Preventing Winter Shutdowns: How Freeze Protection Ensures Continuous Industrial Operations

As winter's icy grip tightens, industries brace for the chilling effects of plummeting temperatures. One of the most significant challenges they face is the risk of operational shutdowns due to freezing conditions. In this scenario, freeze protection becomes a cornerstone for ensuring continuous industrial operations. Freeze protection is critical in preventing winter shutdowns and maintaining industrial productivity.

The first layer of defense against the cold is understanding the risk. Many industrial processes involve fluids – water, chemicals, oils – that can freeze at low temperatures. When these fluids freeze, they can expand, causing pipes and containers to burst or crack, leading to equipment failures, safety hazards, and costly repairs. The consequences aren't just physical; they can significantly impact production schedules, leading to financial losses and compromised client relationships.

This is where heat tracing systems come into play. Heat tracing, an essential component of freeze protection, involves applying heating elements alongside pipes, valves, tanks, and other critical components. These systems maintain a constant temperature, preventing the contents from freezing. Modern heat tracing solutions are sophisticated, with self-regulating capabilities that adjust the heat output based on the surrounding temperature. This ensures energy efficiency while providing reliable freeze protection.

Beyond heating elements, insulation is another vital aspect of freeze protection. Insulating pipes and tanks reduce heat loss, allowing heating systems to work more effectively and efficiently. The suitable insulation materials, combined with expert installation, can significantly reduce the risk of freezing.

Automation and monitoring technologies have also revolutionized freeze protection. With real-time monitoring systems, industries can remotely track the temperatures of their equipment and receive instant alerts if temperatures approach dangerous levels. This proactive approach allows for quick responses, minimizing the risk of a freeze-induced shutdown.

The implementation of freeze protection strategies must be a tailored process. Each industry and facility has unique needs based on its location, the nature of the materials handled, and the specific equipment used. A comprehensive risk assessment is crucial to identify vulnerable areas and design a freeze protection system that addresses these risks effectively.

Training and preparedness are equally important. Employees should be trained in the proper operation of freeze protection systems and emergency response procedures should a system failure occur. This training ensures that issues are addressed swiftly and effectively, minimizing downtime.

Industries must also consider the environmental impact of their freeze protection strategies. Eco-friendly antifreeze solutions, energy-efficient heat tracing systems, and sustainable insulation materials are increasingly available, allowing industries to protect their operations from the cold while being mindful of their environmental footprint.

In conclusion, as the cold season approaches, the importance of freeze protection in industrial settings cannot be overstated. It is a multifaceted approach involving heat tracing, insulation, monitoring, tailored solutions, training, and environmental consideration. By adopting these strategies, industries can safeguard against winter shutdowns, ensuring their operations run smoothly and continuously, regardless of the outside temperature. This proactive approach protects equipment and investments and secures the industry's reputation as a reliable and resilient player in the market.

Ives Equipment Corp., a leader in industrial solutions, is proud to offer an extensive range of Nelson Heat Trace products, renowned for their reliability and efficiency in freeze protection and process temperature maintenance. Our dedicated team specializes in these cutting-edge systems' sales, design, and comprehensive support, ensuring your industrial operations remain uninterrupted, even in the harshest winter conditions. With our in-depth expertise, we provide tailored solutions that align perfectly with your unique requirements. Partnering with Ives Equipment Corp. means gaining access to top-tier heat tracing technology backed by a commitment to exceptional customer service and technical support. Trust us to keep your operations running smoothly, regardless of the weather.

610-768-1600
https://ivesequipment.com

Nelson Heat Trace Design Suite by Emerson: Online Software Used to Develop Bills of Materials and Detailed Design Documents

Nelson Heat Trace Design Suite is an interactive website that enhances client productivity by simplifying and speeding up the specification of Nelson's products. Thanks to this solution, customers may use Nelson heating cables to swiftly create and install a broad range of systems. It is a web-based utility accessible 24 hours a day, seven days a week from any Internet-connected desktop or mobile device and used to develop bills of materials and detailed heat trace designs.

Nelson Design Suite began with Nelson Heat Trace Designer and has since expanded to include commercial applications such as Nelson Snow Melt, Roof and Gutter Deicing, Floor Warming, Frost Heave, and Hot Water Maintenance. 

An individual user or a workgroup submits project information and the data for ongoing and finished projects. The data are readily shared, minimizing needless duplication of labor. Importing project information from customer-generated spreadsheets and database files is also available, resulting in a more straightforward design process. 

Nelson Design Suite runs from Emerson's secure network, and access to the password-protected site requires email verification.

Ives Equipment will collaborate with customers to design their systems or provide onsite training on how to use the program and offer engineered isometric installation drawings.

Ives Equipment.
610-768-1600
https://ivesequipment.com

Protect Your Process Equipment and Your Production Uptime with Heat Tracing Products from Ives Equipment

Allow us to be your trusted and dependable source for staying operating during the severe winter months, based on our decades of experience in industrial and commercial freeze protection. 

As winter weather begins to set in, it is critical to take precautionary measures to preserve essential equipment. Because of the lower temperatures and strong winds, outdoor gear is at risk of freezing, which can cause the production process to prolong or halt. It is now necessary to evaluate your heat trace requirements. Keep the water flowing at low ambient temperatures with industrial pipe tracing. Use Nelson snow melting systems to prevent snow and ice accumulation on driveways, sidewalks, loading ramps, and other paved surfaces. Finally, don't forget about the roof and gutter de-icing products, which prevent the formation of ice dams on roofs, gutters, and downspouts anywhere.

Emerson's Nelson Heat Trace solutions combine conventional heat trace design ideas with cutting-edge installation, control, and monitoring technology to create a more efficient and reliable system. Our solutions are ideal for ensuring that metal pipes or other exposed equipment operate at the appropriate temperature. It is vital to maintain your equipment operational in the face of unpredictable weather circumstances; we provide complete environmental covering, no matter what the weather throws at you.

Ives Equipment
610-768-1600
https://ivesequipment.com

The Weather is Changing. Freeze Protect Your Facility Now!

Ensure frigid temperatures don’t slow you down.
Nelson Electric Heat Trace.

With over 65 years of experience, let us be your trusted and reliable source for staying operational during those harsh winter months.

As winter weather is settling in, the need to protect vital equipment is essential. With lower temperatures and brutal winds, exterior equipment is in danger of freezing which lengthens or completely halts the production process. Now is the time to assess your heat trace requirements.

Nelson Heat Trace products by Emerson incorporate traditional heat trace design philosophies with innovative installation, control, and monitoring technologies. Our solutions are perfect for keeping metal pipes or other exposed equipment working at the right temperature. With unpredictable weather conditions, it is critical to keep your equipment running; we offer total environmental coverage, no matter the elements.

LEARN MORE HERE

For more information about Emerson Nelson Heat Trace Products, contact Ives Equipment. Call them at (877) 768-1600 or visit https://ivesequipment.com/freezeprotect.

An Energy Savings Solution for Domestic Hot Water in Hospitals, Hotels, Campuses, Governmental Facilities and Correctional Institutions

The Smart System: Perfectly heated water – no hot spots, no burnouts, no recirculation.

Self-regulating capabilities, environmental safeguards and a solid design make self-regulating technology the wisest choice, consistently maintaining your water supply at a prescribed temperature. The heating cable is fastened directly to the pipes, running their full length and creating a symbiotic relationship, which allows the cable to gauge any changes in water temperature. Sensing a decrease or increase in temperature, the conductive core then adjusts its own power output in response, and produces a consistent flow of perfectly heated water – no hot spots, no burnouts, no recirculation. The cable is designed to sustain nominal hot water temperatures of 105°F, 115°F, 125°F or 140°F.

Visit this Ives Equipment web page for more information, and to download a Self-Regulating Domestic Hot Water Maintenance Heat Tracing Cable brochure.

Ives Equipment
www.ivesequipment.com
Philadelphia, PA: 610-768-1600
Baltimore, MD: 877-281-5678
York, PA: 717-227-1580
Washington, DC: 877-281-5678
Richmond,VA: 877-281-5678

Don't Risk Equipment or Safety: Freeze Protect Your Plant Now

Don't let this happen at your plant.

Winter is here in its full glory. Plant engineers and plant maintenance have to pay special care in preventing freezing in pipelines, tanks, Vessels, conveyors, and impulse lines.  The cold temperatures in the Mid-Atlantic can often damage or destroy process equipment and it's valuable contents. Most commonly, pipes, instrumentation, and valves are the vulnerable items affected by the sudden drop in temperatures, causing devastating consequences, including costly downtime and unplanned outages. But there's also safety issues to be considered with snow and ice build up, so attention must be paid to snow and ice melting.

Main Categories for Industrial Heat Tracing

• Industrial Pipe Tracing Cable
• Industrial Tank and Vessel Heating
• Industrial Snow Melting
• Industrial Roof Gutter Deicing

Responsible facility management includes protecting buildings and equipment against freeze damage. There are many items in any given manufacturing plant to protect, including piping systems, process instrumentation, holding tanks, transfer vessels, and valves. For each of these items, there's a good freeze protection solution to be applied. Here are some of the more common heat tracing products used in these applications.

Self-regulating Heat Tracing Cable

These self-regulating, cut-to-length cables are normally installed in commercial and light industrial applications, to maintain pipe temperature and/or prevent freezing. These heating cables are available in 120 and 240 voltages and are designed for use in ordinary or hazardous locations (with proper selections and application). Typical applications for this product are freeze protection and low watt density process temperature systems such as product pipelines, fire protection, process water and dust suppression systems.

Constant Wattage Heat Tracing Cable

Constant wattage heater cable is ideal for use in maintaining fluid flow under low ambient conditions. The product is used for freeze protection and process temperature maintenance systems such as product pipelines, process water, dust suppression systems, lube oil and condensate return.

MI (Mineral Insulated) Cable

MI Cable is a metal sheathed cable that uses a metallic conductor as the heating element. It is custom designed and fabricated for specific applications. MI Cable is a high performance, industrial grade heat tracing cable used for applications requiring high temperature exposure, immunity to stress corrosion, high maintain temperature, under tank heating (cryogenic tanks), high power output, constant power output over entire, rugged cable construction heater length, and extended heater life.

It is critical to consider the specific application requirements for any heat tracing application. The following checklist always needs to be clearly understood:

• The mass and material of the item being traced
• Insulation availability - type and thickness
• Temperature to be maintained
• Minimum ambient temperature
• Minimum start-up temperature
• Available supply voltage
• The chemical environment - expose
• Maximum intermittent exposure temperature
• Electrical area classification

Always share your heat tracing requirements and challenges with a process heating specialist. There are many options and product variants from which to choose. A consultation with an expert can help direct you to the safest, most efficient, and most cost effective solution.

Basic Information for the Design and Selection of Heat Trace Products for Pipe and Vessel Heating

Heat Tracing Self-Regulating Cable

To specify components for an effectively designed, totally electric heat trace system, it is necessary to understand the basic principles involved. A heat trace system is designed to replace heat lost through the thermal insulation from equipment in the system. In some applications, heat tracing will also be able to provide enough heat to significantly change the process temperature. 

It is always recommended to use thermal insulation since heat loss from bare surfaces is very high and heat transfer between the heater and the pipe/vessel is highly variable. All insulation should be weatherproofed. Wet insulation is ineffectual and heater output is insufficient to dry it.

There are several distinctively different types of electric heaters - self regulating, constant wattage, mineral insulated and tank heating panels. Each type has its own characteristics, often making one more suitable for a certain application than the others.

Download the entire Nelson Electric
"Heater Product General Information" guide from this link.

Self Regulating Heater Cable

Self Regulating Heater Cable will adjust its own output in response to pipe temperature. Available in a variety of temperature and power ratings up to 230°C (450°F) and 65.6w/m (20w/ft.). Product features include:

• Variable Output
• Self-Regulating heaters will react to variations in temperature encountered at every point along its length. Colder sections receive more heat output, while warmer sections receive less. This provides greater energy efficiency and more uniform pipe temperatures.
• Can Be Overlapped Without Damage
• Because Self-Regulating heaters controls its own output, overlapped sections produce less heat, eliminating “hot spots” and possible burn-through common with other types of cable.
• Fail Safe
• Upon reaching the upper limits of its temperature range, Self-Regulating heaters diminishes its own heat output to an insignificant level. This guarantees that maximum temperatures (T ratings) cannot be exceeded no matter what product is used in any application.
• Easy Installation
• Because of its infinite parallel path circuitry, Self-Regulating heaters can be cut to any length in the field without affecting the heat output or creating “dead zones”.

Constant-Wattage Heater Cable

Constant Wattage Heat Tracing Cable

Constant Wattage Heater Cable is a parallel resistance heater that produces the same watts-per-foot of heat along its entire length.

• EasyInstallation
• Constant-Wattage heaters can be cut to length and terminated in the field. 
• Economical 
• Provides good power densities and exposure temperatures with parallel circuit cable capabilities at economical prices. Exposure Temperatures to +204°C (+400°F). Ideal for maintaining many process temperature applications. 

Mineral Insulated Heater Cable

MI Cable

Mineral insulated Cable is a series conductor, high temperature heater cable with a special, thin metal sheath. Some of MI advantages are:

• Corrosion-Resistant
• Alloy 825 sheath provides excellent corrosion resistance and immunity from chloride stress corrosion - a common problem with stainless steel. 
• Ideal for High Temperature Applications
• Mineral Insulated heaters can withstand exposure temperatures up to 593°C (1100°F). Exposure temperatures can be increased to 750°C (1400°F) with special components. 
• Ratings To 600V
• Mineral Insulated heaters are available in a variety of voltages to match the available power supply. 
• High Heat Output 
• Mineral Insulated heaters have heat output ratings up to 10 times higher than most other cables, reducing the amount of cable required. 
• Rugged Construction
• A durable metal sheath provides greater mechanical protection.
• Thin Wall Construction
• A unique manufacturing process allows thin wall cable construction for easier field installation. 

Tank Heating Panels

Heating Panel

• Low Cost Installation
• Flexible silicone construction allows panel to conform to tank wall. No bonding or heat transfer aids are required. 
• High Temperature 
• Tank Heating Panels maintain temperatures up to 79°C (175°F) and can withstand exposure to 204°C (400°F).

Basics of Self-Regulating Heat Trace Cable

Self-regulating Heat Tracing Layout

Self-regulating heater cable is a parallel circuit electric heater strip. An irradiation cross- linked conductive polymer core material is extruded over the multi-stranded, tin-plated, 18-gauge copper bus wires. The conductive core material increases or decreases its heat output in response to temperature changes. A thermoplastic elastomer dielectric jacket is then extruded over the conductive core. A copper braid is installed over this jacket providing a continuous ground path. A UV stabilized thermoplastic elastomer overjacket is provided to cover the braid for wet applications and exposure to the sun.

Principle of Operation:

The parallel bus wires apply voltage along the entire length of the heater cable. The conductive core provides an infinite number of parallel conductive paths permitting the cable to be cut to any length in the field with no dead or cold zones developing. The heater cable derives its self- regulating characteristic from the inherent properties of the conductive core material. As the core material temperature increases, the number of conductive paths in the core material decreases, automatically decreasing the heat output. As the temperature decreases, the number of conductive paths increases, causing the heat output to increase. This occurs at every point along the length of the cable, adjusting the power output to the varying conditions along the pipe. The self-regulating effect allows the cable to be overlapped without creating hot spots or burnout. As the cable self-regulates it heat output, it provides for the efficient use of electric power, producing heat only when and where it is needed, and also limiting the maximum surface temperature.

Application:

Self-regulating heater cable is ideal for use in maintaining fluid flow under low ambient conditions. Freeze protection and low watt density process temperature systems such as pipelines, fire protection, process water, dust suppression systems, hot water and structure anti-icing are typical applications for this product. For other than metal pipe heating, see appropriate application guide. The base product is supplied with a copper metal braid with a thermoplastic elastomer overjacket for wet applications, exposure to the sun, and where mechanical abuse is a problem. Cables are UL Listed and CSA Certified for use in non-hazardous locations and can be used on branch sprinkler systems.

For more information see the following Nelson Electric product sheet.

Self-Regulating Heat Trace Cable Application and Operating Principles from Ives Equipment