Raychem nvent HCC Installation, Maintenance And Operation Manual

Mineral insulated heating systems

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Mineral Insulated (MI)

series heating systems

INSTALLATION, MAINTENANCE AND

OPERATION MANUAL

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Summary of Contents for Raychem nvent HCC

Page 1 Mineral Insulated (MI) series heating systems INSTALLATION, MAINTENANCE AND OPERATION MANUAL...
Page 2 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 2 | nVent.com/RAYCHEM...
Page 3 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 MI heating cable End cap nVent.com/RAYCHEM | 3...
Page 4 GENERAL INFORMATION Use of the manual This Installation and Maintenance manual applies to nVent RAYCHEM 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 The joints can be either brazed or laser welded, refer to nVent RAYCHEM 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 personnel only.
Page 6 № ЕАЭС RU С-ВЕ.МЮ62.В.00879/19 ООО «ПРОММАШ ТЕСТ» Ambient temp range: -60°C...+70°C 1Ex e IIC T* Gb X Ex tb IIIC T* Db X *: by design Units made in Canada, Germany or Poland. Bulk cable made in Canada or Italy 6 | nVent.com/RAYCHEM...
Page 7 680°C Laser welded heating unit – – Temperatureclassification T6 – T3 T6 – T2 T6 – T1 Minimum cable spacing 25 mm Minimum installation temp. –60°C Minimum bending radius 6 x Cable Diameter Chemical resistance Medium Medium nVent.com/RAYCHEM | 7...
Page 8 The maximum cable power output is directly dependant on the application and control method used. The actual limits of MI heating cables in a specific application are given in Raychem Engineering Software us (e.g. TraceCalc Pro design software). For more details, please contact us.
Page 9 Walk the system and plan the routing of the heating cable on the pipe, including tracing of heat sinks. e.g. valves, flanges, supports, drains etc. Inspect piping for burrs, rough surfaces, sharp edges etc. which could damage the heating cable. Smooth off nVent.com/RAYCHEM | 9...
Page 10 Kinking and crushing Running over it with equipment. Pulling into a spiral Avoid pulling the cable by the flexible pig tail wires of the cold lead(s). The minimum bending radius of the heating cable must be respected. 10 | nVent.com/RAYCHEM...
Page 11 When installing MI and other constant wattage heating cables, ensure that they do not overlap or cross. Doing so may lead to local over-heating and hazard of fire. Figure 5 : Minimal spacing must be respected nVent.com/RAYCHEM | 11...
Page 12 This constraint may be difficult for small pipes and/or multiple cable runs. If required, contact nVent for assistance. 12 | nVent.com/RAYCHEM...
Page 13 On vertical pipe sections fix the heating cables equally distributed around the pipe circumference. Read the design documents, in particular concerning the need for cable allowances and regard the location of junction boxes/ controllers before permanently attaching the cable to the pipe. nVent.com/RAYCHEM | 13...
Page 14 Figure 7: Typical cable layout on large surfaces like tank walls Prepunched Heating cable strapping Banding Temperature sensor Temperature Cold Junction controller leads Figure 8: Fixing device: pre-punched metal strap Avoid sharp edges and properly seal penetration of MI cold lead cables through the insulation cladding. 14 | nVent.com/RAYCHEM...
Page 15 Figure 9: Uncoiling heating cable Figure 10: Attaching hot-cold joint and end cap nVent.com/RAYCHEM | 15 Stainless steel pipe strap, banding,...
Page 16 Tie wire / wire cloth band Tie wire / Note: Do not use up excess cable at one location. wire cloth band Distribute equally along pipe. 16 | nVent.com/RAYCHEM...
Page 17 Wave cables with a minimum spacing of 25 mm to 50 mm along pipe, unless design documentation clearly states other values. Note: Where several heating cables are required, a pre-punched metal strapping may aid the installation and consistent spacing of heating cables. nVent.com/RAYCHEM | 17...
Page 18 See design drawing See design drawing for speciﬁc heating for speciﬁc heating cable length needed. cable length needed. The minimum spacing must be respected, unless design documentation clearly states other values, also refer to page 11, figure 5. 18 | nVent.com/RAYCHEM...
Page 19 2. In hazardous areas, secure the cable to the pipe on either side of the flange using pipe straps. nVent.com/RAYCHEM | 19...
Page 20 The minimum spacing must be respected, unless design documentation clearly states other values, also refer to page 11, figure 5. Figure 21: Dummy supports Stainless steel pipe straps, banding, tie wire or wire cloth band Dummy leg Pipe shoe Insulation Heating cable 20 | nVent.com/RAYCHEM...
Page 21 Cover the heating cable with metal foil or equivalent before applying insulation to ensure the cables do not become trapped in the insulation. General note: Trace pipe fittings as shown to allow easy maintenance. An alternative is the use of metal wire mesh cages. nVent.com/RAYCHEM | 21...
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 nVent RAYCHEM design specification (e.g. TraceCalc Pro reports). 22 | nVent.com/RAYCHEM...
Page 23 INSTALLATION 4.1 General notes Use the Design Specification to select required components. nVent RAYCHEM components must be used to satisfy Standards and Approval Body requirements and the nVent 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 5.1 General rules nVent RAYCHEM 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;...
Page 25 Chimney effect on large size vertical pipes, best location: on the bottom. Accessibility for maintenance purposes, best location: at ground level. Impact of other heat sources, sun etc., best location: at cold side. For details please refer to the engineering documentation. nVent.com/RAYCHEM | 25...
Page 26 Impact of other heat sources, sun etc., best location: at hot side of pipe. It is the responsibility of the installer to ensure that these conditions are met in the most appropriate way. For more details please refer to the engineering documentation. 26 | nVent.com/RAYCHEM...
Page 27 Make sure, that under no circumstances any insulation material is being placed between heated surface and cable, thus disabling intended heat flow to the substrate, which may result in possible overheating of the cable. nVent.com/RAYCHEM | 27...
Page 28 Each MI heating unit is supplied with an identification tag with important details about the type and operation conditions of the unit. In hazardous areas, the cable tag is mandatory. The tag contains the area classification in addition to other relevant design information. 28 | nVent.com/RAYCHEM...
Page 29 “artificial hotspot”). The set point of the limiter must be below the T-class of the area and may require an additional down-adjustment for potential falsifying of the measured temperature, refer to the instructions given by the manufacturer of the limiter. nVent.com/RAYCHEM | 29...
Page 30 Note : If the output power is achieved by power modulation with an SSR control at high frequency (e.g. nVent RAYCHEM NGC-40 controller), it is indicated on the tag by adding ‘PWRCTL’ after the design method.
Page 31 For any heating circuits installed in hazardous areas a means of isolation from the supply is mandatory. 7.5 Circuit marking Make sure for all hazardous area installations, that system is properly marked with a heating cable tag. nVent.com/RAYCHEM | 31...
Page 32 8.3 Commissionning Verify all system documentation is complete as per “9.1 Documentation”. Record and retain all installation & post insulation test values as per the Installation record sheet in this document. 32 | nVent.com/RAYCHEM...
Page 33 (this data is usually part of the as-built documentation or the detailed calculation reports from design software such as TraceCalc Pro, TracerLynx,...). nVent.com/RAYCHEM | 33...
Page 34 L (live) and PE (earth). Functionality test of electrical and protective earth protection: Circuit breaker and residual current device should be tested at least once a year or according to manufacturer’s instructions. 34 | nVent.com/RAYCHEM...
Page 35 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 nVent. nVent.com/RAYCHEM | 35...
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Page 39 Circuit breaker undersized Defective circuit breaker Short circuit in electrical connections Excessive moisture in connection boxes Nicks or cuts in heating cable sheath, moisture present Kinked or crushed heating cable Defective RCD Excessive earth leackage current, RCD trips nVent.com/RAYCHEM | 39...
Page 40 Eliminate short circuit. Thoroughly dry connections Repair damaged section or replace heating cable Repair damaged section or replace heating cable Replace RCD Check insulation resistance. If within acceptable range, evaluate electrical design for compatibility with RCD used. 40 | nVent.com/RAYCHEM...
Page 41 1 Visually inspect the power connections, splices and 2 Look for signs of damage at: end seals for correct installation a) Valves, pumps, flanges and supports b) Areas where repairs or maintenance work has been carried out recently nVent.com/RAYCHEM | 41...
Page 42 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 nVent for further assistance 42 | nVent.com/RAYCHEM...
Page 43 | 43...
Page 44 Fax 0800 0224993 salesthermaluk@nVent.com salesnl@nVent.com nVent.com/RAYCHEM ©2020 nVent. All nVent marks and logos are owned or licensed by nVent Services GmbH or its affiliates. All other trademarks are the property of their respective owners. nVent reserves the right to change specifications without notice.

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