2/23/2015

TOTAL HEAT TRACE

SOLUTIONS
for Power Generating Stations
2015 Update

Electric Heat Tracing: Thermon Makes Them All!

Positive Temperature Parallel and Series Constant Specialty Cables, Skin Effect
Coefficient (PTC) Heat Tracing Wattage Heat Tracing for Systems, Tank and Hopper
for Complex Piping
Interconnecting Piping Heating

Self-Regulating Parallel Constant Watt MI Constant Watt

Skin Effect Heating

Power-Limiting Series Constant Watt Tank Heating

Hopper Heating

1
 2/23/2015

Heating Element Types

Graphically Represented

PTC Self-Regulating &

Power- Limiting Heater
Output
Power

ZTC Constant Wattage

Heater Output

0
Temperature

#1 Heat Trace Application: Winterization

Ruptured
Pipes Loss of Safety
Systems

Winterization Prevents:

Interruption of
Water Supplies
Plant Outages

2
 2/23/2015

HEAT TRACE SOLUTIONS

EMMISSIONS
for Power Generating Stations
2015 Update

Heat Tracing for Fossil Fired Power Stations

3
 2/23/2015

Coal Fired Ash Collection Hoppers

Without proper heat and insulation, hopper

pluggage

Common Fly Ash Hopper Blockage

Compaction of Fly Ash Settlements

Hopper Vibration & Bridging Near Throat

Agglomeration
Fly Ash Temperature Drops Below The Flue Gas Acid
And/Or Water Dew Point

Solidification
Chemical Reaction Possible When Condensates Mix
With Fly Ash Particles And Creates Hopper Blockage

4
 2/23/2015

Fly Ash Hopper Heating

Design Basics:
A hopper is defined as
the structure below
either the precipitator
casing or baghouse
flue gas inlet.

IEEE Standard for Hopper Heating

IEEE Std 1069-1991

In use since September, 1991
Establishes minimum acceptable
performance levels based on
expected service
Has additional testing parameters
in place
Identifies major areas that should
be addressed for design, control,
monitoring and alarm of a hopper
heating system

5
 2/23/2015

All Power Stations: Stack Gas Analysis

TubeTrace for Extractive

CEMS Bundles

SOx
NOx
Hg (Mercury for Coal
Fired Power Stations)
NH (Ammonia)

ICAC and Sample Transport Bundles

Guidelines & Recommended

Practices September 2006
CAMR: Clean Air Mercury
Reduction & MACT Maximum
Achievable Control Technology

6
 2/23/2015

Mercury Emissions
Mercury (Coal Fired Vs. Natural Gas)
CEMS Market Update

TubeTrace with Thermon EHT

Cut-to-Length in the
field vs. Cheap heated
hoses with unreliable
series heating elements.

HPT Power-limiting EHT:

the best choice for
maintaining High temps to
180C (356F)

Approved for use in

electrically classified
hazardous areas

7
 2/23/2015

Custom Instrument Tubing Bundles

Maintain elevated temperatures in

the center section of the TubeTrace
bundle.
Auxiliary conductors to feed probe
heater, solenoid valves, etc without
separate additional power feed.
Un-heated tubes for blowback and
calibration gas also in the bundle.
Factory installed temperature
sensor(s) for control or monitoring.
Special tags and/or markings for
instrument identification if and
where required.

Custom ME Multiple Electrical Bundle with HPT heat trace

Bundles Terminated Outside the Shelter?

8
 2/23/2015

HEAT TRACE SOLUTIONS:

COGEN STEAM SAMPLE &
CHEMICAL INJECTION LINES
EHT for Power Generating Stations
2015 Update

Gas Fired Combined Cycle Stations

TubeTrace Products for Winterizing

Instrument Impulse Lines and Sample Lines*
HRSG** Units for Steam Generation often
require winterization, but also require the ability
to withstand High temperatures.

*Steam Sampling & Chemical Injection Lines

**HRSG: Heat Recovery Steam Generator

9
 2/23/2015

HRSG* Units and Superheated Steam

TubeTrace Products Designed to

Withstand Elevated Temperatures*

High-pressure Drum may have Steam

Sample Temperatures up to 593C
(1100F)

* Heat Recovery Steam Generator

EHT Not suitable for High-Temp Exposure

10
 2/23/2015

MIQ Mineral Insulated Heaters

MIQ Heaters can provide

Freeze Protection with
required exposure to 593C
(1100F)

MIQ Heaters (shown here

on a pipe heating
application) are well suited
for the application, but
require field measurements
for custom fabricated
circuits

Custom MI Circuits

Thermon has complete control over MI circuit

fabrication and can build hundreds of circuits
per week from multiple shops

11
 2/23/2015

Standard MI Circuits

Thermon stocks various pre-fabricated MI circuit

lengths for freeze protection projects

Innovation, Complication, Frustration

12
 2/23/2015

One Trace for Multiple Instruments?

A very expensive installation to pick-up individual

instument lines leaving the group envelope

Splices w/o Consideration of Exposed Tubing?

13
 2/23/2015

Pre-fabricated vs. Field Insulating

One Contractors
thoughts on saving
money

Electric Heat Tracing: Thermon Makes Them All!

Positive Temperature Parallel and Series Constant Specialty Cables, Skin Effect
Coefficient (PTC) Heat Tracing Wattage Heat Tracing for Systems, Tank and Hopper
for Complex Piping
Interconnecting Piping Heating

Self-Regulating Parallel Constant Watt MI Constant Watt

Skin Effect Heating

Power-Limiting Series Constant Watt Tank Heating

Hopper Heating

14
 2/23/2015

Components of a Heat Tracing Circuit

1
4

1 Circuit Protection/Distribution 2

2 Power Connection 5

3 Heat Trace
4 Hot End Termination 6
3
5 Temperature Controller
6 Temperature Sensor

The Most Critical Component of a EHT System . . .

Isnt an Electrical Device or Appliance

Is Rarely Considered a Part of the System

Is Regularly Misapplied, Unprotected and Abused

Is the #1 Cause of Low Temperature Problems

What Is It?

15
 2/23/2015

The Most Critical Component of a Heat Tracing

System . . .

Where is Heat Tracing Required?

16
 2/23/2015

Thermons Three M s

Minimize number of tracers per length of pipe

(preferably one)

Minimize number of connection points (where

applicable)

Minimize the number of circuits

Electrical Heat Tracing

More than EHT and accessories

Transformer
480V 120/208V

Conduit and Wire

Power Distribution /
Control Panel
Heat Trace / Power
4Mount Transformer and Control Connection
Panels
4Run Conduit and Wire
4Install Heat Trace Thermal
4Make All Terminations Insulation
4Install Thermal Insulation
RTD/Temperature
4Test and Commission System
Controller

17
 2/23/2015

Grouping Power Points Reduce Conduit

TubeTrace SEI/MEI for High Temp Exposure

Winterization with High

Temperature Exposure Limits
HPT Power-limiting EHT Isolated
from the tubing (SEI Shown)
Allows Cut-to-Length Fabrication
Freeze Protection with Exposure
to 593C (1100F)
Alternative to MIQ, Field Routed
and/or in TubeTrace Bundles
Proven Product Designed
Specifically for the Application.

18
 2/23/2015

TubeTrace Heated & Isolated Tubing

TubeTrace SEI/MEI tubing bundles are heated

but have the EHT isolated from direct contact
with the routinely hot tubing.

Installation is initiated very quickly without

scaffolding or multiple trades on a given line.

ThermoTube High Temperature Tubing

In some cases winterization might not be of

concern. Here, high temperature ThermoTube is
ideally suited for steam sampling and chemical
injection lines where insulation is required for
energy conservation or personnel projection.

Again, installation is initiated very quickly without

scaffolding or multiple trades on a given line.

19
 2/23/2015

TubeTrace SEI/MEI Bundle Installation

TubeTrace products are

easily installed without
Scaffolding or multiple
Trades on a common
line.

As stainless steel tubing

expands almost 1%
when exposed to 593C
(1100F)

Expansion Loops are

Easily Installed [Straight
runs 30m (100)
require such.]

HT & HTX Bundle Terminations

Proper termiation to a root valve,

extending field insulation over
tubing bundle for applications
where exposure temperature
exceeds 500F (260C)

20
 2/23/2015

TubeTrace SEI/MEI Steam Sampling*

TubeTrace Bundles Easily Installed in

Cable Tray, but Separation is Critical
to Avoid High Temperature on
Bundle Jackets.

* Distances between HRSG and Steam Sample

Analyzer may be over 100m (328)

Steam Sample Bundles Stacked and

Heat accumulation caused jacket temperatures to go too high causing the

jacket to melt
causing insulation to get wet, causing jackets to further degrade, etc

* Distances between Steam Sample Lines need to be observed to keep from getting too hot

21
 2/23/2015

Less than Minimum Bend Radius

Insulation is
compressed, jacket
comes in contract
with the high temp
tube and melts
and

THERMON The Heat Tracing Specialists

No matter what the instrument tubing

requirements
Thermon is Ready!

22
 2/23/2015

HEAT TRACE STANDARDS:

CONTROL & MONITORING
CONSIDERATIONS
EHT for Power Generating Stations
2015 Update

IEEE 515 - 2011 Standard for Electrical Resistance

Trace Heating for Industrial Applications

Piping, Tanks & Instrumentation

Hazardous (Classified) Locations
Controls & Monitoring
Thermal Insulation -
recommendations

23
 2/23/2015

IEC 60079-30 Electrical Trace Heating

Standard - Parts 1 & 2

Part 1 for General and Testing

Requirements
Part 2 for Application Guide for
Design, Installation, and
Maintenance

Hazardous (Classified) Locations

EHT & Earth Leakage Equipment Protection

A system intended to provide protection of

equipment from damaging line-to-ground
fault currents by operating to cause a
disconnecting means to open all
ungrounded conductors of the faulted
circuit. This protection is provided at current
levels less than those required to protect
conductors from damage through the
operation of a supply circuit overcurrent
device.

24
 2/23/2015

Conventional Ambient Sensing Control

Conventional Ambient Sensing Control

12 or 24 Circuit Panel with

Includes:
Ambient Sensing Thermostat
Main Contactor for control
Prewired EPD Distribution
Breakers
Lock-Out / Tag-Out Feature
HOA switch and Lights

25
 2/23/2015

TCM18 OVERVIEW

Controls Up to 18 Heat Trace Circuits Per Control Module with 1 or 2 RTD

Sensors per EHT Circuit.
Displays, Monitors and Alarms for:
Low Current
Low Temperature
High & High-High* Current
High & High-High* Temperature
High & High-High* Ground Leakage Current
Damaged Temperature Sensor (Open or Shorted RTD)
RS 485 Communications to TVNE or DCS System
Solid State or Mechanical Relay Outputs

*High-Highvalues can be set to alarm only or alarm and Trip

TraceNet TCM18 for NEC, CEC, and IEC

26
 2/23/2015

TCM18 CONTROL METHODS

TCM18 Unit Up to Two (2) RTD Sensors

per Heater are Possible

Adjustable Control Differential for Accuracy

Control Options for Each Individual Circuit
Line Sensing:
On/Off, On/Off with Soft Start, Proportional
Ambient Sensing
(Conventional on-off)
APC: Ambient Proportional Control without sacrificing Low
Temperature Alarms on Critical Lines

TCM18 Multi-function Monitoring

TCM18 Unit
Up to Two (2) RTD Sensors
per Heater are Possible

Individual EHT Circuit and Temperature Alarms:

High & Low Current Alarms with separate High
Current Trip Setting
High Earth Leakage Current Monitoring & separate
Trip
High & Low Temperature Alarms with separate
High Temperature Trip Setting
RTD Sensor(s) Failure Functions

27
 2/23/2015

TCM18 Panel with Distribution

Swing-out panel provides complete

access to :

Individual Control Relays

Current & Ground Leakage Current
Monitoring
All Electrical Distribution with
Lock-Out / Tag-Out Feature

Questions ?

28