Self-regulating

Heat Trace

PSD 161
Systems

Continuing Education from Plumbing Systems & Design

OCTOBER 2009

PSDMAGAZINE.ORG

Self-regulating
Heat Trace Systems
A hot water self-regulating heat trace system can be used for prompt
delivery of hot water at the fixtures. A heating cable system is one of
several accepted methods of providing prompt delivery of hot water.
(See Chapter 14.)
Today’s buildings are more architecturally complex than those built
a decade ago and make ever increasing demands on the interstitial
space occupied by HVAC ductwork, mechanical piping, communi-
cation wiring, and electrical conduits. This, combined with the need
to conserve energy and water, challenge engineers to provide cost-
effective, energy-efficient domestic hot water systems. Maintaining the
temperature of a domestic hot water system may entail establishing
a means to continuously recirculate the water via pumps, valves, and
additional piping. An alternative method is to use self-regulating heat
trace systems.
Water conservation has become a major concern in the past few
years. The need to conserve water has led to requirements for the use
of low-flow fixtures, including faucets, showers, and water closets. The
water wastage that occurs when cooled water is dumped down the
drain while the user is waiting for hot water to flow can no longer be tol-
erated. In addition to wasting a precious resource, this practice incurs
extra energy costs to heat the water and waste treatment costs to pro-
cess the wasted water. The ability to keep a pipe warm close to the point
of use is of particular interest with the low-flow fixtures used today.
Note: All decimal equivalencies in the metric calculations are rounded.
Therefore, the metric conversions shown in the text may vary slightly
from theanswers shown in the metric equations.
Variables affecting the performance of a heat trace system include:
the system temperature range, time to tap, water wastage, and energy
efficiency. Designers should consider these factors along with instal-
lation and life-cycle costs when selecting the proper hot water self-
regulating heat trace system for a particular building.
SYSTEM DESCRIPTION
Electric heat tracing systems replace heat lost through the thermal
insulation on hot water supply piping to maintain the water at desired
nominal temperatures, eliminating the need for insulated recirculation
lines, pumps, and balancing valves. Preventing the hot water from cool-
ing also ensures that hot water is readily available when it is needed.
An electrical heat tracing system is not a substitute for a complete,
efficient domestic hot water system. It does not eliminate the need for
an efficient water heater. What a heat tracing system does is provide
another approach to the design and installation of a hot water system.
It does this by simplifying the hot water distribution system, thereby
minimizing the amount of piping required. Items such as additional
piping and balancing valves are unnecessary.
In a heat trace system, a self-regulating heating cable is attached
directly to the hot water supply piping and insulated. A self-regulating
heating cable adjusts its power at each point along its length to main-
tain nominal temperature throughout the piping system. Electrical
energy input is controlled by the cable’s construction to maintain the
required water temperature at the fixtures. No return piping or circula-
tion pump is required.
Reprinted from Domestic Water Heating Design Manual, Second Edition, Chapter 15: “Self-Regulating Heat Trace Systems”
© American Society of Plumbing Engineers, 2008.
2  Plumbing Systems & Design  OCTOBER 2009
CONTINUING EDUCATION
Successful installation of a heat tracing system requires coordination
among the various tradespeople involved. Plumbers and electrical and
insulation contractors must be made aware of the specific require-
ments affecting each other’s work.
The information in this chapter will help the designer understand
electric heat tracing as it applies to hot water systems. With this infor-
mation, a designer should be able to:
1. Compare the merits of heat tracing and a recirculation system
based on the requirements of a specific project.
2. Identify the extent of piping requiring heat tracing. Self-Regulat-
ing Heat Trace Systems
3. Understand the role of thermal insulation in hot water heat trac-
ing.
4. In coordination with an electrical engineer, determine the circuit
breaker/power requirements based on the estimated heat tracing
circuit lengths.
5. Translate the design requirements into a complete design for a
project.
All examples and descriptions in this chapter are based on copper
water piping with fiberglass thermal insulation and other typical
design conditions. While design parameters may differ and pipe and
insulation materials other than those discussed can be and frequently
are equipped with heat tracing, such jobs should be undertaken with
the design assistance of a qualified manufacturer’s representative.
PRODUCT DESCRIPTION
Only Underwriters Laboratories, Inc., listed electric heat tracing sys-
tems for hot water temperature maintenance should be used. (Note:
Thirty mA ground fault equipment protection is to be used for all hot
water heat tracing circuits.) These tested and approved systems are
based on self-regulating heating cables that are specifically designed for
hot water temperature maintenance. (See Figure 1.) Heat is delivered
through a carbon matrix heating element that responds to temperature
changes. Whenever the temperature in the heat traced piping begins to
rise, the cable automatically reduces its heat output. Conversely, when
the water temperature begins to drop the cable reacts by increasing its
heat output. This self-regulating feature occurs along the entire length
of a heat tracing circuit to ensure that each point receives the amount
of heat necessary to maintain thermal equilibrium.
Heating cables, self-regulating or otherwise, intended for pipe freeze
protection or general temperature maintenance should not be used for
hot water temperature maintenance, since their performance has not
been matched to the requirements of hot water applications.
SYSTEM COMPONENTS
A hot water temperature maintenance system (such as the one shown
in Figure 2) typically includes the following components:
1. Self-regulating heating cable.
2. Power connection kit.1
3. Tee/inline splice kit (permits 2 or 3 cables to be spliced together).
4. Cable end termination.
5. Attachment tape (secures cable to pipe, use at 12 to 24 in.
[305 to 610 mm] intervals).
WWW.PSDMAGAZINE.ORG
 copper bus wires

conductive core

heating cable
insulating jacket

foil wrap
Figure 2 Components of a Hot Water Temperature Maintenance System.
Source: Courtesy of Thermon Manufacturing Co.
Note: See “System Components,” above, for identification of numbered parts.
tinned-copper braid

Table 1 Time for Hot Water to Reach Fixture (sec)

Distance from End of Heat Tracing Circuit to
FixtureFlow Rate Point of Use (ft)
outer jacket (gpm) 15 20 25 30 40
1 23 30 38 45 60
1.5 15 20 25 30 40
2 11 15 19 23 30
2.5 9 12 15 18 24
3 8 10 13 15 20
3.5 6 9 11 13 17
Figure 1 Construction of a Typical Heating Cable for Hot Water Temperature 4 6 8 9 11 15
Maintenance.
Source: Courtesy of Raychem Corporation. Source: Courtesy of Thermon Manufacturing Co.
Note: Numbers based on use of ¾ in. nominal diameter type L copper tubing. Calculations
are based on the heat loss from the piping and do not include the amount of heat
required to heat the piping or the water in the piping. See Chapter 14 for these values.
6. Electric heat tracing label (peel and stick label that attaches to
insulation vapor barrier at 10 ft [3.05 m] intervals, or as required
by code or specification).
7. Fiberglass thermal insulation and vapor barrier.2 Table 1(M) Time for Hot Water to Reach Fixture (sec)
Distance from End of Heat Tracing Circuit to
1
Power connection kits do not include electrical junction boxes. FixtureFlow Rate Point of Use (m)
2
All heat traced lines are to be thermally insulated with fiberglass. Refer (L/sec) 4.6 6.1 7.6 9.1 12.2
to the manufacturer’s insulation schedule for insulation information. 0.06 23 30 38 45 60
0.10 15 20 25 30 40
0.13 11 15 19 23 30
IDENTIFYING THE PIPING REQUIRING HEAT TRACING
0.16 9 12 15 18 24
Typically, main and branch lines that are ¾ inch (DN22) and larger
0.19 8 10 13 15 20
are the primary locations for the application of a hot water heat trac-
ing system. A heat traced line can maintain hot water to every point of 0.22 6 9 11 13 17
use. Systems with different pressure or temperature zones can easily be 0.25 6 8 9 11 15
accommodated in the design and layout of heating circuits. Source: Courtesy of Thermon Manufacturing Co.
Note: Numbers based on use of DN22 nominal diameter type L copper tubing. Calculations
Deciding how close to the point of use the heat tracing should be are based on the heat loss from the piping and do not include the amount of heat
installed depends on the following conditions: required to heat the piping or the water in the piping. See Chapter 14 for these values.
1. The gallons per minute (liters per second) of the fixture.
2. The diameter of the runout line.
3. The number of times per day the fixture will be used. the correlation of time to get hot water (in seconds), to fixture flow rate,
4. The acceptable period of time to wait for hot water. to length of ¾ in. (DN22) diameter runout piping that is not tempera-
5. The acceptable level of water waste per fixture per use. ture maintained.
6. Any special requirements at the point of use. While considering the time factor may be important for the purposes
Most new facilities require fixtures that limit the gpm (L/sec) used by of keeping users satisfied, there is a more critical issue. Even with low-
lavatories and showers. As a result, the length of uncirculated, non- flow fixtures, the amount of water wasted by dumping water until the
heat traced piping has become increasingly important. Table 1 shows desired temperature is reached can be significant. (See Table 2.)

OCTOBER 2009  Plumbing Systems & Design  3

 CONTINUING EDUCATION: Self-regulating Heat Trace Systems
Table 2 Water Wasted While Waiting for Hot Water to Reach Fixture (oz)
Nom. Diam. Distance from End Temperature Maintenance
Type L Copper (in.) to Point of Use (ft)
(L/sec) 15 20 25 30 40
3/4 48 64 80 97 129
Source: Courtesy of Thermon Manufacturing Co.
Notes:
1. Remember to add up all the fixtures in a facility and to multiply by both the waste
number shown and the expected number of usages per day.
2. Numbers based on line diameter and distance from end of temperature maintenance.

Table 2(M) Water Wasted While Waiting for Hot Water to Reach Fixture (mL)
Nom. Diam. Distance from End Temperature Maintenance
Type L to Point of Use (m)
Copper 4.6 6.1 7.6 9.1 12.2
DN22 1420 1895 2365 2970 3815
Source: Courtesy of Thermon Manufacturing Co.
Notes:
1. Remember to add up all the fixtures in a facility and to multiply by both the waste
number shown and the expected number of usages per day.
2. Numbers based on line diameter and distance from end of temperature maintenance.

Figure 3 Symbols Used to Indicate Components of a Heat Traced Hot Water

Supply System.
DESIGN CONSIDERATIONS Source: Courtesy of Thermon Manufacturing Co.
Heating cable systems do not require system balancing. Often they are Note: The numberals inside the symbols refer to circuit numbers.
used in buildings with significant lengths of return piping relative to
the lengths of supply piping or in hot water systems requiring multiple Table 3 Nominal Maintenance Temperatures, °F (°C)
circulation loops. Hospitals, Hotels,
Heating cable systems may not be economical in buildings with Ambient Range, Hospitals,Nursing Condos, Prisons, Kitchens,
°F (°C) Homes, Prisons Schools Laundries
doughnut configurations and small amounts of return piping. Such
75–80 105 (42)
systems still may be selected, however, if the designer wishes to elimi-
(24–27)
nate flow balancing.
72–80 120 (49) 140 (60)
(22–27)
Multiple Temperature Systems Source: Courtesy of Thermon Manufacturing Co.
For systems requiring multiple temperatures, heating cable can be
installed on the supply piping after the mixing valve to maintain the
based on the desired maintenance temperature. If temperatures differ
different temperatures independently.
from those shown, contact the manufacturer.

Remodels and Additions

For buildings with existing return systems, heating cable systems can be
installed in the additions so that hot water temperature is maintained
in the new piping without affecting the performance of the existing hot
water systems.
COORDINATING DESIGN INFORMATION
To get the most from each heat tracing circuit, the designer should
establish the maximum circuit length based on the number of circuit
breakers available for the project. (Note: Maximum circuit lengths
vary according to the voltage and temperature selection.) Regardless
of a building’s shape and size, it is recommended that the heat tracing
circuits be organized to follow the layout of the cable. For ease of iden-
tification during the layout process and for effective communication,
the designer should identify the piping requiring heat tracing on the
plumbing drawings. While indication of the heating cable, power con-
nection, end termination, and tee splice kits is given on the plumbing
drawings, only the power connection points need to be referenced on
the electrical drawings.
The symbols shown in Figure 3 are routinely used to indicate compo-
nents of a heat traced hot water supply system.
DETERMINING THE TEMPERATURE TO MAINTAIN
The desired temperatures for most applications are given in Table 3
along with the ambient temperature ranges of the space surrounding
the insulated pipe. The appropriate self-regulating cable is chosen
CHOOSING THE RIGHT CABLE
After determining the extent of the hot water supply piping to be heat
traced, the designer should decide the lengths to be maintained at
105, 120, and/or 140°F (42, 49, and/or 60°C). At this point, the total
length of each type of heating cable can be determined. Using the
manufacturer’s published maximum circuit length for the desired
temperature cable, the designer can figure the required number of
circuits. These maximum circuit lengths should not be exceeded; oth-
erwise, there will be excessive electrical currents in the bus wires of
the heating cable. The maximum circuit length is the total length of
cable that can be fed from a single power connection point, inclusive
of all splices, including tees. Note that circuit lengths that are longer
than these maximum lengths may require larger circuit breakers. The
designer must be sure to check with the electrical engineer the avail-
able amperages of the branch circuit breakers supplying power to the
heat tracing. After the required number of circuits is determined, that
information should also be checked with the electrical engineer. This
will ensure that the proper number of circuits has been allotted in the
power distribution system.
THERMAL INSULATION
While frequently overlooked, thermal insulation plays a critical role in
ensuring that hot water is available at the point of use. This is true for
both recirculation and heat traced hot water systems.
The standard design for heat traced piping (the design that manufac-
turers’ design guides are based on) utilizes fiberglass thermal insula-

4  Plumbing Systems & Design  OCTOBER 2009 WWW.PSDMAGAZINE.ORG


Figure 4 Partial Simplified System Typical of Hospitals,
Correctional Facilities, and Hotels.
Source: Courtesy of Thermon Manufacturing Co.
tion with a kraft paper vapor barrier. Thicknesses range from 1 to 2 in.
(25.4 to 50.8 mm) based on line diameter. If a heat traced hot water
system is designed to use only one cable for each temperature range,
the thickness of the insulation will vary.
Manufacturers of hot water heat tracing systems have established
insulation schedules that outline the thicknesses required to keep the
heat loss within the desired range. Note that in these schedules the
insulation on piping 1 ¼ in. (DN35) in diameter and smaller is over-
sized to allow space for the heating cable.
After the installation of the heating cable and thermal insulation
is completed, the piping is identified with stick-on labels to note the
presence of electric heat tracing. This labeling gives notice to facility
maintenance workers that heating cable has been installed under the
insulation should any pipe maintenance or renovations be required.
HEAT TRACING HOT WATER PIPING
The design of a heat tracing temperature maintenance system for mains
and branch lines can be done on the plumbing drawings. (See Figure
4.) By referring to the manufacturer’s heating cable selection chart for
the desired maintenance temperature, the designer can determine the
maximum heating cable circuit length for circuit breakers of different
sizes. Taking this information into account when laying out the hot
water lines will ensure optimum use of the circuit lengths.
Note, in Figure 4, that the main and branch lines are heat traced and
insulated while the short runouts are only insulated. (Runouts that
feed individual points of use typically contain less than ½ gal [1.89 L] of
water. If the faucet flow rate is above 1½ gpm [0.1 L/sec], hot water will
reach the point of use within 10 sec.) If the distance between the branch
line and the point of use is much longer than 40 ft (12.19 m) or the flow
rate is lower, the potential for water wastage and the time required for
hot water to reach the point of use may be beyond the levels considered
acceptable for the facility. To remedy this situation, simply heat trace
closer to the point of use.
COMBINING HORIZONTAL MAINS WITH SUPPLY RISERS
Designers of multilevel facilities often duplicate floor plans over several
levels, which simplifies the layout of electrical, HVAC, and mechanical
equipment. This practice also simplifies the layout of hot water supply
lines, unless there is a maze of recirculation piping and balancing
valves are required. Figure 5 shows a layout typical of two to four-story
Figure 5 Typical Layout for 2 to 4-Story Hospitals,
Research Labs, Correctional Facilities, and Dormitories.
Source: Courtesy of Thermon Manufacturing Co.
facilities, such as hospitals, research labs, correctional facilities, and
campus dormitories.
In this example, the supply main is located in the interstitial space
between the first-story ceiling and the second-story floor. Because each
story has roughly the same layout and water use points are stacked, a
riser and drop are used to supply water at each plumbing location.
Electric heat tracing is installed on the horizontal mains and the
risers. Since the distance between the horizontal piping and the first-
story runouts is minimal (less than 15 ft [4.57 m]), heating cable is not
required beyond the horizontal line connecting the main to the riser.
Since this example is of a four-story facility, it is recommended that
heating cable be installed up to the feed point for the third story. The
line feeding from level three to level four again is less than 15 ft (4.57
m), and under most conditions a line of this length does not require
heat tracing. Untraced lines should be installed so as to prevent rapid
heat loss between uses.
While this example is somewhat simplistic, the design principles it
demonstrates can be applied to a project of any size.
HOT WATER HEAT TRACING TERMS
The following terms apply to all hot water heat tracing systems and may
aid in the selection of the appropriate system for each project.
1. System temperature range. For a return system, this is the
allowable temperature drop to the end of the system plus any
additional variability caused by improper system balancing.
With return systems, there is a trade-off between desired system
performance and the life-cycle cost of the system. For a heating
cable system, the system temperature range is the range around
the nominal maintenance temperature.
2. Unheated distance. This is the distance in feet (meters) between
the last maintained leg of hot water piping and the point of use.
For example, if hot water temperature is maintained only for the
main run, the distance from the main to the point of use is the
unheated distance.
3. Time to tap. This is the time required for hot water to reach the
fixture when the fixture is turned on. If the hot water temperature
is not maintained all the way to the fixture, the cold water in the
pipe must be drawn out before the user gets hot water. The length
of the wait is called time to tap. It is a function of the unheated
distance, the gpm (L/sec) flow rate, and the diameter of the pipe.
OCTOBER 2009  Plumbing Systems & Design  5
 CONTINUING EDUCATION: Self-regulating Heat Trace Systems

Continuing Education from Plumbing Systems & Design

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About This Issue’s Article
The October 2009 continuing education article is “Self-
regulating Heat Trace Systems,” Chapter 15 of Domestic
Water Heating Design Manual II.

Now Online! A hot water self-regulating heat trace system can be

The technical article you must read to complete the exam is located
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Note: In determining your answers to the CE questions, use only the material
presented in the corresponding continuing education article. Using informa-
used for prompt delivery of hot water at the fixtures. This
chapter helps designers understand electric heat tracing as
it applies to hot water systems, including how to compare
the merits of heat tracing and a recirculation system based
on the requirements of a specific project, identify the ex-
tent of piping requiring heat tracing, understand the role
of thermal insulation in hot water heat tracing, determine
the circuit breaker/power requirements based on the
estimated heat tracing circuit lengths, and translate the
design requirements into a complete design for a project.
You may locate this article at www.psdmagazine.org.
Read the article, complete the following exam, and submit
your answer sheet to the ASPE office to potentially receive
0.1 CEU.

PSD 161
tion from other materials may result in a wrong answer.

CE Questions — “Self-regulating Heat Trace Systems” (PSD 161)

1. All hot water heat tracing circuits should be protected by 7. Heating cable systems may not be economical in buildings with
________ ground fault equipment. a ________ configuration.
a. 10 mA a. square
b. 20 mA b. doughnut
c. 30 mA c. cylindrical
d. 40 mA d. pyramid
2. A typical heating cable for hot water temperature maintenance 8. On the plumbing drawing, a number inside a circle indicates
contains ________. what component of a heat tracing system?
a. foil wrap a. power connection point
b. conductive core b. tee splice kit
c. copper bus wires c. end of circuit termination
d. all of the above d. none of the above
3. Heat-traced lines should be thermally insulated with what? 9. If the ambient temperature surrounding the pipe in a condo is
a. fiberglass 75°F, what is the desired nominal maintenance temperature?
b. foam a. 105°F
c. rubber b. 120°F
d. wool c. 140°F
d. 180°F
4. What should you consider when deciding how close to the point
of use the heat tracing should be installed? 10. Runouts feeding individual points of use typically contain less
a. diameter of the runout line than ________ of water.
b. gpm of the fixture a. 0.5 gallon
c. DFU of the fixture b. 1 gallon
d. both a and b c. 1.5 gallons
d. none of the above
5. How long would it take hot water to travel to a 3-gpm fixture
25 feet from the end of the heat tracing circuit? 11. The system temperature range for a heating cable system is the
a. 15 seconds range around the ________.
b. 13 seconds a. allowable temperature drop
c. 11 seconds b. outside temperature
d. 9 seconds c. nominal maintenance temperature
d. ambient temperature
6. ________ ounces of water are wasted waiting for hot water
to reach a fixture 30 feet from the end of temperature 12. Time to tap is a function of what?
maintenance. a. unheated distance
a. 64 b. flow rate
b. 80 c. pipe diameter
c. 97 d. all of the above
d. 129

6  Plumbing Systems & Design  OCTOBER 2009 WWW.PSDMAGAZINE.ORG

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Self-regulating Heat Trace Systems (PSD 161)
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OCTOBER 2009  Plumbing Systems & Design  7