TECHNICAL SPECIFICATION

ELECTRIC HEAT TRACING

E89-2E

DATE: 04 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 1 OF 8

TABLE OF CONTENTS

Section Title Page No.

1. GENERAL ......................................................................................................................................1
1.1 Scope..............................................................................................................................................1
1.2 KBR Documents, Codes, and Industry Standards .........................................................................2
1.3 Quotations.......................................................................................................................................2
1.4 Supplier Drawings and Data ...........................................................................................................2
2. TECHNICAL REQUIREMENTS .....................................................................................................3
2.1 General ...........................................................................................................................................3
2.2 Heater Types ..................................................................................................................................3
2.3 Application ......................................................................................................................................4
3. TEMPERATURE CONTROL AND POWER DISTRIBUTION .......................................................5
3.1 Ambient Sensing.............................................................................................................................5
3.2 Pipe Sensing...................................................................................................................................5
3.3 Microprocessor-Based Controls .....................................................................................................5
3.4 Power Distribution...........................................................................................................................5
4. INSTALLATION PROCEDURES ...................................................................................................5
4.1 General ...........................................................................................................................................5
4.2 Piping ..............................................................................................................................................6
4.3 Tanks and Vessels .........................................................................................................................6
4.4 Instrumentation ...............................................................................................................................7
5. TESTING ........................................................................................................................................7
5.1 Factory Testing ...............................................................................................................................7
5.2 Field Testing ...................................................................................................................................7
6. NAMEPLATES ...............................................................................................................................7
6.1 General ...........................................................................................................................................7
7. TAGGING AND SHIPMENT...........................................................................................................8
7.1 Tagging ...........................................................................................................................................8
7.2 Packing and Crating .......................................................................................................................8

1. GENERAL

1.1 Scope

1.1.1 This specification, KBR Purchasing Standard E2-1PS, and applicable data sheets cover the requirements
for the design, fabrication, testing, shipping, and optional installation of a complete heat tracing system.

1.1.2 The heat tracing system components provided by Supplier shall include power transformers, electric
freeze protection control panels, process heat trace control panels, electric heating cables, temperature
sensors, temperature controllers, contactors, circuit breakers, enclosures, and all necessary auxiliary equipment
and controls.

1.1.3 If design dictates the necessity for prototype equipment which has not been in service for at least two
years, the Supplier shall provide adequate documentation describing the particular components affected and the
extent of experience with such parts. The Supplier must receive approval from Purchaser prior to use of this
equipment.

1.1.4 All components and material shall be of the latest field-proven design and in current production. Obsolete
components or components scheduled for immediate discontinuation shall not be used.

1.1.5 The equipment shall be designed for use in atmospheres made corrosive by traces of chemicals often
found in petrochemical plants and by environmental conditions such as high humidity, insects, rodents, etc.
which may exist at plant sites.
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ELECTRIC HEAT TRACING

E89-2E

DATE: 04 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 2 OF 8

1.1.6 Ambient conditions for a specific plant site location are as shown in the Project Design Data.

1.2 KBR Documents, Codes, and Industry Standards

1.2.1 Unless specifically indicated otherwise herein or approved otherwise by the engineer, equipment shall be
manufactured in accordance with applicable requirements, as determined/clarified by the engineer, of the latest
editions (as of the date of the Order, or as specified herein) of the following Codes and Standards. The KBR
documents listed below and referenced herein form an integral part of this specification. The issue dates of
these documents shall be as specified on the Requisition.

KBR DOCUMENTS
E2-1PS, "Purchasing Requirements for Electrical Equipment and Component"
SDR-1E, "Supplier Drawing and Data Requirements for Electrical Equipment"

CODES AND INDUSTRY STANDARDS

ANSI - American National Standards Institute
IEEE - Institute of Electrical and Electronics Engineers
NEMA - National Electrical Manufacturers Association
NFPA - National Fire Protection Association (e.g. NFPA 70, "National Electrical Code")

1.2.2 The heat tracing equipment, including materials, fittings, devices, apparatus, and the like shall be
approved by and bear the label of either the Underwriters' Laboratories (UL) or Factory Mutual (FM) for
application in the specified service conditions and area classification. Where no such UL or FM approval exists,
the Seller shall produce documentation that the equipment will meet the required service conditions.

1.3 Quotations

1.3.1 In addition to quotation requirements in E2-1PS, the Supplier shall also furnish the specified number of
copies of the following documents with the proposal:

a. Outline drawings of thermostats and power distribution equipment.

b. Complete list of electrical components, devices, and accessories. (Note: Thermal and electrical limitations
of heat tracing cable shall be clearly identified.)

c. Description of operation of the heater controls and safety factors used to arrive at heater sizes.

d. Descriptive bulletins including installation details.

e. Recommended spare parts.

1.3.2 The Supplier shall provide a separate quotation for installation, field supervision, and testing. The
quotation shall also include unit cost for common parts.

1.3.3 Unless otherwise stated, all units shall be in the U.S Customary System (English).

1.4 Supplier Drawings and Data

1.4.1 The Supplier shall submit drawings and data of the type and quantity specified in KBR Purchasing
Standard SDR-1E. Supplier drawings will identify all the major components with KBR item numbers in
accordance with Section 7.

1.4.2 The title blocks on all Supplier drawings shall contain information as outlined in KBR Purchasing Standard
SDR-1E.
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ELECTRIC HEAT TRACING

E89-2E

DATE: 04 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 3 OF 8

1.4.3 Drawings shall contain certified factory information on:

a. Isometric drawings showing each pipe with its electric heat tracing including line number, heater number,
heater voltage, heater operating power, heater start-up current, location of power supply point(s), location of
control sensing element, all equipment in line, all instrumentation in line, and a bill of materials for all
required electric heating cables and accessories.

b. Wiring diagrams showing the connection of all electric heating cables to their power supply points. All
thermostats and associated power distribution equipment supplied with the electric heating system shall be
included.

c. One-line diagram drawings showing electric heat tracing transformers, contactors, and power distribution
panels.

2. TECHNICAL REQUIREMENTS

2.1 General

2.1.1 The electric heat tracing system shall be designed for a life expectancy of 10 years or more.

2.1.2 The design of the electric heating system shall be based on the following information supplied by the
Purchaser with the Requisition:

a. lists of piping lines, equipment, and instrumentation to be heat traced.

b. insulation thickness, size and type for each.

c. temperature to be maintained for each.

d. maximum exposed temperature for each.

e. minimum ambient temperature.

f. available voltage.

g. area classification drawings

h. piping isometric drawings.

i. plan drawings.

k. process media data.

l. instrument installation details.

2.2 Heater Types

2.2.1 Self-limiting or self-regulating heating cables shall consist of two stranded copper wires separated by a
self-regulating, semi-conductive core, and an overall corrosion resistant jacket. The heating cables may be
covered with a tinned copper braid or nickel plated copper braid for grounding and increased durability. The
temperature limitation shall be as specified in Table I.

2.2.2 Parallel resistance or constant wattage heating cables shall consist of two stranded copper wires
separated by an insulator, on which constant wattage heating elements are mounted or wrapped, and covered
with an overall corrosion resistant jacket. The heating cable may be covered with stainless steel or copper braid
for grounding and for increased durability. The temperature limitation shall be as specified in Table I.
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ELECTRIC HEAT TRACING

E89-2E

DATE: 04 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 4 OF 8

2.2.3 Series resistance heating cables shall be constructed of one, two, or three conductors separated by an
insulator and covered with an overall corrosion resistant jacket. The temperature limitation shall be as specified
in Table I.

2.2.4 Mineral insulated heating cables shall be constructed of one or two conductor heating elements with a
mineral oxide insulation and a metal sheath selected to meet corrosion resistance requirements such as copper,
stainless steel, or special alloy. The temperature limitation shall be as specified in Table I.

2.2.5 Flexible blanket type heaters may be utilized on tanks and vessels. Heater blankets shall have
wire-wound resistance wires vulcanized between two layers of fiberglass reinforced silicone rubber and shall
operate at 120 or 240 volts. Heater output shall not exceed 5 watts per square inch.

TABLE I

DESIRED CABLE APPLICATION

Application Type Max. Exposure Max.

Cable Type Temp (30 minutes) Maintenance
Temp. ºF (ºC) Temp ºF (ºC)
Freeze Heatup
Manta.
Self-limiting
X X 185 (85) 150 (66)
Self-limiting
High Temp. X X X 375 (191) 250 (121)
Parallel
Resistance X X X 400 (204) 150 (66)
Parallel
Resistance X X X 545 (285) 400 (204)
High Temp.
Series Resistance X X X 400 (204) 150 (66)
MI Copper X X 482 (250) 300 (149)
X
MI (Other) X X 1100 (593) 800 (427)

2.3 Application

2.3.1 Freeze protection - Electric heating cable shall be used for piping, valves, equipment, instruments, and
instrument tubing to prevent water freezing when ambient temperature drops below 32°F (0°C). The heater
circuits shall be controlled by an ambient sensing thermostat set to turn on the heater circuit when the ambient
temperature is below 40°F (4.4°C). Safety showers and eye wash stations shall have an over temperature line
sensing thermostat to turn off the heater circuit when the temperature is above 80°F (27°C).

2.3.2 Process temperature maintenance - Electric heating cable shall be used for piping, valves, equipment,
instruments, and instrument tubing to maintain process fluid at a predetermined temperature. The electric heat
tracing Supplier shall be responsible for providing individual thermostat controls for each independent flow path
in the piping system. When two or more pipes join to form optional flow paths, a separate controller shall be
used for the electric heater on each pipe.

2.3.3 Heat up systems - Electric heating cable shall be used when it is necessary to heat piping, valves,
equipment, instruments, and instrument tubing and the process fluid therein from a low temperature to a higher
temperature. Pipe temperature sensing devices shall be used to control the electric heating cables.
 TECHNICAL SPECIFICATION

ELECTRIC HEAT TRACING

E89-2E

DATE: 04 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 5 OF 8

3. TEMPERATURE CONTROL AND POWER DISTRIBUTION

3.1 Ambient Sensing

Electric heat tracing for freeze protection shall utilize an ambient sensing thermostat. Back-up thermostats shall
be provided whenever it is possible for heat tracing circuit surface temperatures to exceed 80% of the ignition
temperature of the gas group governing the point of location. The thermostat will energize a contactor that will
then energize a distribution panel fed from a transformer. All equipment except for the main circuit breakers in
the Purchasers MCC shall be supplied by the electric heat tracing Supplier.

3.2 Pipe Sensing

Electric heat tracing system for temperature maintenance shall utilize temperature sensing devices for each
individual heater circuit. The temperature sensing devices shall energize the heater circuit upon sensing that
the pipe temperature has dropped below the process temperature to be maintained. Protection against over
temperature shall be provided.

3.3 Microprocessor-Based Controls

3.3.1 Electric heat tracing systems for temperature maintenance or freeze protection may utilize one or more
programmable microprocessor-based controller with digital display for control and alarm of heater circuits.

3.3.2 Controller(s) shall be capable of being programmed with independent on/off setpoints and independent
high/low alarm setpoints for each heater circuit. Controller(s) shall have a nonvolatile setpoint memory for
protection against loss of power. Input voltage shall be 120/240 VAC with an output switching capability of 10
amps at 120/240 VAC. In the event that a heater circuit exceeds the 10 ampere rating of the controller(s), a
contactor of sufficient rating shall be used in conjunction with the controller(s).

3.3.3 Temperature monitoring input to the controller(s) shall be from a pipe mounted, RTD sensor for each
heater circuit. Controller(s) shall be capable of sensing and indicating a broken or short-circuited RTD sensor.

3.3.4 Controller(s) shall have a test mode to test alarm circuits and to put all heaters controlled to an "ON"
condition for reading voltage and current.

3.3.5 The controller(s) shall have a lockout feature to prevent tampering once setpoints have been set and the
heat tracing system has been commissioned.

3.4 Power Distribution

3.4.1 The electric heat tracing Supplier shall be responsible for supplying and determining the required number,
location, and enclosures of distribution panels, contactors, and transformers for the electric heat tracing system.

3.4.2 The distribution panelboards shall be equipped with 30 mA GFI type circuit breakers and shall have at
least 15% spare breakers.

3.4.3 The Purchaser will provide a 480 Volt, 3-Phase feeder from a circuit breaker located in the MCC.

4. INSTALLATION PROCEDURES

4.1 General

4.1.1 Heating cable shall not be installed on any pipe, equipment, or instrumentation until hydrostatic testing
and painting is completed.

4.1.2 Heating cables shall not be installed spiraled, or on the top of pipe or in similar locations subject to
mechanical damage, such as that which could be caused by walking on the pipe.
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ELECTRIC HEAT TRACING

E89-2E

DATE: 04 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 6 OF 8

4.1.3 Cable power leads, thermostat capillaries, and conduits shall exit the thermal insulation below the
horizontal to minimize water intrusion under the insulation.

4.1.4 The heating cable shall not cross, touch or overlap itself, except for self-limiting cables designed for such
installations.

4.1.5 Additional heating cables shall be allocated for valves, flanges, pumps, strainers, and other in-line
equipment. The design shall also consider the need for additional heat to compensate for additional heat loss at
pipe hangers, supports, and equipment foundations.

4.1.6 Heating cables shall be installed to allow removal of in-line equipment without cutting the cables.

4.1.7 Other specific manufacturer installation procedures shall be closely adhered to.

4.2 Piping

4.2.1 Installation of the heater cable should begin at the power supply end and proceed toward the end point.

4.2.2 Self limiting and parallel resistance type heater cables shall be attached to the traced pipe by means of
aluminum or fiberglass tape.

4.2.3 The tape shall completely cover the heater cable, installed parallel over the straight pipe runs, valves,
instruments, etc. upon which the heater cable has been installed.

4.2.4 Circumferential bands of polyester tape may be used to hold the heater cable in place until the permanent
aluminum or fiberglass tape is applied.

4.2.5 Mineral insulated heater shall be attached to the pipe by means of stainless steel bands or tie wires.

4.2.6 Stainless steel tie wire shall be used to hold the mineral insulated heater cable in close contact with
valves and other irregularly shaped equipment.

4.2.7 Mineral insulated heaters shall not be field spliced except as approved by the electric heat tracing
Supplier.

4.3 Tanks and Vessels

4.3.1 All types of electric heating cable or blanket type heaters shall be applied to the wetted portion of the
traced tank or vessel. The heating elements should not extend above the normal operating liquid level.

4.3.2 The heater element shall be attached to the tank or vessel in accordance with the manufacturer's
recommended methods.

4.3.3 The electric heat tracing Supplier shall design the heater circuit such that it operates within safe
temperature limits of both itself and the material of construction of the tank or vessel.

4.3.4 A control thermostat shall be provided and have it's sensing bulb located near the lowest point of the
heating element. A high temperature alarm thermostat shall be also provided and it's sensing bulb located near
the highest point of the heating element.
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ELECTRIC HEAT TRACING

E89-2E

DATE: 04 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 7 OF 8

4.4 Instrumentation

4.4.1 In-line instrumentation shall be electric heat traced with the heater cable from the piping, which the
instrument services. Installation of the heater cable shall be in accordance with the electric heat tracing
Supplier's recommendations.

4.4.2 Off-line instrumentation shall be electric heat traced with the separate heater cable from the piping, which
the instrument services.

4.4.3 Pre-insulated and electric heat traced instrument tubing shall be used where ever possible. Tubing shall
be installed with either self limiting or parallel resistance heater cable. Heater cable and tubing shall be
wrapped together with a reflective foil. Insulation shall be covered with a PVC weatherproof jacket. Exposed
ends of the insulation shall be weatherproofed with boots or by applying silicone sealant covering the insulation
entirely.

4.4.4 The electric heat tracing Supplier shall be responsible for supplying electric power to the instrumentation
heat traced boxes supplied with instruments.

5. TESTING

5.1 Factory Testing

Upon request, the manufacturer shall provide the results of testing performed on all heat tracing cables and
equipment prior to shipment.

5.2 Field Testing

5.2.1 Heaters shall be visually inspected for damage and shall be megger tested with a 500 volt megger.
Heaters shall have a minimum conductor-to-sheath resistance of 20 megohms when tested at the following
stages of installation:

a. Before installation.

b. After installation, but before thermal insulation is installed.

c. After thermal insulation and weather barrier have been installed.

5.2.2 Heater cables shall be power tested, during which both the applied voltage and resulting current shall be
measured and recorded. Heating cables shall be power tested at the following stages of installation:

a. After the heating cable is installed on the piping and equipment, but before thermal insulation is applied.

b. After the thermal insulation and weather barrier is installed.

5.2.3 The results of each test outlined above shall be recorded for each individual circuit and retained with the
basic design drawings.

5.2.4 The proper operation of all control thermostats or control/monitoring systems shall be verified and noted.

6. NAMEPLATES

6.1 General

Phenolic nameplates shall be placed on all distribution contactors and panelboards. Nameplates shall be white
with black letters. Nameplates shall be attached with stainless steel screws. Adhesive backed nameplates are
not acceptable.
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ELECTRIC HEAT TRACING

E89-2E

DATE: 04 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 8 OF 8

7. TAGGING AND SHIPMENT

7.1 Tagging

Each assembly, sub-assembly, component, or item shipped loose shall be tagged. Tags shall include the
following information:

a. Part number.

b. Circuit number.

c. Heater voltage and wattage.

7.2 Packing and Crating

7.2.1 Unless otherwise specified in the Order, preparation for shipment shall be in accordance with the
manufacturer's standard practices, which assure adequate protection against breakage, moisture, pilfering, and
tampering during transportation, handling, and storage.

7.2.2 All materials shall be packaged and crated with adequate protection to permit outside storage at the
jobsite. The manufacturer shall indicate his recommendations for on-site storage and handling.