To-HQ-02-018 Rev 00 Philosophy For Lighting and Trace Heatin

OMV Exploration & Production
Philosophy
for
Lighting and Trace Heating
Onshore
Document Number
TO-HQ-02-018-00
00
Final Issue
A2
Client Comments Incorporated
AS/RW
A1
Issued for Comment/Approval
AS/RW
10/2/05
Origin
By
Date
Issue
Rev
Issue or Revision Description
JS
27/5/05
JEA
31/5/05
PZ
31/5/05
MF
3/6/05
Chkd
By
Date
Appd
By
Date
Appd
By
Date
OMV Exploration & Production GmbH
Revision
Description of revision
A1
Issued for Comment/Approval
A2
Client Comments Incorporated
00
Final Issue
Philosophy for Lighting and Trace Heating

OnshoreError! Reference source not found.
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Contents
1.0 PREFACE .......................................................................................................................5
2.0 DEFINITIONS .................................................................................................................5
3.0 ABBREVIATIONS...........................................................................................................6
4.0 INTRODUCTION.............................................................................................................6
5.0 APPLICABLE CODES, STANDARDS AND REGULATIONS........................................6
5.1
5.2
Codes and Standards list.......................................................................................................... 6

References ................................................................................................................................. 8
6.0 SYSTEM GOAL ..............................................................................................................8

7.0 SYSTEM BOUNDARIES ................................................................................................8
8.0 DESIGN PHILOSOPHY ..................................................................................................8
9.0 LIGHTING .......................................................................................................................9
9.1
9.2
Design Considerations.............................................................................................................. 9
General ....................................................................................................................................... 9
10.0 TRACE HEATING.........................................................................................................15

10.1 Design Considerations............................................................................................................ 15
10.2 General ..................................................................................................................................... 15
10.3 Site Conditions ........................................................................................................................ 16
10.4 Degree Of Protection............................................................................................................... 16
10.5 Electrical Supply System ........................................................................................................ 16
10.6 Heating-Up Requirement......................................................................................................... 17
10.7 Start Load ................................................................................................................................. 17
10.8 Performance Requirements.................................................................................................... 17
10.9 Spare Or Over-Capacity .......................................................................................................... 18
10.10 Operation And Maintenance ................................................................................................... 18
10.11 Special Applications/Conditions............................................................................................ 18
10.12 Heater Selection....................................................................................................................... 19
10.13 Self-Regulating/Self-Limiting Heaters ................................................................................... 19
10.14 Constant Wattage Parallel Heaters ........................................................................................ 19
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10.15 Power Limiting Heaters........................................................................................................... 20

10.16 High Temperature Polymer Insulated Series Cable Heaters ............................................... 20
10.17 Temperature Control ............................................................................................................... 20
10.18 Energy Saving.......................................................................................................................... 22
10.19 Temperature Limitation For Safety Reason .......................................................................... 23
10.20 Temperature Limitation For Protection Against Overheating ............................................. 23
10.21 Power Supply And Distribution .............................................................................................. 24
10.22 Installation................................................................................................................................ 25
10.23 Testing And Commissioning .................................................................................................. 29
10.24 Commissioning........................................................................................................................ 30
11.0 DOCUMENTS ...............................................................................................................30

11.1
11.2
11.3
11.4
11.5
General ..................................................................................................................................... 30
Information Required From Omv ........................................................................................... 31
Documents To Be Submitted By The Contractor ................................................................. 32
Database................................................................................................................................... 34
Documents ............................................................................................................................... 34
12.0 REGULATORY AUTHORITY REVIEW REQUIREMENTS ..........................................35

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1.0
PREFACE
This Philosophy defines the OMV Exploration & Production GmbH corporate
policy on the design of Lighting and Trace Heating for onshore hydrocarbon
production and processing facilities.
The document specifies basic
requirements and criteria, defines the appropriate codes and standards, and
assists in the standardisation of facilities design across all onshore
operations.
The design process needs to consider project specific factors such as the
location, production composition, production rates and pressures, the
process selected and the size of the plant. This philosophy aims to address
a wide range of the above variables, however it is recognised that not all
circumstances can be covered. In situations where project specific
considerations may justify deviation from this philosophy, a document
supporting the request for deviation shall be submitted to OMV E&P for
approval.
Reference should be made to the parent of this philosophy, document
number TO-HQ-02-001 for information on deviation procedures and
Technical Authorities, general requirements and definitions and
abbreviations not specific to this document.
2.0
DEFINITIONS
The following definitions are relevant to this document
Ambient
Temperature
The temperature surrounding the object under

consideration. Where electrical heating cable is
enclosed in thermal insulation, the ambient
temperature is the temperature exterior to the thermal
insulation.
Branch Circuit
That portion of the wiring installation between the

overcurrent device protecting the circuit and the trace
heater unit(s).
Cold Lead
Electrically insulated conductor or conductors used to

connect a trace heater to the Branch Circuit and
designed so that is does not produce significant heat.
Parallel Heating
Cable
Heating elements that are electrically connected in

parallel, either continuously or in zones, so that watt
density per unit length is maintained irrespective of
any change in length for the continuous type or for

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any number of discrete zones.

A parallel heating cable with a semi-conductive
element, which responds to temperature variation by
adjusting the thermal output to finally reach
equilibrium.
SelfRegulating/SelfLimiting Heating
Cable
3.0
ABBREVIATIONS
There are no abbreviations with particular relevance to this document.
4.0
INTRODUCTION
This document describes the philosophy to be used for the design,
engineering and installation of lighting and trace heating for onshore plants.
5.0
APPLICABLE CODES, STANDARDS AND REGULATIONS

Codes, standards and regulations referred to in this philosophy shall be of the
latest edition and shall be applied in the following order of precedence:
Local Regulations,
The provision of this document,
International standards (e.g. ISO, IEC etc),
National standards.
Design of the safety system shall comply with the standards listed within this
philosophy, however, for instances where local standards are more onerous
local standards shall apply.
5.1
Codes and Standards list

NFPA 70
National Electrical Code
API RP 540
Electrical Installations in Petroleum Processing Plants

Institute of Petroleum Model Code Of Safe Practice, Part
1, Electrical Safety Code
The Convention on International Civil Aviation, Volume 1
Chapter 6 of Annex 14
European Standards
Electrical apparatus for potentially explosive atmospheres:
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EN 50014
General requirements
EN 50015
Oil immersion "o"
EN 50016
Pressurized apparatus p
EN 50017
Powder filling q
EN 50018
Flameproof enclosure d
EN 50019
Increased saftey e
EN 50020
Intrinsic safety i
EN 50028
Encapsulation m
EN 50039
Intrinsically safe electrical systems i
International Standards
IEC 60079
Electrical apparatus for explosive gas atmospheres
IEC 60529
Degrees of protection provided by enclosures
IEC 60947-2
Low voltage switchgear and controlgear, Part 2: Circuit

breakers
IEC 62086-1

Electrical resistance trace heating, Part 1:
General and Testing requirements
IEC 62086-2
NEMA ICS 1

Electrical resistance trace heating, Part 2:
Application Guide for design, installation and
maintenance
Classification of degrees of protection provided by
enclosures (IP Code)
Identification of apparatus terminals and general rules
for a uniform system of terminal marking, using an
alphanumeric notation
Protection against electric shock Common aspects for
installation and equipment maintenance
Safety of power transformers, power supply units and
similar
Enclosures for electrical equipment (1000 Volts
Maximum)
General standards for industrial controls and systems
NEMA ICS 2
Industrial control devices, controllers and assemblies
IEEE Std 515
Recommended practice for the testing, design,

installation and maintenance of electrical resistance
heat tracing for industrial applications
IEC 60529
IEC 60445
IEC 61140
IEC 61558
NEMA 250

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European Community Directives. (Applicable with the EEC)
5.2
6.0
89/336/EEC
The Electromagnetic Compatibility (EMC) Directive
73/23/EEC
The low voltage equipment (safety) regulations
94/9/EC
The Antmospheres Explosibles (ATEX) directive.
References
TO-HQ-02-011
Philosophy for General Electrical Design Onshore
TO-HQ-02-012
Philosophy for Main Generators and Switchboard Onshore
TO-HQ-02-039
Philosophy for Rotating and Reciprocating Equipment

Onshore
SYSTEM GOAL
The lighting system is intended to provide the correct level of illumination in all
areas and, in the event of emergency, to provide sufficient illumination and
direction to allow escape.
The aim of trace heating is to maintain fluid temperatures at the correct level to
allow processes to proceed as intended.
7.0
SYSTEM BOUNDARIES
The boundaries of the Lighting and trace heating systems are the:
8.0
interface to the main electrical system
Interface to the PCS and HMI
luminaires and heating tape.
DESIGN PHILOSOPHY
The general philosophy for lighting is to provide sufficient lighting to allow safe
working and allow personnel to safely escape in the event of emergency.
The general philosophy for trace heating is to safely maintain fluid temperature to
allow processes to continue uninterrrupted as designed.

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9.0
LIGHTING
9.1
Design Considerations
Lighting levels are as prescribed in Appendix 1. Proportions of luminaires
required to be supplied from an emergency power source are detailed in section
9.2.7.
It should be noted that the CE Mark, or CE marking as it is officially named, is
an obligatory product mark for the European market, which indicates
compliance 'certification' according to the requirements formulated in the
approximately 22 European 'CE Marking Directives' and subsequent
European standards.
9.2
General
9.2.1
General lighting requirements

General lighting shall provide the required level of illumination in accordance with
Appendix 1. It shall be fed from the normal site power supply and shall comply
with the requirements of Section 9.2.2, except that maximum use shall be made
of floodlights where possible.
The preferred type of floodlight is high pressure sodium, which shall be used
except where instant relight is required, e.g., on helipads. Typical areas where
floodlights can be employed in preference to fluorescent luminaires are open or
production and utility areas.
Industrial fluorescent lighting in 'white' colour shall in general be used for
illumination. Where special requirements regarding colour distinction exist, these
shall be met.
Long life lamps in combination with electronic ballasts shall be used in new
installations, and for upgrading old installations, so as to take advantage of their
increased lumen efficiency and economic life.
Incandescent lighting shall be applied only for decorative lighting.
High pressure discharge lamps should be used to light tall buildings or large
areas. In view of the restarting time of this type of lighting after a voltage dip,
sufficient fluorescent luminaires shall be installed for basic lighting requirements
of the area, equivalent to emergency lighting requirements as detailed in Section
9.2.7.
Consideration shall be given to the use of floodlighting, especially around the
perimeter of process and production plants. Care shall be taken to ensure that
this does not result in shadows, especially at operating locations.
Maintenance free, sealed for life discharge lamps and associated luminaires may
be considered with account being taken of their total life-cycle cost. These types
of luminaires are available in industrial and Ex protected executions.

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Low pressure sodium discharge lamps shall not be used, as they constitute a fire
hazard in the event of breakage.
9.2.2
Plant lighting
In Zone 1 and 2 hazardous areas, fluorescent luminaires with type of protection
Ex'e' shall be used. Luminaires for level gauge lighting shall be of the fluorescent
type, bracket-mounted. High pressure discharge luminaires in hazardous areas
shall have type of protection Ex'd'. An isolating switch shall be included within the
fitting to prevent the luminaire from being energised when it is not fully
assembled.
For standardisation reasons the same type of Ex'd' or Ex'e' luminaires should be
used in all plant areas, whether classified Zone 1, Zone 2 or non-hazardous.
Plant lighting circuits shall be fed from dedicated lighting distribution boards
installed in the plant substations.
Plant lighting circuits shall be single phase and neutral or three phase and
neutral, protected with maximum 16 A fuses or MCBs, but not be loaded higher
than 12 A. Plant lighting distribution boards shall include 10 % spare outgoing
circuits.
Adjacent luminaires shall not be supplied from the same circuit, or in the case of
three phase circuits, from the same phase.
As far as practical, fluorescent lighting shall be used throughout the plant
installations. The lighting system shall be designed to give illumination levels as
shown in Appendix 1.
Lighting installations shall be designed to obviate stroboscopic effects.
Luminaires on structures shall be located so that maintenance and lamp
changing can be effected without the use of ladders or scaffolding, where
possible. Where a luminaire mounted from an elevated walkway or platform does
not overhang it, the lamp post shall be arranged to swivel for maintenance
purposes. In tall buildings, such as compressor and turbo-generator houses,
maintenance and lamp-changing by means of the overhead crane shall be
possible.
In view of EMC requirements, all metallic parts of the lighting installation shall be
properly bonded or earthed.
Where no structure is available to support luminaires, fixed lighting poles of
adequate length with high pressure discharge floodlighting shall be used to
supplement the fluorescent luminaires. Lighting poles shall be hot-dip galvanised.
NOTE: For fixed floodlighting columns, lamps will be changed with the aid of a
mobile platform, e.g., vehicle mounted. Alternatively, hinged lighting columns
may be used, if space is available for the columns to be lowered.

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Plant lighting circuits shall be designed for automatic switching via photo-electric
relays. Control circuits for photo-electric relays shall be 'fail-safe', i.e., they shall
switch the lights on if a fault occurs in the photo-electric relay. The plant lighting
shall be designed in such a way that in daytime the lighting of furnaces, boilers
and the ground level plant can be switched on by means of a switch overriding
the appropriate photo-electric relay contact. The remaining photo-electric relayoperated plant lighting shall be able to be switched off at night-time. These
override switches shall be located either outside the plant substation or in the
control room, as required by plant operations. Moreover, the lighting distribution
board shall be provided with an override switch for maintenance purposes.
Level gauge lights shall not be switched by the above-mentioned photo-electric
relays and shall have no maintenance override switches. Level gauge lights shall
normally be on.
Internal lighting of non-process buildings and substations shall be switched inside
the building.
The lighting installation in the control rooms shall be designed so that ceiling
lighting groups can be switched off independently to suit operators' needs.
Electronic dimmer control shall be provided to adjust the illumination level
smoothly down to 20 % of the specified illumination. The luminaires shall be
situated in such a way that reflection on VDUs, instrument windows and displays
is avoided. Attention shall be paid to the selection of the correct category of
luminaire so that low glare units are provided without compromising the lighting
quality.
9.2.3
Building lighting
Luminaires in closed buildings that are classified non-hazardous areas, e.g.,
control rooms and substations, shall be fluorescent bi-pin, switch-start, industrial
pattern. Non-industrial luminaires may be used in control rooms, offices, etc.
9.2.4
Street and fence lighting

Street and fence lighting shall be fed from lighting distribution boards installed in
a conveniently located plant substation. These lighting distribution boards may
either be dedicated to street and fence lighting, or be one or more sub-sections of
a plant lighting distribution board. This lighting shall also be photo-electric relay
controlled and provided with a maintenance override switch, as for ground level
plant lighting.
Generally, for street/fence lighting three phase and neutral LV supply shall be
used. Each lighting pole shall include a fuse box as well as a four pole
terminating box for looping the feeder cable. Teed cable joints are not allowed.
Adjacent luminaires shall not be supplied from the same phase.

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Fence lighting shall be placed in such a way that the fence as well as the area
outside the fence will be illuminated, leaving the patrol road in comparative
darkness.
Normally fence lighting intensity shall be equivalent to the street lighting intensity
stated in (Appendix 1).
If special security fence lighting is required, a floodlight installation shall be
designed based on HP discharge lighting with a minimum illumination of 5 lux at
any point in the area between the fence and 5 m outside the fence, unless
otherwise specified.
9.2.5
Special lighting
Special lighting such as, obstruction warning lights and aircraft warning lights
shall comply with the applicable national and/or international rules and standards.
Special lighting, e.g., obstruction warning lights and aircraft warning lights, shall
be installed in accordance with international and/or national standards. Long-life
lamps or normal lamps at reduced voltage shall be used.
The installation shall be supplied from an interruptible, maintained source.
Aviation warning lighting
Aviation warning lights shall be installed in accordance with Volume 1 Chapter 6
of Annex 14 to the Convention on International Civil Aviation. The luminaires
shall each consist of a double lamp unit with automatic changeover to the standby lamp upon failure of the operating lamp.
Illumination of areas to be observed by means of CCTV monitors
The lighting installation for areas that require surveillance by closed circuit
television monitors shall be designed in particular with regard to uniformity of the
level of illumination as well as to the location of the individual luminaires. The
direct visibility of light-emitting bodies and/or reflections from covers of the
luminaires shall be checked before commissioning of the plant.
9.2.6
Portable lamps
Hand-held lamps shall be rated for maximum 50 V a.c. supply.
The types of portable equipment to be used in both industrial and non-industrial
areas (except in restrictive conductive locations as referred to below) shall be
one or more of the following:
double or reinforced insulation equipment, compliant with IEC 61140,

connected to the mains via a 30 mA RCCB, protecting both the supply
cord and the equipment;

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9.2.7
42 V equipment, compliant with IEC 61140, connected to a safety extralow-voltage circuit by using double-wound safety isolating transformers,
complying with IEC 61558 (SELV system).
Emergency and escape lighting

Fixed emergency lighting shall be installed at strategic points in the installations,
including control rooms, switchrooms, fire stations, first-aid rooms, watchmen's
offices, the main entrances, and all other buildings and areas where required for
safety reasons. Location and electrical arrangement shall be such that danger to
personnel in the event of a power failure is prevented, and escape routes are lit.
The emergency lighting system shall consist of a number of standard luminaires
of the normal lighting installation, which shall be fed via circuits having a stand-by
supply from an emergency generator or from an inverter having a battery with an
autonomy time of at least 1 h. In remote areas, where only a few fittings are
required, self-powered emergency luminaires may be used, subject to economic
considerations.
If power is supplied by an emergency generator, a number of luminaires in the
control room, as well as field auxiliary rooms, shall have a stand-by supply from
an independent source with battery back-up to avoid complete darkness during
start-up of the diesel engine.
The number of emergency luminaires in relation to the total number of fittings
shall be determined as follows:
-
utility area
20 %
process area
10 %
administrative area
control room and auxiliary rooms

(including 10 % connected to inverter
system)
5%
substations, field auxiliary rooms,

compressor
and generator buildings
50 %
30 %
The escape luminaires shall generally be part of the emergency luminaire

installation, but the luminaires shall have integral batteries rated to maintain the
lighting for at least 30 min.
Escape luminaires shall be provided in all buildings to light the way for personnel
leaving the building along defined escape routes to defined muster points, which
shall also be illuminated.
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NOTE: Where emergency lighting is fed from a distribution system classed as

vital or essential, due care shall be taken to avoid harmful overvoltages due to
lightning strikes which could affect the instrumentation and control systems.
Emergency lighting shall provide sufficient level of illumination to permit minimum
operation of the site. The emergency lighting luminaires shall comprise up to 25
% of the total number of luminaires. They shall be fed from the emergency
switchboard but shall also have a stand-by supply from an independent source
with battery back-up to avoid complete darkness during start-up of the
emergency generating set.
Emergency lighting shall be provided to allow limited operational lighting for
inspection, testing, emergency support, and the starting of the emergency
generator. Typical applications are obstruction lights on vent stacks and crane
booms, perimeter lights on helidecks, and key operational areas such as the
control room, radio room, and crane access ladders. The luminaires shall be
suitable for Zone 1 areas.
Emergency lighting shall also be installed in main switchgear and generator
rooms, accommodation and workshop areas.
Portable emergency lighting units shall be provided at the exit doors of all nonhazardous area modules, e.g., installation control centre, switchrooms, utility
areas, and emergency team muster points. Each unit shall comprise a fixed wallmounted battery charger and hand lamps suitable for use in Zone 1 areas. The
unit shall be kept on float charge when not in use and be fed from the emergency
lighting switchboard. The battery shall be rated to energise the hand lamp for not
less than 6 h.
Escape lighting shall form part of the emergency lighting system and be located
so as to illuminate the escape routes, ladders and walkways to allow safe
movement of personnel to the muster points, etc. Escape lighting shall be fed
and equipped in the same fashion as the rest of the emergency lighting except
that, for normally unmanned installations, a central uninterrupted maintained
power supply should be provided with battery back-up for a 24 h autonomy time.
Escape luminaires shall be installed at the following locations:
every exit doorway;
in sleeping accommodation, if provided;
external escape ways (stairways and walkways);
internal escape ways (escape routes in modules or deck areas,

accommodation area corridors, and galley);
embarkation areas (access to helipads);
muster areas (helicopter waiting room, cinema, lounge, dining room

and the emergency response team muster points).

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Escape luminaires installed in any sleeping quarters shall only illuminate on loss
of the a.c. supply to the integral battery charger.
Escape lighting shall be suitable for Zone 1 areas.
10.0
TRACE HEATING
10.1
Design Considerations
The aim of trace heating is to safely maintain fluid temperatures at the correct
level to allow processes to proceed as intended in accordance with appropriate
Standards.
It should be noted that the CE Mark, or CE marking as it is officially named, is
an obligatory product mark for the European market, which indicates
compliance 'certification' according to the requirements formulated in the
approximately 22 European 'CE Marking Directives' and subsequent European
standards.
The selection and installation of Equipment shall be in accordance with the
requirements of the applicable code or standard, as determined by the relevant
regulations. It is required, for plant within the European Economic Area (EEA),
that Equipment be compliant with the requirements of the two ATEX Directives,
94/9/EC: The approximation of the laws of Member States concerning equipment
and protective systems intended for use in potentially explosive atmospheres
(the Equipment Directive) and 1999/92/EC: Minimum requirements for
improving the safety and health protection of workers potentially at risk from
explosive atmospheres (the User Directive).
10.2
General
10.2.1
Safety
For safe and reliable application of electrical heating systems, the climatic,
environmental and operating conditions shall be taken into consideration.
As far as practical, the electrical equipment should be located in non-hazardous
areas or in the least-hazardous areas. It shall not be located in Zone 0 areas.
The trace heating equipment shall comply with IEC 62086-1.
10.2.2
Hazardous Areas
When installed in a hazardous area, the construction of electrical equipment shall
comply with the relevant parts of IEC 60079 or with the relevant parts of EN
50014, EN 50015, EN 50016, EN 50017, EN 50018, EN 50019, EN 50020, EN
50028 and EN 50039. The application of standards other than those above is
subject to the approval of OMV.

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For installations in Zone 1 and Zone 2 areas, the following types of protection
shall be used:
Connection boxes:
Ex "e" enclosure
Local switches:
Ex "d" or Ex "m" switches, or a

combination of these two, with Ex "e"
terminals and enclosure
Thermostats:
Ex "d" or Ex "m", or a combination of

these two, with Ex "e" terminals and
enclosure
Temperature control systems: Ex "i" for e.g. PT 100 connections
For the above-mentioned electrical apparatus, a Declaration of Conformity shall

be obtained from the Manufacturer.
10.2.3
Non-hazardous areas
For standardization, material as specified for Zone 1 and 2 areas should be used
in non-hazardous areas.
Industrial type equipment may be used, subject to the approval of OMV.
10.3
Site Conditions
The parts of a heating system installed outdoors shall be suitable for outdoor use
in a relative humidity of 100%, and exposed to direct sunlight, without protective
shelter. The atmosphere shall be considered saliferous, sulphurous and dusty as
commonly encountered in hydrocarbon production and processing facilities
located close to open water. The possibility of condensation, as experienced
during large temperature fluctuations in a humid atmosphere, shall be taken into
account.
Extremely corrosive and saliferous conditions shall be taken into consideration.
10.4
Degree Of Protection
As a minimum, the enclosures shall have a degree of protection IP 55 in
accordance with IEC 60529.
10.5
Electrical Supply System

The AC supply to the heating system shall be either single phase or symmetrical
three-phase, + neutral, with a nominal voltage and frequency as indicated in the
requisition. The supply variations at the distribution board under steady-state
conditions shall be limited to:
- Nominal system voltage:
10%
- Nominal system frequency: 2%

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In addition to the above, input voltage variations may be subject to temporary

voltage variations of +10% and -20% of the nominal voltage, caused by e.g.
motor starts.
Transient high-frequency voltages of 2 kV peak may also be superimposed on
the input voltage because of system switching operations, etc.
10.6
Heating-Up Requirement
In most applications, trace heating is used for temperature maintenance and not
for heat-up. However, it is often of interest, at initial start up or after a power
shutdown, to see how long it will take the system to reach its maintained
temperature. This depends mainly on how much heat capacity is available. For
critical applications where heat-up time is an important factor during start-up or
after a power shutdown, extra heating capacity of the trace heating in addition to
that required for temperature maintenance becomes an important factor and
shall be taken account of in the design.
Apart from compensation heating, there may be a need to heat-up (to melt) the
contents of a pipeline within a certain period. This may be required for example
when the product is solid under ambient conditions (e.g. wax). Additional heating
capacity would need to be installed to perform such a duty. This can be done by
increasing the capacity of the compensation heating or by installing additional
heaters dedicated for this duty, provided consideration is given to the maximum
heat density allowed under those circumstances.
The most economic solution shall be chosen.
10.7
Start Load
The start-up temperature determines the in-rush current (start-up load). This
temperature determines the rating of the electrical protection (circuit breaker).
Since self-regulating heaters have higher power outputs at lower temperatures;
the lower the selected start-up temperature the higher the power demand will be
and the rating of the protective device will have to be increased accordingly.
If the electrical protection rating is already known, then the maximum length of
the heater circuit has to be limited to a value where the start-up load does not
exceed the circuit breaker rating.
10.8
Performance Requirements
The system (materials, components and assembly methods) shall have a design
life of at least 20 years.
Heating equipment used for piping and equipment that will undergo periodic
steam cleaning shall have a minimum withstand temperature of 190 C, for a
cumulative exposure time of at least 1000 hours, with the Power OFF.

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Heating equipment shall be designed to withstand a temperature of not less than

the maximum operating temperature + 20 C, which can occur under all process
conditions.
The heat density of the heating elements shall be such that the temperature
limits for pipe, heaters or product are not exceeded.
10.9
Spare Or Over-Capacity
The design of initial spare or over-capacity of the heating system shall be
considered if for critical applications the power output is not allowed to drop
below the design values.
A minimum of 20% additional design heat requirement shall be taken into
account. This may not be applicable if Self-Regulating Cable is used.
The safety factor used in the design shall be stated in the heat balance
calculations (8.3).
10.10
Operation And Maintenance

All electrical equipment subject to operating and maintenance activities shall be
easily accessible wherever possible and shall allow for safe and convenient
performance of such activities with minimum use of scaffolds and ladders.
System components shall be standardized as much as possible.
10.11
Special Applications/Conditions
The following typical applications require special attention in design:
loading arms;
lines that require tracing from above ground to underground;
preformed rugged insulation like cellular glass or calcium silicate;
flexible parts like compensators;
short time heat-up requirements;
exposure to special chemicals (e.g. sulphur).

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10.12
Heater Selection
10.12.1 General
For winterising and compensation heating the following heater types may be
used:
10.13
self-regulating/self-limiting heaters;
constant wattage parallel heaters;
power limiting heaters;
high temperature polymer insulated series cables;
mineral Insulated heaters (M.I. cable).
In the case of welded pipelines (i.e. without flanges), a system of skin effect
current tracing heaters shall be considered.
Self-Regulating/Self-Limiting Heaters
Self-regulating/self-limiting heaters shall be utilized where possible, within the
restrictions of heat output and operating temperatures. They can be used for all
winterising and the majority of compensation heating requirements. Heating tape
shall consist of two parallel copper conductors, both being in contact with a selfregulating/self-limiting semi-conductive material. This basic element shall be
insulated by one or more non-hygroscopic jackets, and shall be covered with a
braided metal screen covering at least 70% of the surface and a fluor-polymer
outer jacket. The braided metal screen shall have an electrical conductivity not
less than the conductivity of one of the conductors.
The heaters shall vary the power output in response to the sensed temperature
at every point of the surface. As the temperature increases, the heater output
shall decrease automatically and vice versa. The natural reduction in heat output
by increasing temperatures shall be at least so much that the heater will not be
damaged due to overheating as result of e.g. overlapping, irrespective of the
application.
Self-Regulating Cable shall be capable of being overlapped on itself (but this
should be avoided wherever possible) without causing hot spots.
10.14
Constant Wattage Parallel Heaters

Constant wattage parallel heaters may be utilized when the required heat output
or the operating temperature is beyond the capabilities of self-regulating/selflimiting heaters. A constant wattage Parallel Heating Cable shall consist of two
insulated copper conductors. Heating elements (wires or other types of elements)
are connected to the two conductors at certain distances, forming heated zones.
The maximum length of a heating zone shall not be more than one metre.
The conductor and the heating elements shall be provided with one or more
layers of insulating material. All insulating material shall be heat resistant and

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non-hygroscopic, and shall be covered with a braided metal screen covering at

least 70% of the surface together with a polymer outer jacket. The electrical
conductivity of the braided metal screen shall be not less than the conductivity of
one of the conductors.
The heating pad shall have an external metal earth screen or foil over the
entire surface for mechanical and personnel protection.
The heaters (both cables and pads) shall provide a constant power output
regardless of the operating temperature. In the event of a hot spot, the affected
element(s) may burn out leaving, however, the remaining part of the heater in
operation.
10.15
Power Limiting Heaters

Power limiting heater cables shall be used where the maximum allowable
temperature of Self-Regulating / Self Limiting Heater Cables will be exceeded
OR if high outputs are required. This type of cable can reduce considerably the
use of mineral insulated heating cables.
Power limiting heater cables consist of a metal-alloy heating element, which is
helically wrapped around a fibre substrate, electrically disposed between two
copper conductors.
The element has a Positive Temperature Coefficient characteristic and reduces
its output with increased temperature.
10.16
High Temperature Polymer Insulated Series Cable Heaters

Series cables shall be used where the length of the heating circuit is beyond the
maximum allowable length of parallel heaters. This will help to reduce the
number of power points and/or junction boxes at non-reachable locations. Such
cables shall be used for pipe bridges, etc.
High temperature polymer insulated series cable heaters consist of one or more
conductors insulated by non-hygroscopic insulation material (e.g. Teflon), low
ohmic protective braid metal screen covering at least 70% of the surface and
non-hygroscopic outer jacket (e.g. Teflon).
The heaters (cables and pads) shall provide a constant power output regardless
of the operating temperature.
The maximum watt density shall be 25 W/m, with voltages up to 400 V.
10.17
Temperature Control
10.17.1 General
Each process will impose a unique set of constraints on achieving proper
temperature control. Such constraints may include maintenance and operating
flexibility, energy efficiency, acceptable temperature span, time and manpower
available to correct deficiencies, and the cost assignable to lost production.
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The installation and selection of temperature control depend on the following

criteria:
process/product considerations;
energy saving;
temperature limitation for safety reasons;
protection against overheating of the heating elements.
If Self-Regulating Cable is used (e.g. for winterisation) on impulse lines, the

power off point shall be below the temperature at which the impulse line liquid
starts to strip/evaporate.
10.17.2 Process/Product Considerations
For convenience, three basic process types, along with probable tracing
constraints, are covered herein. It should be recognized, however, that each
specific application may involve a combination of considerations.
Type I
A process where the temperature should be maintained above a minimum point.
An ambient sensing thermostat is acceptable. Equipment might consist of a
mechanical thermostat and few, if any, alarms. Large blocks of power might be
controlled by means of a single thermostat, a contactor, and a panel board. Since
heat input will be provided unnecessarily at times, wide temperature excursions
should be tolerable, and maximum energy efficiency is not essential. Energy
efficiency can be improved through the use of dead leg sensing control.
Type II
A process where the temperature should be controlled within a moderate band.
Pipeline temperature sensing devices, along with some facilities for monitoring
and alarming, are typical. Redundant equipment is not generally specified, and
the tracing requirement would be sufficiently seasonal to permit planned
maintenance and repairs.
Type III
A process where the temperature should be controlled within a narrow band.
Pipe sensing controllers using thermocouple or resistance temperature detector
(RTD) inputs will facilitate field calibration and provide maximum flexibility in the
selection of alarm and monitoring functions. Redundant equipment may be
warranted where maintenance and repairs need to be performed without a
process shutdown. Heat input capability may be provided to warm and/or melt
the fluid within a specified range and time interval.
Type III considerations require strict adherence to flow patterns and thermal
insulation systems with the highest integrity.
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10.18
Energy Saving
10.18.1 General
In a winterising installation, an Ambient Temperature-sensing device shall be
used to activate the heating installation when the temperature drops below 4 C.
One single device can control all winterising heating circuits of an area (see
Appendix 1, circuit B).
Piping with compensation heating does not normally need to be heated when in
operation. Only at low or zero flow rate will the heating system be used to
compensate for the heat losses. Consequently, the heating system shall only be
activated when required, and shall be controlled by local thermostats.
The number and location of the thermostats shall be selected to ensure that
the heating requirements of all piping and equipment involved will be
maintained under all process conditions.
10.18.2 Group Control and Monitoring Device (Station)
A Group Control and Monitoring device (Station) should be considered if this
adds value to the tracing system. This system can be applied to complex trace
heating systems (type II or III). The capabilities of the device should contribute to:
low-cost temperature control and monitoring;
lower maintenance cost;
optimising and simplifying tracing design;
reduced energy cost;
networking to plant control systems.
The station should be capable of central control of the relatively large tracing
system. The number of low stations provided shall be as low as possible (one per
system).
The Manufacturer shall provide the accessories and software for the group
control and monitoring device. The Manufacturer shall provide the RS-485
card(s) for communication and alarm annunciation and RTD temperature sensing
elements.
10.18.3 Proportional ambient sensing controller (PASC)
As part of a complex control system, a proportional ambient sensing control
system can be adopted. Design heat loss and consequently design heat output
are based on extreme operating conditions, i.e. minimum Ambient Temperature.
For most of the time the actual ambient will be much higher and heat loss will be
correspondingly less, so that heaters do not need to be energised 100% of the
time. PASC works by measuring the Ambient Temperature, comparing this to the
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pre-set design minimum Ambient Temperature and then proportioning the heater
output required to compensate for the actual heat loss.
A control group containing all lines to be maintained at a process or winterisation
temperature is defined and these are all switched together by the controller. As
many groups can be defined as there are process or winterisation maintain
temperatures.
If certain lines require accurate temperature control or monitoring, this should be
accommodated into the controller infrastructure. Line mounted PT-100 devices
should be wired back to the main controller via field-mounted remote monitoring
modules and RS-485 connection(s). Selected lines should be energised
according to this line-sensed temperature rather than via the main group control
system.
10.19
Temperature Limitation For Safety Reason

Controlled design applications, which require the use of a temperature control
device to limit the maximum pipe temperature, shall comply with a) for zone 1
and either a) or b) for zone 2:
a)
For zone 1 or zone 2 applications: controlled design applications, which
require the use of a temperature control device to limit the maximum surface
temperature, shall utilize a protective device that will de-energize the system after
the maximum operating temperature has been exceeded, and reset shall only be
possible by hand after the defined process conditions have returned. In case of
an error by, or damage to the sensor, the heating system shall be de-energised
before the defective equipment is replaced. The setting of the protective device
shall be secured and sealed to avoid tampering. The protective device shall
operate independently from the temperature monitoring system.
b)
For zone 2 applications: a single temperature controller with failure
annunciation may be used. If so, adequate monitoring of such annunciation, such
as 24-hour surveillance, shall be provided.
Alternatively, automatic reset may be used if the temperature limiter gives an
alarm in a manned control room when the heater is switched off.
The decision as to which option is to be applied shall be made with the
agreement of OMV.
10.20
Temperature Limitation For Protection Against Overheating

It is sometimes required to install thermostats that monitor the surface
temperature of the heaters and disconnect the system from the supply if the
temperature is too high.
This high temperature could be damaging to:
the material used in the heater and in particular the selfregulating/self-limiting semi-conductive material. Examples of this are

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highly insulated small bore tubing and piping in which a product could
flow with a temperature higher than the maximum exposure
temperature of the heater when energised;
the material used in the process piping or equipment (e.g. plastic);
personnel, e.g. supply piping of safety showers, which may contain
water at too high a temperature.
The maximum allowable temperature when the heater is de-energised, as

stated by the Manufacturer, shall not be exceeded.
The requirement of such temperature limiters shall be discussed with the
Manufacturer in the detailed design stage.
10.21
Power Supply And Distribution
10.21.1
Distribution Panel
The heating system shall be connected to a distribution board which should be
installed in the plant switch house.
It may be economically attractive to install the distribution panel or a subdistribution panel nearer to the heater installation; for this, OMV's approval is
required.
These panels shall be suitable for outside installation. The incoming feeders of
such panels shall be protected by short circuit limiting devices having a maximum
nominal current of 355 A. These (sub-) distribution panels shall be installed in a
non-hazardous area.
The outgoing panels of the distribution board shall consist of a number of threephase fused main circuits, with an isolating switch which is padlockable in the off
position. Fuse sizes shall be selected to limit the short circuit currents to the
capacities of the downstream circuit breakers.
Each main circuit shall be divided into a number of circuits, each provided with a
padlockable miniature circuit breaker (MCB). The circuits may be single phase or
three phase with neutral. In the case of single phase, the circuits shall be equally
divided over the three phases. If the heating system is not controlled by local
thermostats but via an Ambient Temperature device or via a process control
system, contactors shall be incorporated either in the main circuit or in each of
the circuits (Appendix 2, circuits B, C and D).
10.21.2 Circuit Protection Requirements For Branch Circuits

Miniature circuit breakers in the circuits shall be either double pole for singlephase circuits or four pole for three-phase circuits, and shall have trip
characteristics corresponding thermally and electro-magnetically to IEC 60947-2,
Category B or C.
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The maximum rating of the circuit breakers for parallel type heaters shall be 25 A,
and the minimum short circuit breaking capacity shall be 10 kA with current
limiting capabilities.
Auxiliary contacts wired up together for one common trip signal to a manned
control room shall be provided.
It shall be ensured that the protective devices will operate effectively regardless
of the location of a possible fault in the heating cable. The breaker shall be
suitable for the inrush current of the heating elements. The heater Manufacturer
shall approve the type and rating of the circuit breakers.
In a three-phase heater cable, an unbalanced protection relay shall be provided
with a trip setting of maximum of 20% of the nominal current with a maximum of
5 A.
For TT and TN-S systems:
Each Branch Circuit shall be equipped with a circuit breaker with a residual
current protection device with an operating current not greater than 300 mA. The
device shall have a break time not exceeding 150 ms at five times the rated
residual operating current. Values of 30 mA and 30 ms are preferred unless there
is evidence that this will result in a marked increase in nuisance tripping.
For IT systems:
An electrical insulation monitoring device shall be installed to disconnect the
supply whenever the electrical resistance falls below 50 /V of rated voltage.
10.21.3 Field Distribution
The supply cabling between the distribution board and the heaters shall have a
cross section adequately rated for the maximum load, and restricting the voltage
drop over the cable under full load conditions to maximum 5% of the nominal
voltage. The cables shall have copper conductors and a steel wire armouring or
braiding and, if required, lead sheathing.
Cabling and heaters shall be connected via connection boxes. Individual heaters
or groups of heaters of no more than five segments on the same pipeline shall be
provided with a local switch, padlockable in the 'Off' position and installed near
the supply point of the heater(s). Other configurations shall be subject to the
approval of OMV.
Heaters integrated in instruments along the pipelines shall also be connected to a
heater supply circuit.
10.22
Installation
10.22.1 Heater Distribution

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Heaters shall be distributed and grouped logically in order to minimize the

number of switches, thermostats and power cabling required. In installations
where the process flow can follow different routes (for example manifolds and
A/B pump lines, bypass circuits and safety showers), each independent part of
the system shall be controlled separately and supplied via separate MCBs.
Where the same conditions apply in a pipeline, the heaters shall be controlled
from one point unless they are connected to different circuits (see Appendix 2).
Heating systems of duplicated process control instruments shall not be
connected to the same circuit.
Heater circuits shall be loaded with maximum 20 A for single-phase circuits and
3 x 20 A for three-phase circuits.
For the operating current rating of self-regulating/self-limiting heaters, the
minimum operating temperature shall be taken into account.
To prevent overloading of the heater conductors, the maximum length of a
Parallel Heating Cable shall be limited in accordance with the specification of the
Manufacturer. Some heating cables are available with additional power supply
conductors integrated in the tape. This will allow extended heater lengths without
using separate power feeding points.
Through connections or 'Tee-offs' shall not be made underneath the pipe
insulation; only end-seals and 'cold-lead' connections may be used. All other
connections shall be made in connection boxes. Sufficient heater capacity shall
be installed to ensure that, towards the end of the heating cable, the output does
not drop below the minimum design value owing to the voltage drop in the heater
conductors.
10.22.2 Local Switches
Local switches shall have a minimum switching capacity of 16 A and shall be
double pole for a single-phase circuit and four pole for a three phase, + neutral,
circuit.
The switch shall not be loaded with more than 75% of its nominal rating to allow
for future extension.
The switches shall have a clear 'ON - OFF' indication. The 'OFF' position shall be
padlockable.
Local switches shall be installed in the direct vicinity of the associated heating
equipment in an easily accessible position and have the cable glands at the
bottom.
10.22.3 Local Thermostats

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Capillary type
The capillary shall be no more than 5 m long. The contacts of thermostats used
for direct switching shall have a minimum rated capacity of 16 A, which may be
obtained by an integrated local contactor. Each contact shall not be loaded with
more than 75% of its nominal rating. The temperature setting accuracy shall be
better than 5% of the set value, with a maximum of 10 C. The switching
hysteresis shall be between 5% and 10% of the actual setting or between 4 C
and 10 C whichever is the smaller.
Electronic thermostats with PT-100 sensor
If highly accurate control is required, electronic thermostats with PT-100 sensor
should be used. The contacts of the thermostats used for direct switching shall
have a minimum rated capacity of 16A, which may be obtained by an integrated
local contactor. Each contact shall not be loaded with more than 75% of its
nominal rating. The maximum switching accuracy shall be within 1 C for an
actual setting between 0 C and 100 C, or 2% for higher temperature settings.
The switching hysteresis shall be within 3%.
Local thermostats shall only be adjustable with the use of tools. Thermostats
installed as temperature limiters for safety reasons shall be of the fail-safe type.
10.22.4 Connection Boxes
Connection boxes shall be used for:
a)
the connections between supply cable and heater cable;
b)
the distribution of supply from one circuit of the distribution board to subcircuits. Only the supply from one circuit of the distribution board shall be allowed
in a connection box;
NOTE: Combinations of a) and b) are also possible.
c)
splitting of a three-phase circuit into three single-phase circuits.
Connection boxes shall contain sufficient terminals for all the connections to be
made. Individual terminals shall be provided for each conductor. The terminals
shall be of non-loosening construction and of the wedge type or cage clamp type,
obviating the use of cable lugs and constructed in such a way that direct contact
between screw and conductor is avoided. Terminals shall be identified in
accordance with the related diagram. In addition, sufficient earth terminals or an
earth bar with sufficient earth connection points shall be provided to earth the
metal screens of all cables and heaters.
All cables connected to the box shall enter the box through the bottom or the
sides, not the top. Sufficient cable glands, suitably sized for the associated
cables, shall be installed.

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10.22.5 Heater Installation

Extreme care shall be taken to prevent heater cables and pads absorbing water
during transport as well as during and after installation. During transportation
from the Supplier to the site, the ends of the cables or the connection leads shall
be suitably sealed by heat shrinkable adhesive end-seals, which shall remain
fitted until the final connection is made in the junction box, switch, etc.
The heater cables or the Cold Leads shall be terminated in the junction boxes,
switches, etc. in such a manner that any ingress of water through the cores,
braiding or in between insulation layers due to the capillary effect is excluded.
Heaters shall be installed in accordance with the Manufacturer's instructions. All
heaters shall be fixed to ensure continuous and permanent contact with the
surface to be heated over the entire (hot) length. Especially when constant output
heaters are used, this shall receive special attention since lack of contact will
cause hot spots, which may damage the heater. Unrolled heating cable has the
tendency to rewind, and unrolling the drum in a certain direction can improve the
contact with the heated surface (see Appendix 4, Fig. 4).
Heating cables shall normally run straight along the lower quadrant of the pipes
(see Appendix 4, Fig. 1). If spiralling of tapes is necessary, this shall be done as
shown in Appendix 4, Fig. 2, in order to ensure that the cable can easily be
removed. Constant wattage output heaters shall not overlap or touch each other.
Where heaters run close together, special retaining fixings shall be used to
prevent the heaters from touching. Overlapping of self-regulating/self-limiting
heaters shall be avoided wherever possible.
Entry kits shall be used where heating cables, Cold Leads or temperature leads
enter the thermal insulation, to prevent damage and to ensure weatherproofing.
The entry kits may consist of special entry brackets, cable glands or conduit type
entries. Cable glands or conduit type entries shall be fixed to the bottom part of
the pipeline.
The design and the installation of the entry brackets shall be such that ingress of
water is excluded.
Cold-lead joints including a small portion of the Cold Lead shall be fixed to the
heated surface to ensure a good contact of the heater.
Heating cable fixed to pumps, valves, flanges etc. shall allow easy removal of the
equipment without damaging the cable. To obtain good contact between heater
and heated surface, additional metal tape or foil can be used. Additional fixing
straps shall be provided on both sides of the pumps, valves, flanges, etc. to avoid
loosening of the heater from the associated pipes. Special measures shall be
taken to prevent sharp edges or rough surfaces damaging the heaters.
Fixing materials for heaters shall ensure continuous and permanent contact
between heater and heated surface. They shall be non-corrosive and suitable for
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the relevant operating temperature, and shall not damage the heater
mechanically or chemically.
In general, for heaters with a polymer outer jacket, self-adhesive plastic or glassfibre tape shall be used. For heaters with a stainless steel outer sheath, stainless
steel straps or bands shall be used.
10.22.6 Identification
Electrically heat traced piping and equipment shall be clearly identified with
suitable durable weatherproof caution signs, visible from all sides. Signs on
traced pipelines shall not be more than 5 metres apart and positioned on
alternate sides of the sheathing/cladding.
Traced branch pipes, instruments, etc. shall carry individual signs.
The elements of a circuit such as local switches, thermostats, connection boxes
and heaters shall be provided with permanent labels, which shall consistently
indicate the number of the circuit to which the elements are connected.
The labels shall be fixed on a non-removable part; for heaters the labels shall be
fixed on the sheathing of the associated pipelines or equipment.
10.23
Testing And Commissioning
10.23.1 Factory Testing

The distribution board shall be tested in accordance with the requirements of
Document No TO-HQ-02-011 Philosophy for Electical Design Onshore.
On request, the Manufacturer shall supply type test certificates of the trace
heaters quoted.
The Type testing of the trace heaters shall be done in accordance with section
5.1 of IEC 62086-1.
The Routine testing of the trace heater shall be done in accordance with section
5.2 of IEC 62086-1.
If Manufacturer's testing is based on other codes, this shall be stated in the
quotation.
Before leaving the Manufacturer's works, each length of cable or panel shall be
subject to inspection, dielectric testing and verification of rated output.
Results shall be recorded in test reports, which shall be distributed as
specified in the purchasing documents.
Prefabricated control panels should be completely checked at the Manufacturers
shop prior to shipping to verify correct wiring, layout and function. If such a check
is not feasible by the user, documentation should be obtained from the
Manufacturer, stating that such tests have been performed.
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10.24
Commissioning
After the control panels have been received, a general inspection should again
be made with attention to controllers and other devices that may have been
damaged in shipping.
Heating cables and surface heaters should be visually checked for damage
incurred during shipping and handling. Continuity and insulation tests may be
made as a final quality check.
Prior to the application of thermal insulation, the insulation resistance of the
heating cable shall be measured under normal dry conditions and before
associated wiring or control equipment is connected. The measured value should
not be less than 20 M at 500 V(dc).
For heating devices provided with a non-metallic over jacket, an insulation
resistance test should be performed between the metallic covering and ground at
500 V(dc) after:
installation of the heating device on the pipe/vessel, and
installation of the thermal insulation.
These tests are used to detect damage to the over jacket during the installation
process.
If no process temperature measuring system is installed on the traced pipeline,
temperature test points shall be installed at crucial points (for example near heat
sinks) for checking the performance of the trace heating system.
It is recommended that the insulation resistance of the entire Branch Circuit, after
the thermal insulation is complete, should not be less than 10 M measured at
500 V(dc).
For Type II and Type III, if required, the operation of each electric heating cable
should be checked by applying rated voltage and recording current and pipe
temperature at steady-state conditions. Time should be allowed for the current to
stabilize, as the starting current is sometimes higher than the operating current.
11.0
DOCUMENTS
11.1
General
Documents, including drawings, required for the installation shall form an integral
part of the design. The documents shall be distributed as specified in the
purchasing documents. The documents shall show the relevant order and item
numbers and the Manufacturer's reference number. To ensure a workable heattracing design, the designers concerned should be furnished with up-to-date

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piping information and should be notified of any revisions of items and drawings
that pertain to the heat-tracing system.
All documentation shall be submitted in the form of an Electrical Trace Heating
Manual.
11.2
Information Required From OMV

The engineering information required from OMV in order to design a heat tracing
system is listed below.
The data should be provided by the various disciplines, as follows:
These disciplines are:
Process (A)
Mechanical (B)
Electrical (C)
Instrumentation (D)
The information required:
Country and/or local standards (A)
Climatic and environmental conditions (A)
Hazardous area classification information (A)
Piping and Instrumentation Diagrams (A)
Trace heating philosophy (A)
Insulation specification (B)
Pipe support details (B)
Line list for heat tracing only (B)
Piping Isometrics (B)
Plot plans (B)
Equipment drawings (tank, filter, columns and pumps) (B)
Instrument list (D), including:

-
service
process liquid
fill liquid in the impulse line (if applicable)
size of the impulse line (if applicable)
Trace heating specification (C)
Power supply philosophy (C)

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11.3
Documents To Be Submitted By The Contractor

As well as any additional instructions in the requisition/purchase order, the
following detail design documents shall be submitted:
thermal design parameters (heat balance calculations used for the

design);
system flow diagram (isometrics showing the configuration of the heating

circuit);
equipment layout drawings (plans, sections, etc.);
schematic and connection diagrams covering the complete trace heating

installation;
pipe drawings (plans, isometrics, line lists, etc.);
piping specifications;
thermal insulation specifications;
equipment detail drawings (pumps, valves, strainers, etc.);
electrical drawings (single-line, etc.);
bill of materials;
general arrangement information showing location of all main boxes;
electrical equipment specifications;
equipment installation and instruction manuals;
equipment details (technical catalogue data of each item of the tracing

installation);
thermal insulation schedules;
area classification drawings;
ignition temperature of gas or vapor involved;
process procedures that would cause elevated pipe temperatures, e.g.

steam out or exothermic reactions;
Manufacturer's installation manual;
Manufacturer's test reports, certificates of conformity, declarations of

compliance;
Completed design data summary sheet
Each heater circuit should be shown on a drawing depicting its physical location,
configuration, and relevant data for the heating cable and its piping system.
The drawing and/or design data should include the following information:
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piping system designation;
pipe size and material;
piping location or line number;
heating cable designation or circuit number;
location of power connection, end seal, and temperature sensors as

applicable;
heating cable number;
heating cable characteristics such as the following:

-
temperature to be maintained;
maximum process temperature;
minimum Ambient Temperature;
maximum exposure temperature (if applicable);
maximum sheath temperature (if required);
heat-up parameters (if required);
length of piping;
trace ratio of heater cable per length of pipe;
extra length of heater cable applied to valves, pipe supports, and other
heat sinks;
length of heating cable;
operating voltage;
watt per unit length of heating cable at desired maintenance

temperature;
heat loss at desired maintenance temperature per unit length of pipe;
watts, total;
circuit current, start-up and steady-state;
thermal insulation type, nominal size, thickness, and k-factor;
area classification, including the lowest auto ignition temperature for

each area (if applicable);
bill of material.
The drawing should also indicate the power distribution panel number or
designation, the alarm and control equipment designation, and set points.

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11.4
Database
As part of the detailed design a database, in the format specified by OMV, shall
be submitted to OMV for inclusion in a (computerized) management system.
This database shall contain as a minimum the following information for each
individual heater circuit:
11.5
type of heating system (winterising, compensation, heating-up, etc.);
length of the heating cable(s) and number of circuits;
type of the heating cable;
maximum, minimum and maintaining temperature;
power demand per circuit at maintaining temperature;
type and thickness of the insulation;
list of lines selected for steam cleaning;
list of switches and junction boxes, cross-referenced with the marking of the
installation at site;
data on thermostat(s) and or temperature control system; also indicating for

what purpose they are installed.
Documents
The Manufacturer shall provide technical manual(s) and drawings in accordance
with the purchase order requirements, which shall include at least the following
documents (preferably on a CD ROM):
single line diagram of the unit;
general arrangement drawings;
main and control circuit schematic diagrams;
equipment lists;
recommended spare parts lists to cover startup and two years operation;
test reports and performance curves, including oscillograms of output

ripple;
operating manuals incorporating installation, commissioning, operating

and maintenance instructions, and fault-finding procedures;
battery calculation sheet.
CD ROMs shall incorporate all viewer software necessary to access the

information provided.

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12.0
REGULATORY AUTHORITY REVIEW REQUIREMENTS

Generally, works test certificates showing compliance with the relevant
constructional and performance standard(s) will be required for all equipment.

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APPENDIX 1 ILLUMINATION LEVELS

The required illumination levels, measured at the working plane or 1 m above
the floor level in a horizontal plane, are shown in the table below.
These values are mean values and the uniformity ratio (Emin/Emean) is for
normal installations.
These values shall be used as a basis for the design of new installations
unless higher illumination levels are required by national or local regulations in
the country of installation. The tabulated illumination levels apply when the
luminaires are dirty, i.e., after taking account of the following fouling factors:
Location
fouling factor
Plant areas (both indoor and

outdoor):
Non-plant areas (outdoor):
Non-plant areas (indoors):
0.80
0.80
0.85
REQUIRED ILLUMINATION LEVELS

Location
Emean
(Lux)
CONTROL ROOMS
General, including front of
panel
Rear of panels
Auxiliary rooms
Outside, near entrances
PLANT AREAS
Operating areas requiring
regular operator intervention
300/50
0
150
150/30
0
150
pumps,
compressors,
generators,
drivers, valves,
manifolds, loading
arms, etc.
Local control and monitoring indicating
points
instruments,
gauges and
control devices
Level gauges (see-through) to be lit from behind
by single tube fluorescent luminaries
Access ways:
walkways,
Notes
1, 7
150
75
25
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Location
Emean
(Lux)
platforms,
stairways, ladders.
Plant and jetty approaches and road intersections
Non-operational areas with limited attendance,
e.g., tank farms without equipment requiring
regular operator intervention.
Loading gantries:
top loading, walkways
and top of tankers
bottom loading (coupling
handling area)
Road tanker parking
area
NON-PLANT AREAS
Switchrooms, including relay and auxiliary rooms
Workshops and
garages
Warehouses and
stores
Notes
5
0.5
150
150
25
150
indoor general
250
local on workbenches
and machine tools
outdoor storage and
handling areas
indoor between storage
racks
bulk storage
outdoor storage areas
400
Laboratories and
analyser rooms
50
150
50
5
400
lit by twin 40 W
fluorescent or single 70
W HP sodium (SON)
luminaires on standard
8 m poles at, typically,
50 m spacing
NON-INDUSTRIAL AREAS
Canteens (dining areas)
Car parks
Catering areas (food preparation and serving)
Communications rooms
Computer rooms
Conference rooms
5, 6
Street lighting and

fence lighting

100
1
300
400
400
400
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Location
Corridors and stairways
Drawing offices
First aid rooms
Libraries and reading rooms
Lifts
Offices
Plant rooms
Print rooms
Reception areas
Recreation rooms and lounges
Store rooms
Toilets and locker rooms
Emean
(Lux)
100
400
400
400
100
400
150
250
150400
300
150
100
Notes
7, 8
NOTES:
1. 300 lux applies at night and 500 lux during the daytime. Control of the
illumination level down to 100 lux should be possible either by switching off
rows/groups of luminaires, or by use of electronic dimmers, or both.
2. 150 lux applies for normal access and 300 lux for maintenance activities.
The illumination level should be controlled by switching each lamp in a twin
fitting from separately controlled circuits or by switching alternative fittings.
3. Where overhead travelling cranes are installed, floodlights should be fitted
under the crane beam to provide an illumination level of 400 lux for better
illumination during maintenance.
4. In areas where very fine work is carried out, local lighting with higher
illumination levels may be required, e.g., 750 - 1000 lux on an instrument
workshop bench.
5. Higher illumination levels apply where security fence lighting is required,
e.g., for use with video camera surveillance. These shall be specified to be
compatible with the video system utilised.
6. At the security barrier and check point in front of site entrance gatehouses,
higher illumination levels may be required.
7. In rooms where VDUs are permanently installed, the lighting shall be
designed to avoid reflections and glare from the screens.
8. Local lighting shall be provided to give an illumination level of 700 lux on
drawing boards.

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APPENDIX 2 TYPICAL POWER SUPPLY AND DISTRIBUTION DIAGRAM

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APPENDIX 3 TYPICAL EXAMPLE OF HEATER DISTRIBUTION

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APPENDIX 4 TRACE HEATING INSTALLATION EXAMPLES

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Client Comments Incorporated

Issued for Comment/Approval

Issue or Revision Description

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Issued for Comment/Approval

Client Comments Incorporated

Philosophy for Lighting and Trace Heating

OMV Exploration & Production GmbH

Codes and Standards list.......................................................................................................... 6

6.0 SYSTEM GOAL ..............................................................................................................8

10.0 TRACE HEATING.........................................................................................................15

OMV Exploration & Production GmbH

10.15 Power Limiting Heaters........................................................................................................... 20

11.0 DOCUMENTS ...............................................................................................................30

12.0 REGULATORY AUTHORITY REVIEW REQUIREMENTS ..........................................35

Philosophy for Lighting and Trace Heating

OMV Exploration & Production GmbH

The temperature surrounding the object under

That portion of the wiring installation between the

Electrically insulated conductor or conductors used to

Heating elements that are electrically connected in

Philosophy for Lighting and Trace Heating

OMV Exploration & Production GmbH

any number of discrete zones.

APPLICABLE CODES, STANDARDS AND REGULATIONS

The provision of this document,

International standards (e.g. ISO, IEC etc),

Codes and Standards list

National Electrical Code

Electrical Installations in Petroleum Processing Plants

OMV Exploration & Production GmbH

Oil immersion "o"

Intrinsically safe electrical systems i

Electrical apparatus for explosive gas atmospheres

Degrees of protection provided by enclosures

Low voltage switchgear and controlgear, Part 2: Circuit

Electrical apparatus for explosive gas atmospheres

Electrical apparatus for explosive gas atmospheres

Industrial control devices, controllers and assemblies

IEEE Std 515

Recommended practice for the testing, design,

Philosophy for Lighting and Trace Heating

OMV Exploration & Production GmbH

European Community Directives. (Applicable with the EEC)

The Electromagnetic Compatibility (EMC) Directive

The low voltage equipment (safety) regulations

The Antmospheres Explosibles (ATEX) directive.

Philosophy for General Electrical Design Onshore

Philosophy for Main Generators and Switchboard Onshore

Philosophy for Rotating and Reciprocating Equipment

interface to the main electrical system

Interface to the PCS and HMI

luminaires and heating tape.

Philosophy for Lighting and Trace Heating

OMV Exploration & Production GmbH

General lighting requirements

Philosophy for Lighting and Trace Heating

OMV Exploration & Production GmbH

Philosophy for Lighting and Trace Heating

OMV Exploration & Production GmbH

Street and fence lighting