HEAT TRACING INSTALLATION AND TESTING

Preparatory Works for Heat Trace Installation

Ensure that work permit is prepared and secured. Safety concern and precautions are being complied and discuss with the crew.
Subcontractor shall appoint qualified employees as their ‘competent persons’. Such persons shall be capable of working safely and shall be knowledgeable on the precautionary techniques, personnel protective equipment for the installation of heat tracing.
Equipment, tools and other logistics shall be prepared and are ready for installation of heat tracing.
Material Handling prior to installation of heat tracing.
Identify the heating cable to ensure proper type and quantity is received.
Cable model number shall be visible on the parallel heating cables (on braided cables, information is printed on the jacket below the braid).
Visually Inspected material for damage incurred during shipment.

Work flow documents for heat tracing hand-over

Piping QC will handover released package to Electrical Team.
Mechanical QC will handover released package to Electrical Team.
After completion of electrical work Electrical QC will handover released package to Insulation.
After completion of electrical work Electrical QC will handover released package to Insulation.
Document handover with duly accomplished Work Transfer

Preparatory Works for Heat Trace Testing

Review appropriate supplier literature, design drawings and specifications before starting the job.
Compare heater cable, connection and end seal kits and all associated tracing components manufacturers and model number against drawing and specification.
Visually inspect heater cable for damage, correct installation at pipe shoes and other heat sinks.
Correct installation tape spacing, heater orientation on pipe and overall general construction installation.
Check the design heater length against the actual length (start and stop cable lengths may be printed on the heater).
Inspect end seals for proper sealing and installation.
Inspect connection kit for proper location sealing and installation.
Inspect RTD for correct type, securely taped to pipe at the right location, damage (such as field bending) and correct wiring.
Verify continuity of heater cable. This to be documented at receipt of material on reel, after the heater cable is installed and after insulation is installed.
Measure insulation resistance of each heater cable conductor. This is to be documented at receipt of material on reel, after the heater cable is installed and after insulation is installed.

Heat Tracing Installation Work Procedure

Prior to heat trace installation, verify material specification to be in conformance with the classification area requirements especially hazardous areas. This shall be included in the material receiving inspection procedure and to be included in the QC Material Receiving Inspection Report.
Explosion proof identification to the specific materials shall be verified stipulating certification (if any) depending on the intensive usage of the material according to the drawing and area classification.
Survey location of equipment, piping and instrument to be traced in reference to given drawing and details. Identify area classification to include hazardous area in accordance with EPC Latest Issued for Construction (IFC) drawings.
Installation of heat trace equipment, devices and junction boxes should consider possible clashing against nearby plant equipments, instruments, valves, pipes and flanges to be added.
Install necessary supports as per detail drawing. Ensure that the support is suitable to the heat trace device/material in consideration to the various environmental classification stated in the latest Issued for Construction (IFC)
Install necessary supports as per detail drawing. Ensure that the support is suitable to the heat trace device/material in consideration to the various environmental classification stated in the
Support shall be assembled with proper fittings mounted plumb, level and rigidly secured to the structure. No welding shall be executed in any process plant equipment such as vessels.
Fix all support including fabricated steel supports to which welded or cut portion of the support will be treated with zinc rich paint.
Install the heating cables as shown on the project as per vendors manual recommendation.
The elevation, level and vertical alignment of panels, junction boxes and devices shall be checked ensuring that it is securely and rigidly fixed in place.

Heating Cable Installation on Pipes

Unroll heater cable adjacent to the pipe to be traced, starting at the power connection of the circuit.
Attach cable at both ends of the circuit with approved pipe straps and work toward the middle.
If mounting junction boxes and other equipment onto pipes via brackets, install bracket on pipe before installing heating cable.
For removable valve bodies, leave loop of tracing of the proper length when tracing the pipe. Then trace the valve so that it can be serviced without cutting the heater cable.
Make a loop with the required cable length at each in-line components.
Piping branches whose length from the main pipe to the first valve is less than three times of the nominal pipe diameter of the main pipe should be traced through the branch valve with the main pipe tracer. Longer branches should be traced independently from the main pipe tracer.
Instrument lines and the associated instruments shall be traced in reference to the given approved drawings.
On vessels, tanks or large surfaces, the heating cable is worked onto the area to form a heating mat as detailed in the vendor recommended installation.
After installation following the complete drawing and details, clean the junction boxes, panel and other devices. Dust and dirt shall be removed using rags.
Terminate all wiring or cable connections according to the termination schedule installing all termination requirements including identification required with cable reference numbers, as noted in the cable schedule, clearly visible.
Double check all wiring and circuit connections for the panels/devices with respect to circuit diagram to avoid possible short-circuiting and damages.
Devices, junction boxes and equipment grounding shall be properly connected to grounding system as per AFC drawing.

SAFETY PRECAUTION DURING HEAT TRACING INSTALLATION

Obtain necessary work permits from the concerned EPC Representative intended for the job before starting any work.
Conduct proper preparation to include required safety equipment and tools for the commencement of the work.
Activities shall be executed in accordance with this procedure and related standards and specifications.
Provide warning sign and sufficient barricade on working area. Only assigned personnel will be allowed in the area to maintain a safe work environment.
Conduct safety briefing to all working crew to remind them of all the basic safety requirements on the job to ensure safe work flow.
All necessary personal protective equipment (PPE) shall be provided and to be worn at all times in accordance with site Safety Procedure.
Safety harness with double lanyards shall be used all the time when working at elevated temporary platforms 1.8 meters high and above.
Continuous monitoring and inspection shall be implemented by the Site Supervisor/Foreman together with the assigned Safety Engineer in the area. Any unsafe practices while performing the work activities shall be corrected immediately to avoid stoppage of the work.
Good housekeeping shall be maintained throughout the work activity. The work site shall be kept clean and safe.
Safety Engineer shall monitor the work activities to help and protect all assigned workers against exposure to safety hazards. He shall ensure that Personal Protective Equipments (PPE’s) are supplied and worn at all times.
Proper tools to be used for the activities should have been checked by Safety Officer, conformed to the designated electrical maintenance and tagged with monthly color code tape.

Industry Codes/Standard

IEEE Institute of Electrical and Electronic Engineers

TOOLS AND EQUIPMENT USED IN HEAT TRACING

Tools and equipment needed should be in good condition and must be checked by Supervisor / Safety Engineer prior to use in the construction area. These includes but not limited to:

Common Hand Tools
Volt-ohm meter
Clamp-on ammeter
Insulation tester
Thermometer
Torque Wrench
Flashlight
Screwdriver
Cleaning materials
Ladder
Electrical Hand Tools
Electrical Power Tools
Termination Tools