EN TankHeating DG H56887 - tcm432 26444 PDF

Self-Regulating Cables Power-Limiting Cables
TANK HEAtING
This step-by-step design guide provides the tools necessary to design a tank heating system for temperature maintenance using electric heating cables or tank heating pads. For design assistance, contact your Pentair Thermal Management representative or phone Pentair Thermal Management at (800) 545-6258. Also, visit our web site at www.pentairthermal.com. Contents Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Self-Regulating Heating Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Power-Limiting Heating Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Mineral Insulated Heating Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tank Heating Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tank Tracing Design and Product Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tank Heat Loss Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Mineral Insulated Cables Longline Heating RTB Tubing Bundles Tank Heating Snow and Ice
INTRODUcTiON Pentair Thermal Management provides a wide selection of heat-tracing solutions for tanks and vessels. Typical applications for electrical heat tracing of tanks and vessels include: Freeze protection of low and medium viscosity uids (e.g., water, ammonia) Temperature maintenance for medium viscosity uids (e.g., oils, resins) Crystallization prevention (e.g., caustic soda) Condensation prevention (e.g., y ash in conical bases of silos)
Control and Monitoring Heat-Trace Panels
Contact Pentair Thermal Management for heat-up applications, hazardous locations, heat tracing of high viscosity uids (e.g. heavy oils), applications where agitation is used, and other nonstandard applications. Tank heating applications can be quite varied. For this reason, Pentair Thermal Management offers a wide range of technologies to optimize your tank and vessel heat-tracing system. Self-regulating heating cables Power-limiting heating cables Tank heating pads Mineral insulated heating cables A description of the features and benets of each technology is provided, followed by the design and product selection steps.
Engineered Products Steam-Tracing Systems Technical Data Sheets Appendixes
THERMAL MANAGEMENT SOLUTIONS
EN-TankHeating-DG-H56887
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TANK HEAtING
Self-Regulating Heating Cables Raychem brand self-regulating heating cables (BTV, QTVR, XTV) are ideal for tank heating when design and installation exibility are required. The benets include: Forgiving technology For over 30 years, Raychem self-regulating heating cables have proven their reliability and remain the premier self-regulating heating cables in the market. Easy installation Because of parallel circuitry and at cable design, Raychem self-regulating heating cables are easy to handle and install. They can be cut to any length on site and overlapped without the risk of overheating. Raychem cables readily accommodate design adjustments between specications and actual on-site installation needs. Uniform temperatures Heat is evenly distributed over the heat-traced surface. The self-regulating feature of the heating cable responds to actual conditions of the traced surface. Temperature control is simplied, especially for tanks with ll-height variation. T-ratings Raychem self-regulating heating cables have a T-rating per national electrical codes. Approvals Pentair Thermal Management self-regulating systems are approved and certied for use in nonhazardous and hazardous locations by many agencies, including FM Approvals, CSA International, UL, PTB, Baseefa, DNV, and ABS. Raychem self-regulating heating cables can be used for maintain temperatures up to 250F (121C). Technical information is provided in the data sheets on the Pentair Thermal Management web site, www.pentairthermal.com.
BTV and QTVR
XTV
Fig. 1 Self-regulating heating cables
Power-Limiting Heating Cables Raychem brand power-limiting heating cables (VPL) feature high power output at high maintain temperatures. These exible heating cables are rated for maintain temperatures up to 300F (150C) and exposure temperatures to 500F (260C). Power-limiting heating cables feature: Superior temperature capability in a exible heater These cables are especially suited to applications requiring high power output at elevated temperatures and requiring eld installation exibility to accommodate small tank structure or design modications. Easy installation Cables can be cut to length and terminated in the eld. Uniform distribution of heat Heat is evenly and widely distributed over the heat-traced surface. Approvals Pentair Thermal Management power-limiting systems are approved and certied for use in nonhazardous and hazardous locations by many agencies, including FM Approvals, CSA International, and Baseefa.
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Self-Regulating Cables
Introduction
Additional technical information can be found in the data sheet. Data sheets can be found on the Pentair Thermal Management web site, www.pentairthermal.com, or the Technical data sheet section of the Advanced Industrial Solutions Heat-Tracing Products & Services Catalog (H56550).
Power-Limiting Cables Mineral Insulated Cables Longline Heating
VPL
Fig. 2 Power-limiting heating cables
Mineral Insulated Heating Cables

RTB Tubing Bundles
Pyrotenax brand mineral insulated heating cables (MI) offer a very reliable solution and are recommended for maintain temperatures above 300F (150C) or where exposure temperatures exceed 500F (260C). Pyrotenax MI heating cables feature: Superior toughness Pyrotenax MI heating cables and nonheating cold leads are manufactured with a seamless sheath of Alloy 825 and have proven their reliability in over 40 years of service. MI provides superior toughness in dynamic cut-through and tough mechanical environments. Easy installation Pyrotenax MI heating cables are preterminated, eliminating the need for special termination expertise. Special annealing procedures maximize exibility for ease of on-site handling. Uniform temperatures Heat is evenly distributed over the heat-traced surface. Pyrotenax MI heating cable on tank installations is the choice where both higher power and even distribution are required. Approvals Pentair Thermal Management mineral insulated heating systems meet the requirements of the U.S. National Electrical Code and the Canadian Electrical Code. Pentair Thermal Management MI systems are approved for use in hazardous locations. Based on the application, temperature ID number (T-rating) can be established by calculating the maximum sheath temperature. Contact Pentair Thermal Management for assistance. Additional technical information can be found in the Mineral Insulated Heating Cables design guide (H56884) and on the data sheet on the Pentair Thermal Management web site.
Tank Heating Snow and Ice Control and Monitoring Heat-Trace Panels Engineered Products Steam-Tracing Systems
Alloy 825
Fig. 3 MI heating cables
Technical Data Sheets Appendixes
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TANK HEAtING
Tank Heating Pads Raychem brand tank heating pads (RHS) are recommended when high wattage density is required. The RHS system provides heat to selected areas on the tank. The heat is then distributed through convection in the uid (natural or agitated). RHS is built from durable components for use on tanks in industrial applications. The heating pads have a constant power output and are available with two power densities, making them suitable for both metal (lined and unlined) and plastic tanks. RHS tank heating pads have been designed to include the following benets: Easy installation Raychem RHS tank heating pads can easily be installed by a single person. Over-temperature thermostat A sealed, self-resetting, over-temperature thermostat is integrated into the product. Approvals FM Approvals (FM) and CSA International (CSA) have approved RHS tank heating pads for both nonhazardous and hazardous locations. Additional technical information can be found in the RHS data sheet (H56842).
Silicone rubber base with a fiber-reinforced layer containing the Nichrome heating wire (2 layers)
Fiber-reinforced silicon rubber top layer Nichrome heating wire
Stainless steel flexible ground plane
Liquid-tight electrical conduit exiting a lowprofile junction box RHS
Fig. 4 Tank heating pads
The stainless steel grounding plane is exible enough to contour to most tank surfaces, and it is oversized to protect the heating elements and maximize contact with the tank. RHS can be used for maintain temperatures up to 200F (93C) and maximum exposure temperatures of 366F (186C). For technical details, refer to the RHS data sheet. Data sheets can be found on the Pentair Thermal Management web site, www.pentairthermal.com, or the Technical data sheet section of the Advanced Industrial Solutions Heat-Tracing Products & Services Catalog (H56550).
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Tank Tracing Design and Product Selection

TaNK TRaciNg DesigN aND PRODUcT SelecTiON Overview Follow the ve steps below to select the heating products and create a bill of materials for your tank application. If your tank application requires heat-up or condensation prevention, contact Pentair Thermal Management for assistance.
Power-Limiting Cables Mineral Insulated Cables
1 Gather the necessary application data.

Tank type Tank diameter Tank height Tank support Tank insulation type and thickness Maintain temperature Tank contents
Longline Heating
2 Calculate the tank heat loss. 3 Choose the heating technology. 4 Product selection. 5 Select the thermostatic control.
RTB Tubing Bundles Tank Heating
Tank Tracing 1. Gather information 2. Calculate tank heat loss 3. Choose heating technology 4. Product selection 5. Select thermostatic control
Step Gather the necessary data

Gather and record the following information. Alternatively, use the design worksheet in Appendix B to record your application data. You will use this information for the steps that follow. Tank type Tank diameter Tank height Tank support Tank insulation type and thickness Maintain temperature Tank contents
Snow and Ice Control and Monitoring
Example: Information on three sample applications

Heat-Trace Panels
Tank type (all) Tank diameter (all) Tank height (all) Tank support (all) Tank 1 Maintain temperature Contents Tank 2 Maintain temperature Contents Tank 3 Maintain temperature Contents
Vertical cylinder 3 ft 6 ft 4 legs
Tank insulation type and thickness (all) Fiberglass insulation, 2-in 100F at 0F polyol 40F at 0F water 400F at 0F bitumen
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TANK HEAtING
Step Calculate the tank heat loss

The tanks thermal heat loss determines the power needed to maintain the tank at the desired temperature. To determine the heat loss, see Tank Heat Loss Calculation beginning on page 19, for formulas and tables. Using these resources, the heat loss of the example tanks was found to be: Example: Results of tank heat loss calculations Tank 1: Tank 2: Tank 3: Qtotal = 458 W (from Tank Heat Loss calculation) Qtotal = 178 W (from Tank Heat Loss calculation) Qtotal = 2070 W (from Tank Heat Loss calculation)
Step Choose the heating technology

Pentair Thermal Management offers a range of tank heating solutions. Table 1 provides a rough guide for the selection of technologies for different applications. The continuing discussion that follows will help you understand and select the appropriate technology when more than one product choice is available or when an application does not easily t those dened in the table. Your choice of heating method depends on factors such as: Required maintain and exposure temperatures Material of the tank wall (metal or plastic) Temperature sensitivity and viscosity of the tank contents Whether or not the tank is agitated Additional requirements such as heat-up or prevention of condensation TaBle 1 PRODUcT SelecTiON GRiD
Tank pads Selfregulating Power- Mineral BTV, QTVR, limiting insulated XTV VPL MI RHS-L RHS-H
Application or requirement Flexible eld design required Plastic tank wall Plastic-lined tank wall Even heat to all walls needed Maintain temperature more than 120F (49C) Maintain temperature more than 200F (93C) Maintain temperature more than 250F (121C) Low installed cost desired High watt density needed Distributed high watt density needed Temperature-sensitive uids Condensation prevention Small-diameter stagnant tanks Limited tank surface area available High heat-loss tanks
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self-RegUlaTiNg heaTiNg caBles
Power-Limiting Cables
Uses Tanks containing temperature-sensitive uids Tank materials such as PVC or PE Applications requiring uniform heating (condensation prevention) Tanks with unusual shapes to trace Advantages Very exible design and installation Cables can be installed on any type of tank surface Cables adapt to any shape or surface Cables allow tracing with more power on high heat loss areas just reduce the spacing between the heating cables in those areas Cables can be cut to length in the eld Even heat distribution due to larger heated surface Very smooth heating for tank walls with a low withstand temperature
POWeR-LimiTiNg HeaTiNg CaBles
Mineral Insulated Cables Longline Heating RTB Tubing Bundles
Uses Tanks containing uids that are less temperature sensitive Tanks with high heat loss, and where exibility in installation is a premium Tanks with a maintain temperature between 250F (121C) and 300F (150C) Advantages Very exible design and installation Cables can be installed on any type of tank surface Cables adapt to any shape or surface Cables allow tracing with more power on high heat loss areas just reduce the spacing between the heating cables in those areas Cables can be cut to length in the eld Even heat distribution due to larger heated surface Very smooth heating for tank walls with a low withstand temperature
miNeRal iNsUlaTeD heaTiNg caBles
Tank Heating Snow and Ice Control and Monitoring Heat-Trace Panels
Uses Maintain temperatures above 300F (150C) Exposure temperatures above 500F (260C) Tanks with high heat loss or high power requirements at elevated temperatures Advantages Flexible design and installation Cables can be installed on any type of tank surface Cables can adapt to any shape or surface Cables allow tracing with more power on high heat-loss areas just reduce the spacing between the heating cables in those areas Even heat distribution due to larger heated surface Capability for high power output and density
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TANK HEAtING
TaNK heaTiNg paDs
Uses Tanks containing uids that are not temperature sensitive Tanks where the surface is space-constrained Tanks with high heat loss Fluids with low viscosity (such as water or light oil) Advantages Lower installation cost Capability for high power output and watt density
Step Product selection

When you have determined the most appropriate heating technology for your application, proceed to: Step 4a Product selection for self-regulating and power-limiting heating cables Step 4b Product selection for mineral insulated heating cables Step 4c Product selection for tank heating pads Example: Tank 1: We recommend the use of self-regulating heating cables. Tank 2: We recommend the use of RHS tank heating pads. Tank 3: We recommend the use of MI mineral insulated heating cables.
Step 4a Product selection for self-regulating and power-limiting heating cables

OveRvieW
Orientation of tank Spacing and arrangement of the heating cables Traced surface Vertical cylindrical tanks Horizontal cylindrical tanks Conical outlets Thermal design for heating cables Determine heating cable compatible with your tank application Select heating cable with the lowest maximum exposure temperature Adjust for aluminum tape attachment Determine minimum required length of heating cable Determine cable distribution Electrical design of heating cable Determine maximum allowable circuit length of heating cable Adjust for aluminum tape attachment Ground-fault protection Heating cable component selection
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The heating cable you select and the length of cable you will need depend on the orientation of the tank and the spacing and arrangement of the heating cables.
Fig. 5 Heating cable arrangement on a vertical tank
RTB Tubing Bundles
Fig. 6 Heating cable arrangement on a horizontal tank
Tank Heating Snow and Ice
Fig. 7 Heating cable arrangement on a truncated cone DeTeRmiNaTiON Of The TRaceD sURface
Control and Monitoring
Vertical cylindrical tanks Vertical cylindrical tanks are traced on the lower one-third of the side wall (maximum half) and the bottom (if accessible). Horizontal cylindrical tanks
Heat-Trace Panels
Horizontal cylindrical tanks are traced on a third of the bottom (maximum half). Conical outlets Conical outlets of vessels are often traced to prevent condensation inside. We recommend that the entire surface of the conical outlet be traced and additional tracing used on heat sinks, such as xings/supports. Heat sinks should be thermally isolated. Because the surface area of the conical outlet is often much smaller than the rest of the vessel, it may be necessary to extend the tracing beyond the conical area in order to fully compensate for the heat loss.
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TANK HEAtING
TheRmal DesigN UsiNg heaTiNg caBles
Determine the heating cable families compatible with your tank application To select a heating cable that is compatible with your application, familiarize yourself with the selection process for pipes as outlined in Self-Regulating Cables design guide (H56882) and Power-Limiting Cables design guide (H56883). Considering factors such as exposure temperature, maintain temperature, wall material, hazardous location requirements, etc., list all heating cable families that would be compatible with your tank application e.g., BTV, QTVR, XTV, VPL. The power outputs for the different heating cables are found in the Self-Regulating Cables and Power-Limiting Cables design guides. Select the heating cable with the lowest maximum exposure temperature Use the heating cable with the lowest possible maximum exposure temperature. Within each heating cable family, start with the cable that has the highest power output. Example: Heating cable selection Tank 1 Maintenance temperature Heat loss Recommended cable 100F maintain (from Step 1) 458 W (from Step 2) Raychem 10BTV2-CR
Adjust for aluminum tape attachment For optimal heat transfer, the heating cable must be xed to the tank wall (both metal and plastic) with aluminum tape. For self-regulating cables on metal tanks, this leads to an increase in the power output; on plastic tanks, the much lower thermal conductivity of plastic necessitates a de-rating of the power output of the cables. Table 2 below provides approximate adjustment factors for the power. TaBle 2 AppROximaTe POWeR OUTpUT ChaNge fOR HeaTiNg CaBles ATTacheD WiTh AlUmiNUm Tape AT-180 Heating cable
BTV QTVR XTV VPL
Adjustment factor on metal tanks

1.20 1.20 1.15 1
Adjustment factor on polypropylene tanks

0.70 N/R N/R N/R
Adjustment factor on ber-reinforced plastic tanks

0.80 N/R N/R N/R
N/R Not recommended due to temperature limitations of tank wall.
Multiply the power output at the maintain temperature (Pheater) by the appropriate adjustment factor adj from Table 2 above. Formula: Padj = Pheater x adj Example: Calculating the adjusted power of the heating cable (Padj) Input Pheater = 3.7 W/ft (10BTV2-CR power output at 100F) Input adj = 1.20 (from Table 2) Calculation Padj = 3.7 W/ft x 1.20 Padj = 4.4 W/ft for Raychem 10BTV2-CR at 100F
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Divide the total heat loss (Qtotal) by the adjusted power of the heating cable (Padj) at the desired maintain temperature to obtain the minimum required length (Lheater).
Formula Lheater = Padj (W/ft) Qtotal (W) (round up)
Example: Calculating the minimum required cable length (Lheater) Input Qtotal = 458 W (from Step 2) Input Padj = 4.4 W/ft (from previous calculation)
Calculation Lheater = 458 W 4.4 W/ft (round up)
Mineral Insulated Cables Longline Heating
Lheater = 104 ft (rounded up) Next, determine how to distribute cable over the surface you wish to trace. An average spacing of the heating cable (Taverage) can be calculated by dividing the traced surface (Straced) by the total length of the heating cable (Lheater).
Formula Taverage = Straced (ft2) Lheater (ft) (round up)
RTB Tubing Bundles
Example: Determining cable distribution For our vertical cylinder tank (3 ft diameter, 6 ft high), tracing the lower one-third of the wall of the tank: Input Straced = 3 ft x 3.14 x 2 ft (as determined in Step 4a) Input Lheater = 104 ft (from previous calculation)
Taverage (ft)= (3 ft x 3.14 x 2 ft) 104 ft = (18.8 sq ft) 104 ft = 0.18 ft (2.2 in)
In this case, the result is close to the minimum spacing interval, so some of the tracing may be placed on the bottom of the tank. The spacing should be reduced locally to bring more power to areas that require more heat, such as supports and xings. The maximum spacing should typically not be more than 12 inches (~300 mm). Do not space adjacent heating cable closer than two inches (50 mm), because interaction will occur and power output will decrease. By changing the heating cable and the spacing in the calculation, you can obtain the solution that best ts the specic requirements of your tank application.
ELECTRICAL DESIGN OF HEATING CABLE
Control and Monitoring Heat-Trace Panels
Determine maximum allowable circuit length WARNING: Fire hazard There is a danger of re from sustained electrical arcing if the heating cable is damaged or improperly installed. To comply with Pentair Thermal Management requirements, certications, and national electrical codes, and to protect against the risk of fire, ground-fault equipment protection must be used on each heating cable circuit. Arcing may not be stopped by conventional circuit breakers. To determine the maximum allowable circuit length of your heating cable, refer to the data sheet on the Pentair Thermal Management web site for that heating cable. For metal tanks, however, the maximum circuit length needs to be reduced by the appropriate factor shown in Table 3 because of the use of the aluminum tape and the increased power. For plastic tanks, the maximum circuit length need not be adjusted. Adjust for aluminum tape TaBle 3 AppROximaTe ADJUsTmeNT FacTORs fOR MaximUm CiRcUiT LeNgTh Of Self-RegUlaTiNg HeaTiNg CaBles ON MeTal SURfaces ATTacheD WiTh AT-180 AlUmiNUm Tape Heating cable
BTV QTVR XTV Circuit length adjustment factor on metal tanks 0.8 0.8 0.9
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TANK HEAtING
Simply multiply the allowed footage shown on the heating cable data sheet on the Pentair Thermal Management web site by this factor to determine the footage that can be installed on a given breaker size. Ground-fault protection To minimize the danger of re from sustained electrical arcing if the heating cable is damaged or improperly installed, and to comply with the requirements of Pentair Thermal Management, agency certications, and national electrical codes, groundfault equipment protection must be used on each heating cable branch circuit. Arcing may not be stopped by conventional circuit protection. Many DigiTrace control and monitoring systems meet the ground-fault protection requirement.
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cONNecTiON KiT selecTiON fOR self-RegUlaTiNg aND pOWeR-limiTiNg caBles
Now that you have determined your heating cable type and length, use the following chart to select the proper connection kits. Note: Pentair Thermal Management offers a full range of connection kits for power connections, splices, and end seals. These connection kits must be used to ensure proper functioning of the product and compliance with warranty, code, and approvals requirements.
Mineral Insulated Cables Longline Heating RTB Tubing Bundles Tank Heating Snow and Ice
E-100 E-100-A
E-100-L E-100-L
Fig. 8 Tank-tracing system connection kits and accessories
WARNING: Fire hazard To prevent re or shock, Raychem brand specied connection kits must be used. Do not substitute parts or use vinyl electrical tape.
TaBle 4 CONNecTiON KiT aND AccessORY SelecTiON fOR Self-RegUlaTiNg aND POWeR-LimiTiNg CaBles Description Connection kits
Catalog number JBS-100-A JBS-100-L-A S-150 (not for use with VPL) E-150 (not for use with VPL) E-100-A E-100-L1-A, 100120 V E-100-L2-A, 200277 V AT-180 ETL SB-100-T
Heat-Trace Panels
Power connection kit (not shown)

Power connection kit with light Splice connection (not shown) Below insulation Above insulation Above insulation, with light
Engineered Products
End seal
Steam-Tracing Systems
Accessories Aluminum tape
Labels Support bracket

Controls
Technical Data Sheets
Thermostat (see Control and Monitoring design guide (H56889))
Appendixes
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TANK HEAtING
Step 4b Product selection for mineral insulated heating cables

For MI product selection and design, refer to Mineral Insulated Heating Cables design guide (H56884) or contact your Pentair Thermal Management representative.
Step 4c Product selection for tank heating pads

Tank material and power density determine which RHS tank heater series to select. The number of heaters required depends on the amount of heat distribution the application requires. A large number of low-power pads will disperse the heat better than a few high-power heaters. Pentair Thermal Management recommends distributing the heat over as much wall surface as is economically feasible. Note: Pentair Thermal Management does not recommend the use of tank heating pads for applications with: Highly temperature-sensitive uids High-viscosity uids Double-wall tanks Tank diameters of less than four feet A requirement for uniform heating A location where an installation temperature above 0F (18C) cannot be assured.
TaNK MaTeRial
Table 1 on page 6, indicates the heater to select based on tank type, heat loss, and surface area available. Metal tanks RHS-H series heaters are used for metal tanks. RHS-H heaters have a power density of 1.9 W/in at specied voltage with integrated thermostatic over-temperature protection. Table 5 lists the RHS-H congurations available. To determine the number of heaters required, divide the nal design heat loss for the tank by the heaters power output. TaBle 5 RHS-H SpecificaTiONs (NOmiNal) Voltage (Vac)
120 120 120 240 240 240
Catalog number Overall dimensions

RHS-H-500-1 RHS-H-1000-1 RHS-H-1400-1 RHS-H-500-2 RHS-H-1000-2 RHS-H-1400-2 14" x 24" (356 mm x 610 mm) 24" x 26" (610 mm x 660 mm) 24" x 36" (610 mm x 914 mm) 14" x 24" (356 mm x 610 mm) 24" x 26" (610 mm x 660 mm) 24" x 36" (610 mm x 914 mm)
Power output (W)

500 1000 1400 500 1000 1400
Current draw (A)

4.2 8.3 11.7 2.1 4.2 5.8
Polypropylene, FRP, and metal tanks RHS-L series heaters are for plastic or metal tanks. RHS-L heaters have a power density of 0.6 W/in at the specied voltage with integrated thermostatic overtemperature protection. The available RHS-L congurations are shown in Table 6.
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Self-Regulating Cables Power-Limiting Cables

TaBle 6 RHS-L SpecificaTiONs (NOmiNal) Catalog number
RHS-L-150-1 RHS-L-300-1 RHS-L-420-1 RHS-L-150-2 RHS-L-300-2 RHS-L-420-2
Overall dimensions
14" x 24" (356 mm x 610 mm) 24" x 26" (610 mm x 660 mm) 24" x 36" (610 mm x 914 mm) 14" x 24" (356 mm x 610 mm) 24" x 26" (610 mm x 660 mm) 24" x 36" (610 mm x 914 mm)
Voltage (Vac)
120 120 120 240 240 240
Power output (W)

150 300 420 150 300 420
Current draw (A)

1.3 2.5 3.5 0.6
Mineral Insulated Cables Longline Heating
1.3 1.8
RTB Tubing Bundles
Considerations for plastic tanks When designing heating systems for plastic tanks, be sure to keep the wall temperature below the recommended maximum material temperature. Common plastic tank walls are polyethylene and FRP. This section provides the algorithms you may use to determine the temperature generated by RHS tank heating pads. Determine the power density of the RHS-L heater, QA . 1. QA = 295 Btu/ft -hr equal to 0.6 W/in for nominal voltages of 120 Vac and 240 Vac 2. For voltages other than 120 Vac and 240 Vac, (QA ) adjusted = (QA ) x (V/ Vnominal) Determine the maximum uid maintain temperature, Tf. Enter this data on the design worksheet found in Appendix B. Determine the uid gradient, Tf. The uid gradient will depend on uid type and temperature. For applications not involving temperature-sensitive uids, the following values may be used for simplicity. Tf = 10F (6K) for uids similar to water Tf = 30F (16K) for uids similar to warm light oils Tf = 100F (56K) for uids similar to warm heavy oils Calculate the tank wall gradient, Tw. The gradient depends on wall thickness, t(inches), and material conductivity, k. Tw = Qa x t/k Wall thickness is expressed in inches. Typical conductivity values for hightemperature plastics are: k = 1.7 Btu-in/hr-ft2 -F for polypropylene (PE) k = 2.1 Btu-in/hr-ft2-F for ber-reinforced plastic (FRP) Calculate the maximum outer wall temperature, Tout-max Tout-max = Tf + Tf + Tw Contact the tank manufacturer to determine the type and temperature capability of the tank material. The maximum temperature for polypropylene and FRP is typically 220F (104C). Other plastics, like PVC and polyethylene, have much lower temperature capabilities and are more suitable for use with Raychem self-regulating heating cables.
Tank Heating Snow and Ice Control and Monitoring Heat-Trace Panels Engineered Products Steam-Tracing Systems Technical Data Sheets Appendixes
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TANK HEAtING
Example: Tank Checklist Fluid: RHS heater: Water RHS-L-XXX Maintain temperature: 50F Tank wall thickness: Voltage: 1/2-in 277 Vac Tank material: FRP
Calculate adjusted heater power density: (Qa) adjusted = (295) x (277/240) = 393 Btu/ft2-hr Determine uid maintain temperature: Tf = 50F Determine uid gradient for water: Tf = 10F Calculate wall gradient for a FRP tank with 1/2" wall thickness: Tw = (393 x 0.5) / 2.1 = 94F Calculate maximum outer wall temperature: Tout-max = 50F + 10F + 94F = 154F The maximum material temperature for FRP is approximately 220F. Therefore, the application is compatible with the tank material. Power adjustment factors For all heating pads with catalog number X-XXX2, power output is calculated at 240 Vac. If the source voltage is either 208 Vac or 277 Vac, the following power output adjustment factors should be used. 208 Vac: Power output adjustment factor = 0.75 277 Vac: Power output adjustment factor = 1.33 Location and arrangement of heating pads For vertical tanks, locate the heater on the lower one-third of the tank wall. Arrange the heaters on vertical, horizontal, and truncated cone tanks as shown in Fig. 1 through Fig. 1.
Primary thermostat bulb
Fig. 9 Vertical tanks with RHS heaters
Fig. 10 Horizontal tanks with RHS heaters
Fig. 11 Truncated cones with RHS heaters
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Tank heating pad electrical design WARNING: Fire hazard There is a danger of re from sustained electrical arcing if the heating cable is damaged or improperly installed. To comply with Pentair Thermal Management requirements, certications, and national electrical codes, and to protect against the risk of re, groundfault equipment protection must be used on each heating cable circuit. Arcing may not be stopped by conventional circuit breakers. Size your circuit breaker according to the load of the heating pad(s). If your tank requires several heating pads, these can be grouped to one electrical circuit as long as the circuit breaker rating allows. Ground-fault protection To minimize the danger of re from sustained electrical arcing if the heating pad is damaged or improperly installed, and to comply with the requirements of Pentair Thermal Management, agency certications, and national electrical codes, groundfault equipment protection must be used on each heating pad branch circuit. Arcing may not be stopped by conventional circuit protection. Many DigiTrace control and monitoring systems meet the ground-fault protection requirement. Heating pad accessory selection
Power-Limiting Cables Mineral Insulated Cables Longline Heating RTB Tubing Bundles Tank Heating Snow and Ice Control and Monitoring Heat-Trace Panels
Fig. 12 Tank pad system components
WARNING: Fire hazard To prevent re or shock, Raychem brand specied components must be used. Do not substitute parts or use vinyl electrical tape.
TaBle 7 AccessORY SelecTiON fOR TaNK PaD HeaTeRs Description

Components RHS-INSTALLATION-KIT Installation kit ETL Labels Thermostat (see Control and Monitoring design guide (H56889)) Catalog number
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TANK HEAtING
Step Select the thermostatic control There are two kinds of sensors for indicating temperature: in-uid and on-surface. The in-uid approach typically uses a thermowell protruding through the tank wall and into the uid. Control of the heater is achieved by using a solid-state control device that receives its input from an RTD inside the thermowell. The on-surface approach uses RTDs or bulb and capillary thermostats to control tank heaters by sensing temperatures on the outside surface of the tank wall. Sensors should be located midway between heating cables or heating pads. If your application has high heat-loss supports or accessories, place the primary sensor midway between the heating pad or cable and the support or accessory. The primary temperature sensor should be placed horizontally on the tank, refer to Fig. 9, Fig. 10, Fig. 11, and Fig. 12. Raychem RHS tank heaters have integrated, resettable thermostats that provide over-temperature protection in the event of a primary thermostat failure. The RHS integrated thermostat must not be used as the primary means of temperature control. For more details regarding the many options in control devices see Control and Monitoring design guide (H56889).
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09/13
Tank Heat Loss Calculation

TaNK HeaT LOss CalcUlaTiON The Tank Tracing Design and Product Selection section presented a general approach to selecting a heat-tracing system for a tank or vessel. The tank heat loss can be calculated by using the graphs and equations on the following pages. The approach for the calculation is based on those in the TraceCalc Pro design software. The overall heat loss (QT) of an insulated tank can be expressed as: QT = QV + QS + QA where: QV = Heat loss through the insulated body of the tank QS = Heat loss through the slab, legs, saddle, or other base support QA = Heat loss through accessories such as manholes, handholds, ladders, or handrails To calculate the tanks overall heat loss (Qt), follow these six steps:
Power-Limiting Cables Mineral Insulated Cables Longline Heating RTB Tubing Bundles
1 Calculate the surface area of the tank. 2 Calculate the QV (heat loss through the insulated body of the tank). 3 Calculate the QS (heat loss through the base support). 4 Calculate the QA (heat loss through the accessories). 5 Calculate the QT (overall heat loss). 6 Calculate the nal-design heat loss.
The heat-loss rates for insulated tank bodies (see Table 9 and Graph 1) are based on the following IEEE 515 provisions: Fiberglass insulation Tank located outdoors No insulating airspace between tank surface and insulation The tank body heat loss rates in Table 9 and Graph 1 assume a tank that is completely full and insulated with a minimum of one inch of berglass. However, Table 10 provides factors for adjusting the tank body heat loss for insulations other than berglass.
Tank Heating Snow and Ice Control and Monitoring Heat-Trace Panels Engineered Products Steam-Tracing Systems Technical Data Sheets Appendixes
09/13
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TANK HEAtING
Tank Heat Loss Calculation 1. Calculate surface area of tank 2. Calculate QV 3. Calculate QS 4. Calculate QA 5. Calculate QT 6. Calculate finaldesign heat loss
Step Calculate the surface area of the tank

CYliNDeR SURface ARea
The surface area of the cylindrical tank is equal to the area of the body (Abody) plus the area of both ends of the tank (Aend), or, in the case of a vertical cylinder resting on a slab, the area of the tank body (Abody) plus the area of the top (Aend). If the tank is a vertical cylinder resting on a slab, do not add in the bottom area at this point.
Fig. 13 Cylinder surface areas
To calculate the total surface area (AV) of the tank cylinder: Calculate the surface area of the body: (Abody) = DH Calculate the surface area of one or both ends: (Aend) = D/4 Add the results. Table 8 below provides both the end and body areas of cylindrical tanks 6 to 20 feet in diameter and 8 to 25 feet high. TaBle 8 CYliNDRical TaNK SURface AReas Abody (ft) H (ft) D (ft)
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
or (Aend) = (D/4) x 2
Aend (ft)
29 39 51 64 79 95 114 133 154 177 202 227 255 284 315
8
151 176 202 227 252 277 302 327 352 377 403 427 452 478 503
9
170 198 227 255 283 311 340 368 396 425 453 481 509 538 566
10
189 220 252 283 315 346 377 409 440 472 503 535 565 597 629
11
208 242 277 311 346 381 415 450 484 519 553 588 622 657 692
12
227 264 302 340 377 415 453 491 528 566 604 641 679 717 754
13
245 286 327 368 409 450 491 531 572 613 654 695 736 776 817
14
264 308 352 396 440 484 528 572 616 660 704 748 792 836 880
15
283 330 377 425 472 519 566 613 660 707 754 802 849 896 943
16
17
18
340 396 452 509 565 622 679 736 792 849 905
19
359 418 478 538 597 657 717 776 836 896
20
311 440 503 566 629 692 754 817 880 943
21
396 462 528 594 660 726 792 858 924
22
415 484 553 622 692 761 830 899
23
434 506 579 650 723 795 868 940
24
453 528 604 679 754 830 905
25
471 550 629 707 786 864 943
302 321 352 374 403 427 453 481 503 535 553 588 604 641 654 695 704 748 754 802 805 855 855 908 905 962
981 1021
968 1012 1055 1100
990 1037 1084 1131 1179
955 1006 1056 1106 1157 1207 1257
962 1015 1069 1121 1175 1229 1282 1336 1018 1075 1131 1188 1244 1301 1357 1414
955 1015 1075 1135 1194 1254 1314 1373 1433 1493 1006 1069 1131 1194 1257 1320 1383 1446 1508 1571
Note: For the area of a horizontal tank, add the area of both ends.
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09/13

TRUNcaTeD CONe SURface ARea
The total surface area (Av ) of a truncated cone tank (Fig. 14) is calculated as follows: (AV) = (Abody) + (Atop) + (Abottom)* * Do not include (Abottom) if the bottom of the tank is resting on a slab. Abody = (D+d) S 2 =
H
S
Mineral Insulated Cables
(D+d) 2 D2 4 d2 4
(D+d)2 + H2 4
Atop =
d
Longline Heating
Abottom =
Fig. 14 Truncated cone surface areas RTB Tubing Bundles

Step Calculate the QV (heat loss through the insulated tank body)
pRepaRaTiON
Calculating the QV requires the following tank information: Maintain temperature (TM) Minimum ambient temperature (TA ) Insulation thickness
calcUlaTiON
Use the maintain and minimum ambient temperatures to arrive at the temperature differential. With the T and the insulation thickness, calculate the QV: Obtain T by subtracting the minimum ambient temperature (TA ) from the maintain temperature (TM): T = (TM) (TA ) Determine the heat loss rate (qV) for the application. Table 9 shows the heat-loss rates (qV) for typical temperature differentials and insulation thicknesses. Determine the insulation adjustment factor. Table 10 provides insulation factors for the most commonly used tank insulations. Calculate the total heat loss through the tank body: QV = AV x qV x Insulation adjustment factor TaBle 9 HeaT LOss RaTe (qV) peR SqUaRe FOOT (WaTTs/fT) Insulation thickness T F (C)
50 (10) 100 (38) 150 (66) 200 (93) 250 (121) 300 (149)
Control and Monitoring Heat-Trace Panels Engineered Products
1" (25 mm)

3.4 7.1 11.0 15.3 20.0 24.9
1.5" (38 mm)

2.3 4.8 7.5 10.3 13.5 16.8
2" (51 mm)

1.7 3.6 5.6 7.7 10.2 12.7
3" (76 mm)

1.2 2.4 3.7 5.2 6.8 8.5
4" (102 mm) 0.9 1.8 2.8 3.9 5.1 6.5
Steam-Tracing Systems Technical Data Sheets Appendixes
09/13
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TANK HEAtING
30 25 Heat Loss (watts/ft2) 20 1.5" (38 mm) 15 2" (51 mm) 10 5 0 50 (10) 100 (38) 150 (66) T F (C) 200 (93) 250 (121) 300 (149) 3" (76 mm) 4" (102 mm) 1" (25 mm) of insulation
Graph 1 Heat loss rate per square foot (watts/ft)
TaBle 10 INsUlaTiON ADJUsTmeNT FacTORs fOR TYpical INsUlaTiONs Insulation types

Fiberglass Cellular glass Calcium silicate (Type 1) Expanded perlite Flexible elastomer Mineral ber blanket Polyisocyanurate Rigid polyurethane, preform Rigid polyurethane, spray Rock wool/mineral wool
Insulation adjustment factor

1.00 1.46 1.48 1.85 1.15 1.26 0.67 0.60 0.60 1.06
k factor* 0.270 0.395 0.400 0.499 0.311 0.340 0.180 0.161 0.161 0.287
* Based on a 50F (10C) mean temperature with units Btu/hrFft /in
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09/13

Step Calculate the QS (heat loss through the base support)

The following heat loss tables and accompanying graphs (Graph 2Graph 5) provide typical base-support heat losses (QS) through the following types of base supports: Concrete slab or earth foundation Legs Concrete saddles Uninsulated skirt
CONcReTe SlaB OR EaRTh FOUNDaTiON
Based on the T and tank diameter, select the QS from Table 11 or Graph 2 below. TaBle 11 HeaT LOss (W) fOR a CONcReTe SlaB OR EaRTh FOUNDaTiON T F (C) Tank diameter ft (m)
5 (1.5) 10 (3) 20 (6) 30 (9) 40 (12) 50 (15)
10000 9000 8000 7000 6000 5000 4000 D = 20 ft (6 m) 3000 2000 1000 0 50 (10) 100 (38) 150 (66) T F (C) 200 (93) 250 (121) 300 (149) D = 30 ft (9 m) D = 40 ft (12 m)
50 (10)
137 283 566 848 1131 1374
RTB Tubing Bundles
100 (38)
278 573 1163 1767 2388 2945
150 (66)
451 864 1760 2616 3518 4320
200 (93)
566 1154 2325 3535 4649 5891
250 (121) 300 (149)

711 1452 2922 4383 5906 7265 857 1703 3488 5231 7037 8836
D = 50 ft (15 m)
Heat Loss (W)
Heat-Trace Panels
D = 10 ft (3 m)
Engineered Products
D = 5 ft (1.5 m)
Graph 2 Heat loss (W) for a concrete slab or earth foundation
Technical Data Sheets Appendixes
09/13
23 / 30
TANK HEAtING
Legs
Determine the heat loss for legs (QS) as follows: Based on the T and tank diameter, select the heat loss from the Table 12 or Graph 3. Multiply the heat loss by the number of legs. TaBle 12 HeaT LOss (W) fOR a Leg SUppORT T F (C) Tank diameter ft (m)
5 (1.5) 10 (3) and above
50 (10)
26 85
100 (38)
52 169
150 (66)
77 351
200 (93)
103 336
250 (121) 300 (149)

129 420 155 505
600 500 Heat Loss (W) 400 300 200 D = 5 ft (1.5 m) 100 0 50 (10) 100 (38) 150 (66) T F (C) 200 (93) 250 (121) 300 (149) D = 10 ft (3 m) and up
Graph 3 Heat loss (W) for leg support
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09/13

CONcReTe SaDDles
Determine the heat loss for saddles (QS) as follows: Based on the T and tank diameter, select the heat loss (QS) from Table 13 or Graph 4. Multiply the heat loss by the number of saddle supports. TaBle 13 HeaT LOss (W) fOR a CONcReTe SaDDle T F (C) Tank diameter ft (m)
5 (1.5) 10 (3) 15 (4.6) 20 (6)
50 (10)
93 145 198 250
100 (38)
186 290 395 500
150 (66)
275 430 586 741
200 (93)
368 576 783 991
250 (121)
461 721 981 1241
300 (149) 553 866 1179 1491

RTB Tubing Bundles Longline Heating
1600 D = 20 ft (6 m) 1400
Tank Heating
1200
D =15 ft (4.6 m)
1000 Heat Loss (W) D = 10 ft (3 m) 800
Snow and Ice
600
D = 5 ft (1.5 m)
400
200
0 50 (10) 100 (38) 150 (66) T F (C) 200 (93) 250 (121) 300 (149)
Heat-Trace Panels
Graph 4 Heat loss (W) for a concrete saddle
09/13
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TANK HEAtING
UNiNsUlaTeD SKiRT
Based on the T and tank diameter, select the QS from Table 14 or Graph 5. TaBle 14 HeaT LOss (W) fOR aN UNiNsUlaTeD SKiRT T F (C) Tank diameter ft (m)
5 (1.5) 10 (3) 15 (4.6) 20 (6)
50 (10)
402 806 1209 1613
100 (38)
805 1612 2419 3225
150 (66)
1193 2389 3585 4780
200 (93)
1595 3195 4794 6393
250 (121) 300 (149)

1998 4000 6003 8006 2400 4806 7212 9619
10000 D = 20 ft (6 m) 9000 8000 7000 6000 5000 4000 3000 D = 5 ft (1.5 m) 2000 1000 0 50 (10) 100 (38) 150 (66) T F (C) 200 (93) 250 (121) 300 (149) D = 10 ft (3 m) D = 15 ft (4.6 m)
Graph 5 Heat loss (W) for an uninsulated skirt
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Heat Loss (W)
09/13

Step Calculate the QA (heat loss through the accessories)

The following heat loss tables and accompanying charts provide typical accessory heat losses (QS) through the following types of accessories: Manholes Handholes Ladders Handrails
MaNhOles
Select the heat loss for a manhole from Table 15 or Graph 6. The heat loss is based on a 2-foot diameter cover and a 1-foot tall base. The base and cover are uninsulated. TaBle 15 HeaT LOss (W) fOR a MaNhOle
RTB Tubing Bundles
T F (C) 50 (10)
Heat loss (W) 564
100 (38)
1120
150 (66)
1680
200 (93)
2237
250 (121) 300 (149)

2807 3401
Tank Heating
3500 3000 2500 Heat Loss (W) 2000 1500 1000 500 0 50 (10) 100 (38) 150 (66) T F (C) 200 (93) 250 (121) 300 (149)
Snow and Ice Control and Monitoring
Graph 6 Heat loss (W) for a manhole
Heat-Trace Panels Engineered Products Steam-Tracing Systems Technical Data Sheets Appendixes
09/13
27 / 30
TANK HEAtING
HaNDhOles
Calculate the heat loss for handholes as follows: Select the heat loss from Table 16 or Graph 7 based on the T. Heat loss is based on a 0.5 foot diameter, uninsulated surface. Multiply the heat loss you select by the number of handholes. TaBle 16 HeaT LOss fOR a HaNDhOle T F (C) 50 (10)
Heat loss (W) 90
100 (38)
178
150 (66)
265
200 (93)
351
250 (121) 300 (149)

437 526
600 500 400 300 200 100 0 50 (10) 100 (38) 150 (66) T F (C) 200 (93) 250 (121) 300 (149)
Graph 7 Heat loss (W) for a handhole

Step Calculate the QT (overall heat loss)

Add the heat-loss rates (QV, QS, and QA ) from Steps , , and . Outdoor application: QT = QV + QS + QA Indoor application: QT = 0.9 x (QV + QS + QA )
Step Calculate the nal design heat loss

Pentair Thermal Management recommends that the nal design heat loss should include a 20 percent safety factor. Final design heat loss = QT x 1.20 Note that this same heat-loss calculation approach should be used for insulated polypropylene and ber-reinforced plastic (FRP) tanks.
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Heat Loss (W)
09/13
Self-Regulating Cables Longline Heating RTB Tubing Bundles Tank Heating Snow and Ice Control and Monitoring Heat-Trace Panels
Engineered Products
Technical Data Sheets
Appendixes
09/13
29 / 30
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Self-Regulating Cables Power-Limiting Cables

Control and Monitoring Heat-Trace Panels

Engineered Products Steam-Tracing Systems Technical Data Sheets Appendixes

THERMAL MANAGEMENT SOLUTIONS

BTV and QTVR

Fig. 1 Self-regulating heating cables

THERMAL MANAGEMENT SOLUTIONS

Power-Limiting Cables Mineral Insulated Cables Longline Heating

Fig. 2 Power-limiting heating cables

Mineral Insulated Heating Cables

Fig. 3 MI heating cables

Technical Data Sheets Appendixes

THERMAL MANAGEMENT SOLUTIONS

Fiber-reinforced silicon rubber top layer Nichrome heating wire

Stainless steel flexible ground plane

Liquid-tight electrical conduit exiting a lowprofile junction box RHS

Fig. 4 Tank heating pads

THERMAL MANAGEMENT SOLUTIONS

Tank Tracing Design and Product Selection

Power-Limiting Cables Mineral Insulated Cables

1 Gather the necessary application data.

RTB Tubing Bundles Tank Heating

Step Gather the necessary data

Snow and Ice Control and Monitoring

Example: Information on three sample applications

Vertical cylinder 3 ft 6 ft 4 legs

Engineered Products Steam-Tracing Systems Technical Data Sheets Appendixes

THERMAL MANAGEMENT SOLUTIONS

Step Calculate the tank heat loss

Step Choose the heating technology

THERMAL MANAGEMENT SOLUTIONS

Tank Tracing Design and Product Selection

Mineral Insulated Cables Longline Heating RTB Tubing Bundles

Engineered Products Steam-Tracing Systems Technical Data Sheets Appendixes

THERMAL MANAGEMENT SOLUTIONS

Step Product selection

Step 4a Product selection for self-regulating and power-limiting heating cables

THERMAL MANAGEMENT SOLUTIONS

Tank Tracing Design and Product Selection

Power-Limiting Cables Mineral Insulated Cables Longline Heating

Fig. 5 Heating cable arrangement on a vertical tank

RTB Tubing Bundles

Fig. 6 Heating cable arrangement on a horizontal tank

Tank Heating Snow and Ice

Control and Monitoring

Engineered Products Steam-Tracing Systems Technical Data Sheets Appendixes

THERMAL MANAGEMENT SOLUTIONS

Adjustment factor on metal tanks

Adjustment factor on polypropylene tanks

Adjustment factor on ber-reinforced plastic tanks

N/R Not recommended due to temperature limitations of tank wall.

THERMAL MANAGEMENT SOLUTIONS

Tank Tracing Design and Product Selection

Mineral Insulated Cables Longline Heating

RTB Tubing Bundles

Tank Heating Snow and Ice

Control and Monitoring Heat-Trace Panels

Engineered Products Steam-Tracing Systems Technical Data Sheets Appendixes

THERMAL MANAGEMENT SOLUTIONS