choose the most extreme (coldest possible) start-up temperature, for example
-40 degrees, you may unnecessarily shorten the circuit lengths, or require larger breaker sizes or
additional panels and power cable.
However, keep in mind that if the heating system starts up at a lower temperature than it was
designed for, you may experience breaker tripping.
To determine maximum circuit length and breaker size required, refer to tables found on the cable
data sheets available at www.drexanheattracer.com.
For voltages other than 120/240V refer to cable data sheets at www.drexanheattracer.com.
All heating cable systems require ground fault protection (27- or 30-mA trip level) as per the
National and Canadian Electrical Codes.

STEP 4 – SELECTING CABLE

When determining the minimum ambient temperature for your location, always consider the
worst case or lowest temperature. Selecting a low ambient design temperature will provide an
increased safety factor.
From the following tables you can determine the amount of heat (watts/ft. pipe) required to
maintain your pipe @ 40°F / 5°C - Table 3
For example: An ambient temperature of minus 20°F (-29°C) and a 2” pipe with 1” of Glass Fiber
thermal insulation will require 3.8 Watts per foot of pipe.
Note: The charts used in this guide are based on Glass Fiber Thermal Insulation. These charts may
also be used with Polyisocyanurate and Mineral Wool insulations of the same thickness.
When installing cable on pipe with high process temperatures or on pipes that will be steamed out
during maintenance, consideration must be given to the cable exposure temperature.
For example:
If the cable will be exposed to temperatures in excess of 65°C/150°F then you must select a cable
with a higher temperature rating such as Drexan HeatTracer PipeGuard Hot (PGH) or PipeGuard
CMH. Refer to the cable data sheets located on the Drexan HeatTracer Website
www.drexanheattracer.com

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HD100707-1 Rev0
Table 3
WATTS PER FT. PIPE REQUIRED
Pipe Dia. Ambient Temp. Insulation Thickness
Inch °F °C ½" 1" 1 ½" 2" 2 ½" 3" 4"
0 -18 2 1.3 1 1 1 0.8 0.7
-10 -23 2.5 1.6 1.3 1.2 1 1 0.8
½
-20 -29 2.9 2 1.6 1.4 1.2 1 1
-40 -40 3.9 2.5 2 1.8 1.6 1.5 1.3
0 -18 2.3 1.5 1.2 1 1 0.8 0.7
-10 -23 2.9 1.9 1.5 1.3 1 1 0.9
¾
-20 -29 3.5 2.2 1.8 1.5 1.4 1.3 1
-40 -40 4.5 2.9 2.3 2 1.8 1.6 1.4
0 -18 2.8 1.7 1.4 1.2 1 1 0.8
-10 -23 3.4 2.1 1.7 1.4 1.3 1.2 1
1
-20 -29 4.1 2.5 2 1.7 1.5 1.4 1.2
-40 -40 5.3 3.3 2.6 2.2 2 1.8 1.6
0 -18 3.3 2 1.6 1.3 1 1.1 0.9
-10 -23 4.1 2.5 2 1.6 1.4 1.3 1.1
1¼
-20 -29 4.9 3 2.3 1.9 1.7 1.6 1.3
-40 -40 6.4 3.9 3 2.5 2.2 2 1.8
0 -18 3.7 2.2 1.7 1.4 1.3 1.1 1
-10 -23 4.5 2.7 2.1 1.8 1.5 1.4 1.2
1½
-20 -29 5.4 3.3 2.5 2 1.8 1.7 1.4
-40 -40 7.1 4.3 3.3 2.7 2.4 2.2 1.9
0 -18 4.4 2.6 2 1.6 1.4 1.3 1.1
-10 -23 5.5 3.2 2.4 2 1.8 1.6 1.4
2
-20 -29 6.5 3.8 2.9 2.4 2.1 1.9 1.6
-40 -40 8.6 5 3.8 3.1 2.7 2.5 2.1
0 -18 5.2 3 2.3 1.8 1.6 1.4 1.2
-10 -23 6.4 3.7 2.8 2.3 2 1.8 1.5
2½
-20 -29 7.6 4.4 3.3 2.7 2.4 2.1 1.8
-40 -40 10 5.8 4.3 3.6 3 2.8 2.3
0 -18 6.1 3.5 2.6 2.1 1.8 1.6 1.4
-10 -23 7.6 4.3 3.2 2.6 2.3 2 1.7
3
-20 -29 9 5.2 3.8 3 2.7 2.4 2
-40 -40 11.9 6.8 5 4 3.5 3.1 2.6
0 -18 7.6 4.3 3.1 2.5 2.2 1.9 1.6
-10 -23 9.5 5.3 3.9 3.1 2.7 2.3 1.9
4
-20 -29 11.3 6.3 4.6 3.7 3.2 2.8 2.3
-40 -40 14.9 8.3 6 4.9 4.1 3.7 3

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HD100707-1 Rev0
Table 3 cont.
WATTS PER FT. PIPE REQUIRED
Pipe Dia. Ambient Temp. Insulation Thickness
Inch °F °C ½" 1" 1 ½" 2" 2 ½" 3" 4"
0 -18 11 6 4.6 3.4 2.8 2.5 2
-10 -23 13.5 7.4 5.3 4.2 3.5 3.1 2.5
6
-20 -29 16 8.8 6.3 5 4.2 3.7 3
-40 -40 21.1 11.6 8.2 6.5 5.5 4.8 3.9
0 -18 14 7.5 5.3 4.2 3.5 3 2.4
-10 -23 17.2 9.3 6.6 5.2 4.3 3.8 3
8
-20 -29 20.5 11 7.8 6.2 5.2 4.5 3.6
-40 -40 27 14.6 10.3 8.1 6.8 5.9 4.7
0 -18 17 9.2 6.4 5 4.2 4 3
-10 -23 21 11.4 8 6.2 5.2 5 4
10
-20 -29 26 13.6 10 7.4 6.2 5.3 4.2
-40 -40 34 18 13 10 8.1 7 6
0 -18 20 11 8 6 5 4.2 3.3
-10 -23 25 13.3 9.3 7.2 6 5.1 4.1
12
-20 -29 30 16 11 9 7 6.1 5
-40 -40 39 21 15 11.3 9.3 8 6.4
0 -18 22 12 8 6.3 5.2 5 4
-10 -23 27.2 15 10 8 7 6 4.4
14
-20 -29 33 17.3 12 9.3 8 7 5.2
-40 -40 43 23 16 12.2 10.1 9 7
0 -18 25 13.2 9.2 7.1 6 5 4
-10 -23 31 17 11.4 9 7.3 6.2 5
16
-20 -29 37 20 14 11 9 7.4 6
-40 -40 48.5 26 18 14 11.3 10 8
0 -18 28 15 10.2 8 7 6 4.3
-10 -23 35 19 13 10 8 7 5.4
18
-20 -29 42 22 15 12 10 8.2 6.4
-40 -40 54.3 29 20 15.3 13 11 8.4
0 -18 31 17 11.3 9 7 6.1 5
-10 -23 38 21 14 11 9 8 6
20
-20 -29 46 24 17 13 11 9 7
-40 -40 60.2 32 22 17 14 12 9.2
0 -18 37 20 14 11 9 7.1 6
-10 -23 46 24 17 13 11 9 7
24
-20 -29 55 29 20 15 13 11 8
-40 -40 72 38 26 20 16.3 14 11

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HD100707-1 Rev0
The following Table 4 shows the amount of extra cable required to heat trace pipe hardware such
as valves and supports.
Allow an extra 4 feet of cable per cable circuit run for the power and end seal terminations.
Example: 3 feet for the power termination and 1 foot for the end termination.

Table 4
HEAT LOSS ADDERS (CABLE PER FOOT)
Pipe Hardware Types
Pipe Size Flange Vent Pipe Globe, Ball Gate
Inches Per Pair Drain Support & Butterfly Valve
½ 0.3 1 1 1 1
¾ 0.3 1 1.5 1 1.5
1 0.3 1 1.5 1 2
1¼ 0.3 1 2 1.5 2.5
1½ 0.3 1 2 1.5 2.5
2 0.3 1 2 2 2.5
2½ 0.3 1 2 2.5 3
3 0.3 1 2 2.5 3
4 0.5 1 2.5 3 4
6 0.8 1 2.5 3.5 5
8 0.8 1 2.5 4 7
10 0.8 1 3 4.5 8
12 0.8 1 3 5 9
14 1 1 3 5.5 10
16 1 1 3.5 6 11
18 1 1 3.5 7 12
20 1 1 3.5 7.5 13
24 1 1 4 8 15

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HD100707-1 Rev0
STEP 5 – CABLE COMPONENTS
A typical heat tracing system will include cable, cable components and controls as required

Low Profile Metallic Components

LP-PC-1 AL LP-PC-2 AL
Power Connection Power Connection –
– Single Cable Two Cables

LP-E AL LP-S AL
End Seal Splice Kit

LP-T AL LP-PCT-2 AL
Tee Kit Tee Power Connection
– Two Cables

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HD100707-1 Rev0
High Profile Components

HP-PC-1 AL HP-LE-1R/HP-LE-2R
Power Connection – Single Cable Lighted End Seal 120V/277V

HP-LEA-1R/HP-LEA-2R
Adapter Kits - Light Enclosure Only
(for use with LP-E AL Kit)

Heat Shrink® Components

HS-PC HS-TSPLICE
Power Connection Splice Kit
(Junction box not included)

HS-ESK HS-JB
End Seal Kit Junction Box

PowerPod® Components

PP-PC-HL (Hazardous) & PP-PC-OL (Ordinary)

PowerPod Power Connection and Splice Kit allows a power supply to
one heating cable (power to heater) or a splice between two heating
cables (heater to heater).

PP-RE-L
PowerPod Re-enterable End Seal is an above thermal insulation
end seal designed for repeated use and entry should cable
modification be required in the field.

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HD100707-1 Rev0
STEP 6 – MONITORING AND CONTROL
Select the thermostat or control device that best suits your application. The method of control can
range from simple mechanically switched thermostats, electronic control and monitoring systems
or ambient air sensing control.

Mechanical
STAT-LS-40F
The STAT-LS-40F thermostat is ideal for applications where freeze protection or lower-range
temperature control is critical. In cold climates the thermostat switches heating devices that
prevent pipes, valves, tanks and fittings from freezing. This thermostat can be used in ambient-
sensing applications by placing the sensor in the air or as a line-sensing thermostat by securing the
bulb to the pipe or tank. It can be used as a single circuit control or as a pilot control for several
circuits by switching a contactor. Set point at factory is 40 °F/5°C.
STAT-LS-ADJ
The STAT-LS-ADJ thermostat is ideal for applications where freeze protection or lower-range
temperature control is critical. In cold climates this thermostat switches heating devices that
prevent pipes, valves, tanks and fittings from freezing. This thermostat can be used in ambient-
sensing applications by placing the sensor in the air or as a line-sensing thermostat by securing the
bulb to the pipe or tank. It can be used as a single circuit control or as a pilot control for several
circuits by switching a contactor.
STAT-TXR-ADJ
The STAT-TXR-ADJ thermostat is ideal for applications where freeze protection or temperature
control in hazardous locations is critical. This thermostat can be used in ambient-sensing
applications by placing the sensor in the air or as a line-sensing thermostat by securing the bulb to
the pipe or tank.
The STAT-TXR-ADJ can be used as a single circuit control or as a pilot control for several circuits by
switching a contactor.

Electronic
TRACEMATE and TRACEMATE II CTR
The TraceMate™ family of electronic controls is designed for indoor or outdoor use in general
purpose non-hazardous and hazardous Class I Division 2 / Zone 2 areas.
TraceMate™ comes complete with a built in Ground Fault Protection Device (GFPD) eliminating
the need for a separate ground fault breaker.

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HD100707-1 Rev0
INSTALLING SELF REGULATING CABLE
 Install heating cable on the bottom half of the pipe between 4 & 8 o’clock. Install cable
straight along the pipe. In some instances it may be necessary to install more than one run
or spiral the cable around the pipe. Example: pipe heat loss requires 12 watts/ft, cable
output is 8 watts/ft. therefore apply 1.5 feet cable per foot of pipe.
 For typical installations the heating cable should be fastened with fiber glass tape.
Note: Do not use metal strapping or tie wire to fasten cable to pipe.

 Aluminum foil tape (TAPE-AL) is typically used when installing heating cable on plastic
pipes. By applying a layer of foil tape on the pipe under the cable provides more efficient
heat transfer. An additional layer of foil tape fastening the cable to the pipe also assists in
the heat transfer as well as can prevent the cable from being embedded in the insulation.
 Do not cut the cable until it is fastened to the pipe. This ensures you will have a sufficient
amount of cable for terminations and heat sinks such as valves, flanges, pipe supports and
any other piping equipment.
 Install the heating cable in such a way as to allow for easy removal of valves and other
equipment.

 Heating cable ends must be kept dry at all times. Until the cable is terminated all end
should be sealed from the environment with a moisture proof tape.
 When pipe is buried ensure the power and end of circuit terminations are above grade.
 After insulation has been applied to the pipe, over the cable, visually inspect to ensure
there are no gaps in the seams or damage to the insulation.
Note: An improperly insulated pipe will result in a cold pipe.

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HD100707-1 Rev0
TESTING SELF-REGULATING CABLE
A test should be performed when the heating cable is received, prior to installation and after
installation using a 500 VDC megger.
Note: Do not use a megger in excess of 2500 VCD.
Detecting cable damage prior to the application of insulation can prevent additional labor costs.
Minimum readings of 20 Megohms for each circuit is an acceptable level to test for.

A record should be kept of the reading after the cable has been installed. This reading can be used
as a reference point when taking future readings during regular maintenance.
A history of resistance readings can be useful in spotting moisture ingression into the cable from
either junction boxes or physical damage to the cable.

See the following page for a “Test Report” template.

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HD100707-1 Rev0
 HEATING CABLE TESTING REPORT

Customer ___________________________ Contractor

Phone No. __________________________ Phone No. _

Site Location ________________________ Project Ref.

Readings Prior to Installation:

Cable Reference No ___________________ Heater Length

Insulation Resistance (M Ohms) __________________

Tested By ___________________________ Date

Witnessed By ________________________ Date

Readings after Installation:

Insulation Resistance (M Ohms) ______________________________________

Tested By ___________________________ Date

Witnessed By ________________________ Date

Final Readings:

Insulation Resistance (M Ohms) ______________________________________

Panel No. ___________________________ Breaker No.

Ambient Temp ___________ Volts Amps ____________

Tested By _______________ Date ______________

Witnessed By Date ______________

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HD100707-1 Rev0
 TROUBLESHOOTING SELF-REGULATING HEATING CABLE
Symptom Probable Cause Remedy

Circuit Breaker Breaker undersized for the length of the Revisit the current loads and resize breakers or
Trips cable on that circuit shorten the cable run lengths
Note: Check Feeder wire size to confirm a larger
breaker may be used

Start-up temperature too low Start cables up at a higher temperature by adding a

thermostat

Physical damage to cable causing a short Locate and repair

Buss wires touching at the end seal Locate and repair

Heating cable connections or feeder wire Locate and repair

may be shorting out either by
contaminations, moisture, or contact
between wires in the connection

Zero power Low or no input voltage Repair electrical supply

output
Connections not properly made Repair connections

Pipe is at elevated temperature Check pipe temperature and recalculate the output
wattage

Heating cable has been exposed to Replace the heating cable with appropriate
excessive temperature temperature rated cable

Power output is correct Insulation is wet or open exposing the Remove and replace with dry insulation
but pipe temperature pipe to the ambient air.
is below design values
Insufficient cable was installed on pipe Splice in additional cable BUT do not exceed the
shoes, valves or other heat sinks maximum cct length for the breaker size

Thermostat setting is incorrect Adjust thermostat to correct setting.

Incorrectly designed. Revisit the design conditions and criteria

FOR HEATTRACER TECHNICAL ASSISTANCE CALL 1-800-663-6873 (NORTH AMERICA ONLY) OR +1.780.413.1774

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