Installation Procedure For SkinTrace Heating System

Date: 29/06/2017 Revision: 7

SkinTrace Installation Manual | 29th June 2017 | Rev 7 Page 1 of 12

SKINTRACE ELECTRIC HEAT TRACING SYSTEM LAYOUT

End Box Splice/Pull Box

Power Box

Coupling

Pipeline

Heat Tube with Skin Cable inside

SkinTrace Control Panel

Load Balancing Unit

Isolation Transformer

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1.0 Installation Sequence of Tubing and Boxes

Tools requiredfor installation:

Safety PPE

Welding equipment

Fire resistant mats

Chamfering tool to remove sharp burs

Sand paper

Tube bending poles

Tube bender

Pigging Tool

Air powered drill

Heat Gun

Megger tester

Resistance tester

For leak test o Blanking plug o Pressure regulated attachment for the tube o Air canister

The heater cable must not be installed if the ambient temperature is below -40°C. The Full storage and preservation requirements must be adhered to to all of the equipment, up to and prior to the installation of the heating equipment (e.g. the ends of the heater cable must be kept dry). The selection of tube and conductor size, as well as the applied voltage must be calculated and adhered to according to the following standards.

ATEX IECEx

EN 60079-0:2012

EN 60079-30-1:2007

IEEE 844:2000

IEC 60079-0:2011 Ed. 6

IEC 60079-30-1:2007 Ed. 1

IEEE 844:2000

SkinTrace Installation Manual | 29th June 2017 | Rev 7 Page 3 of 12

1. 1 Preparation of heat tube The standard heat tubes used for SkinTrace heating system are of ASTM 106B Sch40, Carbon steel either welded or seamless type. Typical sizes used are 0.75”, 1.0” and 1.25”. Heat tube ends shall be finished and removed from burs before installation to the pipe. On the tube ends, no burs or dents are allowed. If dents or major deformation of the tube is found, the tube should be rejected. If any burs are found, then finish with chamfering tool and provide a smooth round surface on the outer edge. The outer edges of the tube shall be further finished with sand/abrasive paper. The inner edges of the tube will be chamfered to 45° and deburred and finished as described. Clean the inside of the heat tubes with the help of pressurized air (pressure 6 bar or 90 psi). Cleaning is completed if air is coming out from other end without any dust or dirt. This is very important step to ensure complete cleaning of all heat tube pipes before installation. Any foreign particles of dust, dirt or loose metal can damage the skin cable which will be pulled later on. Please insert the end caps/sleeves (plastic) when you have cleaned and finished the tubes to prevent further ingress of foreign particles.

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1.2. Heat tube jointing This is a crucial procedure in the SkinTrace system. The heating tubes must be electrically connected throughout the entire system for the system to operate correctly. This is done by welding the tubes together with the help of a coupling shown below. The heat tubes and coupling shall be welded by an experienced and certified welder. On some projects preinsulated pipe sections are provided with a heater tube is already attached to the carrier pipe and insulated. In this scenario, the pipe sections are welded together ensuring the heater tubes are aligned. Following successful testing of that weld, the coupling is arranged over the two tube ends and it is welded as per below Figure #1a. If the project is not using pre-insulated piping (i.e. the tube is not installed on the pipe yet) then welding of the coupling should be completed before the welding or strapping of the heat tube with carrier pipe to make the welding procedure easier. Please refer Figure #1b shown.

Figure #1a

Figure #1b

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1.3. Welding of Heat tube with carrier pipe

The heat tube shall be placed properly on the carrier pipe and avoid the offsets. Put the heat tube on the carrier pipe & hold it with straps or tag weld as recommended by the design. The following methods of attaching the tube to the pipe are as follows;

Strap to the pipe only

Tack weld to the pipe

50% weld to the pipe

100% weld both sides of the tube to the pipe

50% welding of heat tube with the carrier pipe shall be as per below Figure #2. Great care should be taken when welding to avoid any kind of burn, pit or damage to the carrier pipe or heat tube which will affect the system performance. The welding shall be stitch weld for 50mm interval at both side of Heat tube with carrier pipe.

Figure #2

It is important to ensure that heat tube shall be in intimate contact with the carrier pipe over the entire pipe route otherwise system performance may be affected. Where the carrier pipe bends around elbows or other bends with a large radius, the bending radius of the tube must match precisely. After the installation of the heat tubes complete inspection shall be carried out on the entire length of heat tube for electrical continuity, water tightness & visual inspection of the heat tube installation. After a successful visual inspection the following two tests are carried out on heat tube.

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1.4. Leakage Test

Heat tube shall be tested with pressurised air (approx. 5 – 15 psi / 0.3 to 1 bar) to check the water tightness and electrical continuity. One end of the heat tube is made air tight (fitted with a blanking plug) and from other end, pressurised air is passed into system for at least 5 minutes. During this time, the pressure is monitored. If the pressure is being lost it means that somewhere a joint is leaking. Apply liquid soap on all the joints to check for the leakage and repair the joint. If a leak is found and repaired the above test should be repeated. Please refer Figure #3 for the pressure gauge used to monitor a stable or leaking system.

Figure #3

1.5 Heat Tube Pigging Before the pulling of the heating cable, the heat tube shall undergo pigging. The pigging tool is to be supplied by piping contractor installing the tube. This test will ensure and correct any kind of deformation at elbows and bends and help clear out any remaining debris within the tube.

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1.6 Installation of Pull and Splice box Remove the moisture, dust dirt from the pull and splice box before installation on the pipe line. The pull box shall be installed at every 60 to 80 meter of distance of carrier pipe. These pull boxes are fixed under the thermal insulation. The installation of one pull box shall be considered at every 90° bend, elbow & fittings. If the SkinTrace tube passes through two 45° bends a pull box shall be installed. Consideration should be made for any significant changes in pipe route (e.g. road culverts, large changes in topography, etc.) Pull boxes shall be welded with heat tube as per the Figure #4. Welding should not be done inside the box.

Figure #4

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1.7 Installation of Feed and End box

Feed box shall be used for giving power supply to the heating system and end box shall be used for termination. A prefabricated ‘L’ shaped section of tube is welded to the heater tube on the pipe. A temperature rated conduit gland is screwed to the top of the ‘L’ section and this gland is placed through the bottom of the junction box (or gland plate where applicable). The heater tube should not be in contact with any live terminals within the power box. These boxes are above thermal insulation and attached directly to the carrier pipe. Thismethod allows for future maintenance and testing the need to removine insulation from the pipe. See Figure 5 below.

Figure #5

The end junction box is installed in a similar manner with the SkinTrace cable connecting to a central stud and eventually wired back to the heater tube.

Welded to pipe And heater tube

Conduit Gland

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2.0 Installation sequence of SkinTrace Cable 2.1 Installation of SkinTrace cable Before installing or servicing the SkinTrace system, any existing power feeds to that circuit must be de-energised to prevent harm or death to any personnel. The minimum bend radius for SkinTrace cable is 65mm. In no circumstance should the cable be bent past this as it will damage the insulation layer. SkinTrace cable installation is also one of the important steps for SkinTrace heating system installation. The correct size of conductor shall be confirmed as per the design documents for the project before being pulled into the tube. SkinTrace cable shall be pulled with the help of double braided, low stretch poly propylene rope. If required, a fishing cable can be blown up the tube to aid in installing the pulling rope into the tubes. SkinTrace cable pulling shall be started from either the start or end of the circuit. Whilst pulling the SkinTrace cable, there should be no significant resistance on the pull rope. If there is large resistance, then the installation team should go to the last pull box where the cable is visible to determine if a reason can be found (e.g. snagging on the pull box tube entry). If a reason cannot be found it may be necessary to retract the whole SkinTrace cable and identify that pull box as being a position to create a splice. Note that the reason that the cable cannot be pulled further is that the installation team have simply tried to pull the cable too far.

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In the event you cannot pull the cable any further into the tubes, or retract the cable back out of the tube, then the decision should be made whether to cut the cable at the last pull box where the cable is visible. The cut should be made at the farthest end of the pull box to allow for a future splice to be made. The remaining short length of cable can then be retracted out of the tube. Investigation should be made to see if there is any blockage in the section of tube that the cable was removed from. Cable pulling shall be done carefully to avoid any kind of damage. The cable reel must be placed optimally to avoid any kind of twisting while pulling. Avoid sharp edges whilst pulling the cable (e.g. directly against the top edge of the tube in the start junction box). Ideally the cable should feed as parallel as possible to the heat tube. Sufficient loop shall be given (half-loop) while pulling the cable into pull boxes to allow for thermal expansion. Care should be taken if the cable is pulled further again so that these expansion loops are not pulled straight again. Care should be taken not to surpass the minimum bending radius stated earlier. Note: Before the pulling of skin cable please ensure for the grounding of SkinTrace cable to the nearest metal structure. No welding work is allowed once the SkinTrace cable is installed. Any kind of cleaning /flushing by high temperature steam shall not be done after SkinTrace cable installation. This will damage the SkinTrace cable. 2.2 Skin cable testing Following tests are to be performed after the installation of SkinTrace cable. 2.3 Dielectric Test Dielectric test shall be performed on SkinTrace cable on each section before commissioning High Voltage of 5KV to 15KV shall be applied based on the SkinTrace cable type & rating. Results are recorded in report given. The above test shall be carried out for one minute and record the final mega ohm value. Note: Heat tube & SkinTrace cable are tested at high voltages. Do not to touch to SkinTrace cable and heat tube during the test and also do the grounding of SkinTrace cable and heat tube immediately after the test.

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2.4 Splicing of cable and termination Cable splicing & termination shall be done as per Figure #6. Special connectors & lugs shall be used as supplied by Heat Trace Ltd. Correct crimping tools shall be used to ensure that no gaps or loose connections are made.

Crimping the cable with non-approved crimping tools will not be acceptable and may result in future failures.

Figure #6

2.5 Connections in the Feed and End box

The live power is connected to the end of the SkinTrace cable within the power box via the isolated terminals (or crimped directly to the SkinTrace cable). The neutral is connected to the lug inside of the junction box (effectively connecting it to the heater tube). The end of the SkinTrace cable will be terminated with the approved crimp lug joint and connected to the internal lug on the junction box. The end junction box also has an external lug which will be connected to an available earth point. The power junction box will be marked with a label as follows;

Certificate number CML 17ATEX3155 IECEx Certificate number IECEx CML 17.0076 CE mark 0518 ATEX marking II 2GD Code Ex e IIC Tx Gb

Ex tb IIIC T#°C Db Ambient (-40°C≤Ta≤+200°C) Rating Up to 5 kV

Up to 300 A

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3.0 Recommended Installation Training Trained and competent personnel should only be used for the installation of the heating components. For the welding of the tube to the carrier pipe, the welder must possess evidence of such training and suitably prove their knowledge of the method of welding to be used. For the installation of the cable into the tube and all of the inline splices, as well as connections to the remote and feed junction boxes, the personnel must have had training from Heat Trace Supervisors as to the correct method to prevent damage to the cable and to ensure that the splices are carried out correctly and with suitable tools. Upon completion of training and evidence of competence, the installers will be issued with a certificate of competence. It is advised that Heat Trace visit regularly visit site to ensure that the correct working practices are being adhered to.