Heating Cable –

Testing Procedures
September 11, 2010

Company Confidential Service Strategy 1

SEPTEMBER 2010 1
 Agenda

• System Overview • Testing

– Megger Test
• System Start-up
Start up
– Cold Resistance Test
• Mechanical Checks – Stabilized Current Test
• Electrical Tests – End of Circuit Voltage Test
• Documentation
• For Each Test
• Maintenance
– What is it
– Why do it
– When to do it
– How to do it

SEPTEMBER 2010 2
 Overview

SEPTEMBER 2010 3
 System Start-up

• General Considerations
– All parties involved should have a representative present for start-up.
– All start-up info should be logged and signed off by appropriate parties.
– All test equipment used for start-up testing should be in good repair and
CALIBRATED!
– Have all appropriate drawings, specifications, and instruction sheets on-hand for
reference.
f
• Mechanical Inspection
– Inspect all insulation and weatherproofing. (Wet insulation is Bad!)
– Inspect all junction box, connection box and sensor connections
– Verify sensors are in appropriate locations
– Verify all circuits have been properly grounded
– Verify all circuits are connected in proper panel locations
– Verify proper circuit breakers are in place
– Verify all circuit lengths are within manufacturers specified limits
– Verify all proper safety warnings are in place
– Verify all end seal, splice/tee locations are marked on lagging

SEPTEMBER 2010 4
 System Start-up

• Electrical Tests
– Insulation Resistance (Megger)
• Before tracing pipes
• After installing terminations
• Before Insulating pipes
• Aft Insulating
After I l ti pipes
i
• Before Energizing System
– Circuit Voltage
– Initial Current
• Note ambient temp and pipe temp
– Stabilized Current (15 minutes of operation)
• Note ambient temp and pipe temp

SEPTEMBER 2010 5
 Documentation

SEPTEMBER 2010 6
 Megger Test

• What is it??? • Equipment

– Tests Insulation Resistance – Insulation Resistance Tester
Between Conductive Core • Megger
and Grounding Braid – 1000VDC Minimum
– Detects damage that can – 2500VDC Best
result in cable short to
ground – Digital or Analog OK
• Failure could trip circuit – B tt
Battery O
Operated
t d Best
B t
breaker or cause fire
• How to do it
• When to do?? – Disconnect cable from
– Performed at the factory terminals in junction box
– After receipt at job site – One lead to ground braid
– After cable install – One lead to buss wire
– Aft Insulation
After I l ti – One minute
– At Start-up – Must have 50 Meg Ohms
– Periodically per Plus at 1000VDC
maintenance procedure – Record tested value

SEPTEMBER 2010 7
 Megger Test

Open Cover

Remove braid and lead from terminal block

SEPTEMBER 2010 8
 Megger Test

T t lead
Test l d position
iti R
Result
lt > 50M
50Mohm
h

SEPTEMBER 2010 9
 Cold Resistance Test

• What is it??? • Equipment

– Tests Resistance Between – Standard Multi Meter
C bl B
Cable Buss wires
i – Auto Range to 50Kohm
– Quick test to verify cable – Digital or Analog OK
output – Battery Operated Best

• When to do?? • How to do it

– Performed at the factory – Take one foot sample
p
– After receipt at job site – Condition for one hour at 70
– Prior to installation Deg F +/- 2 deg F
– One lead to each buss wire
– Set on Ohms
– Compare to known values
– Record

SEPTEMBER 2010 10
 Cold Resistance Test

Result = 2.2Kohms

Test lead position

SEPTEMBER 2010 11
 Stabilized Current Test

• What is it??? • Equipment

– Tests cable current at full – Standard Multi Meter with
g
voltage clampp on current
– Insures cable power output attachement
is correct for design and – Auto Range to 100 amps
stable – Digital or Analog OK
– Battery Operated Best
• When to do It?? Insulation
– After Insulation • How to do it
– At Start-up – Open UPC box
– Periodically
P i di ll per – Cl
Clamp onto
t one b buss wire
i
maintenance procedure – Energize circuit
– Allow circuit to run for 20
minutes minimum
– Take current reading /
record
Watts = Current * Voltage – Divide by circuit length
– Multiply by Voltage
– Compare to output at pipe
temp
SEPTEMBER 2010 12
 Stabilized Current Test

Open Cover

Clamp on buss wire

Read Result

Watts = Current * Voltage

SEPTEMBER 2010 13
 Stabilized Current Test
Watts = Current * Voltage

Compare
p calculated result to output
p chart at temp
p

SEPTEMBER 2010 14
 End of Circuit Voltage Test

• What is it??? • Equipment

– Tests Voltage at end of Line – Standard Multi Meter
– Verifies proper Voltage – Auto Range to 600 Volts
Applied – Digital or Analog OK
– Verifies Buss wires are – Battery Operated Best
good over entire length of
cable
• How to do it
• When to do?? – De-energize circuit
– At start-up – Remove end cap
– Periodically per – Expose buss wires
maintenance procedure – One test lead to each buss
wire
– Energize circuit
– R d voltage
Read lt
– Compare to desired value
– Record

SEPTEMBER 2010 15
 End of Circuit Voltage Test

Remove Cap Expose

p Buss Wires

SEPTEMBER 2010 16
 End of Circuit Voltage Test

Test lead position

Result = 120Vac

SEPTEMBER 2010 17
 Maintenance

• General Considerations
– All personnel should be qualified and trained to perform maintenance
work.
– All test equipment used should be in good repair and calibrated.
– All inspection and test results should be documented on circuit
maintenance
i t log.
l
– Freeze Protection should be checked prior to cold weather each year
as a minimum.
– Process Lines should be checked as the p process requires.
q

• Mechanical Inspections
– Follow same p
procedure as system
y start-up
p

• Electrical Inspections
– Follow same procedure as system start-up

SEPTEMBER 2010 18