Related Manuals for Pentair Mi Series
Summary of Contents for Pentair Mi Series
- Page 1 Installation, Maintenance and Operation Manual Mineral insulated (Mi) series Heating systeMs Thermal managemenT EN-PyrotenaxMI-IM-DOC586 R4...
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Page 2: Table Of Contents
General information Heating cable selection and storage Heating cable installation Components selection and installation Temperature control and limitation Thermal insulation and marking Power supply and electrical protection System testing Operation, maintenance and repairs Trouble Shooting Installation Record Sheet... - Page 3 Typical configuration for mi-heating cable system (single conductor) Junction box Circuit identification tag MI cold lead cable (single conductor) Hot/cold joint Loop of MI heating cable (single conductor) Typical configuration for mi-heating cable system (dual conductor) Junction box Circuit identification tag MI cold lead cable (dual conductor) Hot/cold joint Dual conductor...
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Page 4: General Information
This Installation and Maintenance manual applies to Pentair Thermal Management Mineral Insulated (MI) series resistance heating cable systems installed on thermally insulated pipes and vessels and associated equipment. In particular it refers to mineral insulated (MI) series heating systems, which feature a specific power output depending on various design parameters, in particular, cable length and voltage. - Page 5 Heating cable length Flexible tail length The joints can be either brazed or laser welded, refer to Pentair Thermal Management product literature for more detailed information. please note that this manual only covers the installation of pre- fabricated mi heating units. The complete termination process and repair of heating cable units is not covered by this manual and must be carried out by qualified and experienced personal only.
- Page 6 II 2 G EEx e II T6 to T1 hCC/hCh/ hDC/hDf/hsQ/hax/hiQ (bulk cable) Baseefa 02ATEX0045U II 2 G EEx e II T6 to T1 For other national approvals please contact Pentair Thermal Management. The order reference of mi heating units uses the following nomenclature b/hsQ1m1000/43.0m/1217/230/2.0m/sC1h2.5/X/m20/eX...
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Page 7: Heating Cable Selection And Storage
High The hot-cold junction used in a heating unit may lead to temperature limits below the limit of the heating cable. Contact Pentair Thermal Management if the exposure temperature exceed values given in the tables above for more detailed instructions how the unit can be installed under those circumstances. - Page 8 For the evaluation of the chemical resistance of MI heating cables (for corrosion aspects), refer to our product datasheets or contact Pentair Thermal Management for assistance. Check the design specification to make sure the correct heating cable is installed on each pipe or vessel.
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Page 9: Heating Cable Installation
heaTing Cable insTallaTion Warning as with any electrical equipment or wiring installation that operates at line voltages, damage to heating cable and components, or incorrect installation that allows the penetration of moisture or contamination can lead to electrical tracking, arcing and potential fire hazard. in case of damage and later repair on site any unconnected heating cable end, exposed to the environment, must be sealed appropriately. - Page 10 Inspect piping for burrs, rough surfaces, sharp edges etc. which could damage the heating cable. Smooth off or cover with layers of aluminium foil. At elevated sheath temperatures consider the use of stainless steel foil. (e.g. HSQ; HIQ or HAx). Surface areas where heat-tracing is to be installed must be reasonably clean.
- Page 11 figure 4 : minimum bending radius of mi heating cables 6 x ∆ Cable ∆ > 6 mm Do not repeatedly bend and straighten the cable. Keep heating cable strung loosely but close to the pipe being traced, to avoid interference with supports and other equipment. add additional heating cable to trace the fittings and supports as required by the design specification or engineering documents.
- Page 12 This constraint may be difficult for small pipes and/or multiple cable runs. If required, contact Pentair Thermal Management for assistance. The field variance is important to accomodate expansion and contraction of the heated equipment.
- Page 13 3.3 heating cable attachment Fix in place with metal bandings, tie wire or wire cloth band at a typical interval of 300 mm and additionally where necessary. The use of tie wire with softer sheath MI heating cables (like copper HC and cupro-nickel HD) should be avoided, as the tie wire can damage the heating cable surface over time.
- Page 14 Verify if the design documentation requires that the heating cables have to be covered by aluminium or stainless steel foil before the insulation is applied. Installation on tanks typically requires additional fixing devices as pre-punched steel strips as shown below: figure 7: Typical cable layout on large surfaces like tank walls Prepunched Heating cable...
- Page 15 3.4 attachment materials Stainless steel pipe straps for different pipe dimensions up to 36 “ (e.g. PB 300). Stainless steel banding (30 m roll) together with stainless steel buckles (one per fixing) (e.g. SNLS + SNLK). Tie wire (e.g. RMI-TW) is especially suitable for the fixation on irregular shapes like pumps, valves etc..
- Page 16 Attach hot-cold joint to end of pipe nearest the power supply point, and the other end of heating cable to the other end of the pipe. Support hot-cold joint by attaching cable with pipe straps/ banding at a distance of 6 inches (150 mm) on either side of joint.
- Page 17 figure 13: Completed mi heating cable installation Hot-cold joint Tie wire / wire cloth band figure 14: pipe strap spacing Junction box Cold Hot-cold Stainless steel pipe straps, banding, lead joint or tie wire, wire cloth band, etc... 150 mm Insulation app.
- Page 18 figure 16a: Valves for valve sizes 3 “ (90 mm) or smaller Stainless steel pipe straps, banding, tie wire or wire cloth band Stainless steel pipe straps, banding, tie wire or wire cloth band Pipe Valve body Valve body Pipe Apply tie wire, wire cloth Apply tie wire,...
- Page 19 figure 17: installation at 90° elbow Steel pipe Stainless steel pipe straps, banding, tie wire or wire cloth band(typical) MI heating cable MI heating cable is applied to outside radius of elbow. figure 18: flanges Stainless steel pipe straps, banding, tie wire or wire cloth band Flange Apply tie wire or wire...
- Page 20 figure 19: Cable layout over clamps and straps figure 20 : shoe and sleeve type support See design drawings for specific heating cable length needed. MI heating cable Pipe Stainless steel pipe straps, banding, tie wire or wire cloth band (typical) The minimum spacing must be respected, unless design documentation clearly states other values, also refer to page 11, figure 5.
- Page 21 The minimum spacing must be respected, unless design documentation clearly states other values, also refer to page 11, figure 5. Check drawings for dummy leg insulation. Pumps should have their own heating cable, separate from the connection box. figure 22: pumps Junction box Stainless steel pipe straps, (series connect)
- Page 22 In such cases sufficient cable should be added to at least enable removal of instruments, valves etc (“maintenance loop”). For further details on individual allowances please refer to Pentair Thermal Management design specification (e.g. TraceCalc Pro reports).
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Page 23: Components Selection And Installation
ComponenTs seleCTion anD insTallaTion 4.1 general notes Use the Design Specification to select required components. Pentair Thermal Management components must be used to satisfy Standards and Approval Body requirements and the Pentair Thermal Management warranty to apply. 4.2 Component installation hints On horizontal pipes locate junction boxes below pipe where ever possible. -
Page 24: Temperature Control And Limitation
TemperaTure ConTrol anD limiTaTion 5.1 general rules Pentair Thermal Management MI series heating cables are constant power output heaters and as such typically require temperature control, unless otherwise explicitly specified. Good practice and local regulations may require additionally independent temperature limitation devices; The selection of such devices also depends on environmental conditions (non-haz or haz area). - Page 25 The setpoint might need to be adjusted accordingly. Contact pentair Thermal management or the supplier of the limitation device in order to obtain detailed information concerning offsetting of limitation devices.
- Page 26 5.3 sensor placement: Temperature limiter device Typically the sensor is being placed on a length of cable, that is separated from the pipe by means of insulating material, in order to create an “artificial hotspot”. The choice of the right location for the limiter sensor depends on, but is not limited to following aspects: Flow direction of the fluid, best location: upstream in case of warmer inrushing fluid.
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Page 27: Thermal Insulation And Marking
Verify that the max. sheath temperature of the heating cable is compatible with the insulations materials to be used. Contact your Pentair Thermal Management representative if you have any questions. Check that all pipes, including fittings, wall penetrations and other areas are completely insulated. - Page 28 Good practice requires wrapping of the installed heating system with an appropriate metal foil prior to installation of the thermal insulation. This is especially so at places where intimate contact between heat-tracing cable and heated surface is not possible, such as valves or flanges where a suitable heat sink of temperature rated metal foil and wire cloth band may be used to improve heat-transfer.
- Page 29 figure 24: Typical mi identification tag (for use in hazardous areas) 1180 MI Unit Reference: B/HSQ1M1000/43M/1187/230/2M/SC1H2.5/X/M20/EX Heating Cable Ref.: HSQ1M1000 Element Length: 43 m Year of Manufacture: 2006 Circuit Length (if different): Grade: (high) Design Temperature Class: T1 Zone1 Design Method: Limiter-Lockout Maximum Withstand Temperature: 450°C Max.
- Page 30 – maximum Withstand Temperature is the max. withstand temperature of the heating cable and the hot-cold joint used, it may also be limited by the hazardous area approval – max. sheath Temperature is the max. sheath temperature of the MI heating cable based on the application design data –...
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Page 31: Power Supply And Electrical Protection
7.3 residual current (earth fault) protection Pentair Thermal Management requires the use of a 30mA residual current device to provide maximum safety and protection. When design results in a higher leakage current, a maximum 300mA RCD may be used. -
Page 32: System Testing
(hot work permit). 8.1 Testing of insulation resistance and conductor resistance Pentair Thermal Management recommends insulation resistance test before installing heating cable, while the cable is still on the reel before installing thermal insulation prior to initial start-up/ after completion of thermal insulation as part of the periodic maintenance (see Section 9.2). -
Page 33: Operation, Maintenance And Repairs
operaTion, mainTenanCe anD repairs Warning: heating cables are capable of reaching high temperatures during operation and can cause burns when touched. avoid contact when cables are powered. Thermally insulate the traced pipe or equipment before energizing the cable. use only properly trained personnel. -
Page 34: Trouble Shooting
It should be carefully evaluated, whether the severity of the damage allows on-site repair or whether the entire heating cable needs to be replaced. Also refer to the Troubleshooting guide on the following pages. If the problem persists after following the guidelines, contact Pentair Thermal Management. - Page 38 sYmpTom anD probable Causes symptom: Insulation resistance less than expected probable Causes Rainy or high humidity Nicks or cuts in heating cable sheath, with moisture present Kinked or crushed heating cable. Arcing created by damage to the heating cable. Physical damage to heating cable is causing a direct short.
- Page 39 Corrective actions Dry tails and face of seal 2, 3, 4 Visually inspect cable for damage, especially at elbows, flanges, and around valves. If damaged, repair or replace heating cable. Inspect power connection box for moisture or signs or tracking. Dry out connections and retest.
- Page 40 symptom: Power output appears correct but pipe temperature probable Causes Wet or missing insulation with proper weather-proofing Insufficient heating cable on valves, maintain temperature at flanges, supports, pumps, and other heat sinks Temperature controller set incorrectly Improper thermal design used Temperature sensor in wrong location Low fluid temperature entering pipe symptom:...
- Page 41 Verify voltage and connect to proper voltage if necessary Look for crushed or damaged insulation and cladding along the pipe If after 1, 2 and 3 above the fault has not been located, then consult Pentair Thermal Management for further assistance...
- Page 44 Tel. 0800 0224978 Fax 0800 0224993 salesnl@pentair.com www.Pentairthermal.com All Pentair trademarks and logos are owned by Pentair or its global affiliates. Pentair reserves the right to change specifications without prior notice. © 2013 Pentair All Rights Reserved. Thermal managemenT EN-PyrotenaxMI-IM-DOC586 R4...