nvent RAYCHEM BTV, Installation And Maintenance Manual

Page 1: ...Industrial Heat Tracing Installation and Maintenance Manual for Self Regulating and Power Limiting Heating Cable Systems nVent com ...

Page 2: ... short They must be properly insulated and kept dry Damaged bus wires can overheat or short Do not break bus wire strands when preparing the cable for connection Damaged heating cable can cause electrical arcing or fire Do not use metal attachments such as pipe straps or tie wire Use only RAYCHEM approved tapes and cable ties to secure the cable to the pipe Do not attempt to repair or energize dam...

Page 3: ...ion Notes 2 2 Heating Cable Selection 3 3 Heating Cable Installation 4 3 1 Heating Cable Storage 4 3 2 Pre Installation Checks 4 3 3 Installation 5 4 Heating Cable Components 16 4 1 General Component Information 16 5 Control and Monitoring 19 6 Thermal Insulation 21 6 1 Pre Insulation Checks 21 6 2 Insulation Installation Hints 21 6 3 Marking 21 6 4 Post Insulation Testing 21 ...

Page 4: ...nd Fault Protection 22 8 Commissioning and Preventive Maintenance 23 8 1 Tests 23 8 2 Preventive Maintenance 24 9 Test Procedures 25 9 1 Visual Inspection 25 9 2 Insulation Resistance Megger Test 25 9 3 Power Check 28 9 4 Fault Location Tests 29 10 Troubleshooting Guide 34 11 Installation and Inspection Records 36 ...

Page 5: ...ent warranty and agency approvals to apply the instructions that are included in this manual and product packages must be followed 1 2 Safety Guidelines The safety and reliability of any heat tracing system depends on proper design installation and maintenance Incorrect handling installation or maintenance of any of the system components can cause underheating or overheating of the pipe or damage ...

Page 6: ... Industrial Product Selection and Design Guide nVent literature H56550 or TraceCalc Pro software or the website design software Ensure all pipes tanks etc have been released by the client for tracing prior to installation of the heating cables Typically heating cables are installed at the 4 and 8 o clock positions on a pipe All heat traced pipes tanks vessels and equipment must be thermally insula...

Page 7: ...ign specification to make sure the proper heating cable is installed on each pipe or vessel Refer to the Industrial Product Selection and Design Guide TraceCalc Pro or the nVent web site nVent com to select the proper heating cable for your application ...

Page 8: ... on its jacket Ensure that the heating cable voltage rating is suitable for the service voltage available Inspect the heating cable and components for in transit damage Verify that there no holes in the heating cable jackets by conducting the insulation resistance test refer to Section 9 on each reel of cable Check piping to be traced Make sure all mechanical pipe testing i e hydrostatic testing p...

Page 9: ...ng it along the pipe making sure that the cable is always next to the pipe when crossing obstacles If the cable is on the wrong side of an obstacle such as a crossing pipe or I beam you will need to reinstall it or cut and splice it Single cable Pipe Pipe Multiple cables from two reels Multiple cables from a single reel ...

Page 10: ...NG OUT THE HEATING CABLE AVOID Sharp edges Excessive pulling force or jerking Kinking and crushing Walking on it or running over it with equipment WARNING Fire and Shock Hazard Do not install damaged cable Components and cable ends must be kept dry before and during installation Positioning heating cables If possible position the heating cable on the lower section of the pipe at the 4 and 8 o cloc...

Page 11: ... above GT 66 or GS 54 glass tape across heating cable nVent RAYCHEM AT 180 aluminum tape Heat transfer tape for plastic pipes pump bodies and odd shaped equipment Install above 32 F 0 C Tape lengthwise over the heating cable as required by the design AT 180 aluminum tape over heating cable WARNING Fire and Shock Hazard Do not use metal attachments such as pipe straps or tie wire Do not use vinyl b...

Page 12: ...o the reel Leave extra heating cable at the power connection at all sides of splices and tees and at the end seal to allow for future servicing Allow a loop of extra cable for each heat sink such as pipe supports valves flanges and instruments as detailed by the design Refer to Typical installation examples on page 12 for attaching heating cable to heat sinks Install heating cable components immed...

Page 13: ...should have extra heating cable installed at heat sinks as called out in the design It is recommended to supply the extra heating cable at heat sinks alternately from both runs in order to balance out both circuit lengths SPIRAL TRACING When the design calls for spiralling begin by suspending a loop at every 10 foot pipe section To determine the loop length obtain a spiral factor from the design a...

Page 14: ...able loop length Wrap loops in opposite directions Tape after spiraling heating cable on pipe Heating cable BENDING THE CABLE Power limiting minimum bend radius 3 4 Self regulating minimum bend radius 1 2 When positioning the heating cable on the pipe do not bend tighter than 1 2 for self regulating cables and 3 4 for power limiting cables ...

Page 15: ...E Self Regulating cables BTV HBTV QTVR HQTV XTV HXTV KTV allow for multiple overlapping of the heating cable Power Limiting cable VPL allows for a single overlap of the heating cable per zone FOR VPL HEATING CABLE ONLY CUTTING THE CABLE Cut the heating cable to length after it is attached to the pipe Heating cable can be cut to length without affecting the heat output per foot ...

Page 16: ...llow easy access for maintenance The exact amount of heating cable needed is determined in the design VALVE Valve body Multiple crossovers allowed for self regulating cables Single crossover only allowed for power limiting cables Glass tape Pipe Heating cable Pipe Heating cable Note Cable loop length varies depending on heat loss FLANGE Glass tape typical Heating cable Loop length is twice the dia...

Page 17: ...PE SUPPORT SHOE Heating cable secured to pipe Glass tape Heating cable loop Support shoe Pipe ELBOW Heating cable Glass tape typical For pipe diameters of 2 and larger the heating cable should be installed on the outside long radius of the elbow ...

Page 18: ...able Installation 3 14 nVent com PRESSURE GAUGE Heating cable Glass tape Pipe SPLIT CASE CENTRIFUGAL PUMP Glass tape Pump discharge Pump body Heating cable Pump suction Use AT 180 tape Motor To power connection ...

Page 19: ...PE HANGER Heating cable Heating cable Glass tape Do not clamp heating cable with support Pipe hanger Pipe hanger No additional heating cable is required for pipe hangers unless called for in the design specification then use loop length specified ...

Page 20: ...ection kits should be mounted on top of the pipe when practical Electrical conduit leading to power connection kits should have low point drains to keep condensation from accumulating in the conduit All heating cable connections must be mounted above grade level Special adapters are available for mounting on small pipes Be sure to use these adapters if installing cables on pipes of 1 inch O D or l...

Page 21: ...ction kit and an HAK JB3 100 or a Division 1 Nationally Recognized Testing Lab NRTL approved junction box WARNING The black heating cable core and fibers are electrically conductive and can short They must be properly insulated and kept dry Damaged bus wires can overheat or short Do not break bus wire strands when stripping the heating cable ...

Page 22: ...0 L Power Connection Splice Tee End Seal PMKG LS PMKG LE RAYCHEM Components for CID1 Hazardous Locations HAK C 100 connection kit HAK JB3 100 junction box UMB Junction box connection kit and mounting bracket sold separately Splice End seal Tee Power connection WARNING Fire and Shock Hazard RAYCHEM brand specified components must be used Do not substitute parts or use vinyl electrical tape ...

Page 23: ...n and Design Guide or contact your nVent representative Refer to the installation instructions supplied with control and monitoring products Control and Monitoring systems may require installation by a certified electrician nVent Control and Monitoring Products THERMOSTATS CONTROLLERS AMC F5 AMC 1A AMC 1H AMC F5 AMC 1B AMC 2B 2 E507S LS E507S 2LS 2 Raystat EX 03 A RAYCHEM Series1 2 910 920 200N T2...

Page 24: ...0 Communications Local display Remote display Network to DCS 1 RAYCHEM controllers used in CID1 areas require the use of appropriate hazardous area enclosures or Z purge systems 2 480 V VPL must use RAYCHEM 920 200N T2000 or NGC 30 controllers only 3 Continuity monitoring is supported when PLI Power Line Carrier Interface technology is implemented nVent Control and Monitoring Products ...

Page 25: ...hen installing cladding be sure drills screws and sharp edges do not damage the heating cable To weatherproof the insulation seal around all fixtures that extend through the cladding Check around valve stems support brackets and thermostat capillaries 6 3 Marking Apply Electric Traced labels on outside of the cladding at 10 foot intervals on alternate sides to indicate presence of electric cables ...

Page 26: ...ctrical Code and the Canadian Electrical Code require both ground fault protection of equipment and a grounded metallic covering on all heating cables All RAYCHEM products meet the metallic covering requirement Following are some of the ground fault breakers that satisfy this equipment protection requirement Square D Type GFPD EHB EPD 277 Vac Cutler Hammer Westinghouse Type QBGFEP 480 V VPL must u...

Page 27: ...eplaced Insulation Resistance Insulation Resistance IR testing is used to verify the integrity of the heating cable inner and outer jackets IR testing is analogous to pressure testing a pipe and detects if a hole exists in the jacket IR testing can also be used to isolate the damage to a single run of heating cable Fault location can be used to further locate damage Power check The heating cable p...

Page 28: ...ures such as valves pumps and pressure gauges that are likely to incur maintenance work Maintenance records The Installation and Inspection Record refer to Section 11 should be filled out during all maintenance and repair work and kept for future reference Repairs Use only RAYCHEM cable and components when replacing any damaged heating cable Replace the thermal insulation to original condition or ...

Page 29: ...e testing is recommended at five stages during the installation process and as part of regularly scheduled maintenance Before installing the cable Before installing components Before installing the thermal insulation After installing the thermal insulation Prior to initial start up commissioning As part of the regular system inspection After any maintenance or repair work Procedure Insulation resi...

Page 30: ...f discharge discharge phase connection to ground with a suitable grounding rod Disconnect the megohmmeter 11 Repeat this test between braid and pipe 12 Reconnect bus wires to terminal block 13 Reconnect the thermostat Important System checkout and regular maintenance procedures require that insulation resistance testing be performed from the distribution panel unless a control and monitoring syste...

Page 31: ...an installation where optimum conditions may not apply All insulation resistance values should be greater than 1000 megohms If the reading is lower consult Section 10 Troubleshooting Guide Important Insulation resistance values for Test A and B for any particular circuit should not vary more than 25 percent as a function of measuring voltage Greater variances may indicate a problem with your heat ...

Page 32: ...ctual ambient temperature is higher than the desired thermostat setting turn the thermostat setting up high enough to turn on the system or with some models manually set the selector switch to the ON position Turn on the main circuit breaker Turn on the branch circuit breakers After a minimum of ten minutes measure the voltage amperage ambient temperature and pipe temperature for each circuit and ...

Page 33: ...ons supplied with the product for commissioning tests and records 9 4 Fault Location Tests FAULT LOCATION There are three methods used for finding a fault within a section of heating cable the ratio method 1 R method and the capacitance method The capacitance method can also be used to determine total heating cable length RATIO TEST METHOD a To locate bus wire short The ratio method uses resistanc...

Page 34: ...along the circuit as measured from the front end A b To locate low resistance ground fault To locate a low resistance ground fault measure resistance between bus and braid A B A B A B Braid The approximate location of the fault expressed as a percentage of the heating cable length from the front end A is Fault location D A x 100 A B Example A 0 6 ohms B 0 9 ohms Fault location D 0 6 0 6 0 9 x 100 ...

Page 35: ...tion of pipe and many not trip the circuit breaker A B A B A B Braid Measure the bus to bus heating cable resistance from the front end measurement A and the back end measurement B of the suspect section The approximate location of the fault expressed as a percentage of the heating cable length from the front end A is Fault location D 1 A x 100 1 A 1 B Example A 100 ohms B 25 ohms Fault location D...

Page 36: ...acitance reading from one end of the heating cable The capacitance reading should be measured between both bus wires twisted together positive lead and the braid negative lead Multiply the measured capacitance with the heating cable s capacitance factor as listed in the following table EXAMPLE 20XTV2 CT Recorded capacitance 16 2 nF Capacitance factor 10 1 ft nF Fault location 16 2 x 10 1 nF 164 ft...

Page 37: ...TV1 CT T3 10 8 5BTV1 CR 7 5 5XTV2 CT T3 11 1 5BTV2 CT 10XTV1 CT T3 10 3 5BTV1 CR 10XTV2 CT T3 10 7 5BTV2 CT 15XTV1 CT T3 9 7 8BTV1 CR 5 5 15XTV2 CT T3 9 9 8BTV2 CT 20XTV1 CT T2 9 3 8BTV1 CR 20XTV2 CT T2 10 1 8BTV2 CT 5KTV1 CT 10 8 10BTV1 CR 5 5 5KTV2 CT 11 1 10BTV2 CT 8KTV1 CT 10 3 10BTV1 CR 8KTV2 CT 10 5 10BTV2 CT 15KTV1 CT 9 7 10QTVR1 CT 4 7 15KTV2 CT 9 9 10QTVR2 CT 20KTV1 CT 9 3 15QTVR2 CT 20KT...

Page 38: ...low IR reading Retest at ambient Reference tests Insulation Resista Symptom Probable Causes Corrective Action Circuit breaker trips Circuit breaker is undersized Start up at too low a temperature Connections and or splices are shorting out Recheck the desig Do not exceed the used Check to see with circuit breake improperly sized V and end seals for p Physical damage to heating cable is causing a d...

Page 39: ...ssary Insulation Resistance Test Visual Inspection Corrective Action ized mperature ces are Recheck the design for startup temperature and current loads Do not exceed the maximum circuit length for heating cable used Check to see if existing power wire sizing is compatible with circuit breaker Replace the circuit breaker if defective or improperly sized Visually inspect the power connections splic...

Page 40: ...obable Causes Corrective Action Low or no power output Low or no input voltage applied Repair the electri The circuit is shorter than the design shows due to splices or tees not being connected or the heating cable having been severed Check the routing drawings to refer Connect all splice heating cables T Improper component connec tion causing a high resistance connection Check for loose w Control...

Page 41: ...nected or the ng been severed Check the routing and length of heating cable use as built drawings to reference actual pipe layout Connect all splices or tees Locate and replace any damaged heating cables Then recheck thea power output ent connec h resistance Check for loose wiring connections and rewire if necessary t is wired in ition Rewire the thermostat in the normally closed position ted temp...

Page 42: ...ull length Damaged or wet thermal insulation damaged missing cracked lagging or weather proofing gaps in caulking Covered end seals splices and tees properly labeled on insulation cladding Control and Monitoring system checked for moisture corrosion set point switch operation capillary damage and protection Insulation resistance Megger test Ohms Ohms Test A 500 Vdc bus to braid 1000 Vdc 2500 Vdc T...

Page 43: ...nVent com 39 ion Record Commission e us ly Ohms Ohms Ohms Ohms Ohms ...

Page 44: ...ation damaged missing cracked lagging or weather proofing gaps in caulking Covered end seals splices and tees properly labeled on insulation cladding Control and Monitoring system checked for moisture corrosion set point switch operation capillary damage and protection Insulation resistance Megger test Ohms Ohms Test A 500 Vdc bus to braid 1000 Vdc 2500 Vdc Test B 500 Vdc braid to pipe 1000 Vdc 25...

Page 45: ...nVent com 41 ection Record Commission re rly r n Ohms Ohms Ohms Ohms Ohms ...

Page 46: ...__ Device trip level Installation instructions Correct components per manufacturer s specification ____________________________________ Seal fittings opened and inspected properly poured _____________________________________ Ground leakage device tested ____________________________________________________________ Insulation resistance testing Use 2500 Vcd for Self Regulating and Power Limiting cab...

Page 47: ... trip level _____________________________________________ ecification _______________________________________________________________________________ y poured ________________________________________________________________________________ ___________________________________________________________________________________________ er Limiting cables ___________________ Calibration date installed Te...

Page 48: ...ifications without notice Raychem IM H57274 SelfRegPowerLimitingHeatTracing EN 1805 nVent com North America Tel 1 800 545 6258 Fax 1 800 527 5703 thermal info nvent com Europe Middle East Africa Tel 32 16 213 511 Fax 32 16 213 604 thermal info nvent com Asia Pacific Tel 86 21 2412 1688 Fax 86 21 5426 3167 cn thermal info nvent com Latin America Tel 1 713 868 4800 Fax 1 713 868 2333 thermal info nv...