Welcome to Tactics Automation

 You should consider trace heating if:

✓ Your pipes are exposed to freezing temperatures and contain water or other freeze-sensitive fluids

✓ You need to maintain product viscosity for pumping or processing

✓ You have process temperature requirements that must be maintained during shutdown or low flow

✓ You want to prevent condensation in instrumentation or electrical enclosures

✓ You operate in harsh environments where reliable heating is critical

 Trace heating (also called heat tracing or electric heat tracing) is a method of using electrical heating cables to prevent pipes, vessels, and equipment from freezing or to maintain specific process temperatures.

If you've ever wondered how industrial facilities keep their pipework from freezing in winter, or how they maintain viscous materials at the right temperature, the answer is usually trace heating.

In this guide, you'll learn:

• How trace heating works
• The different types of heating cables
• When and where trace heating is used
• How to choose the right system
• Compliance and safety standards

Trace heating works by running an electrical heating cable alongside or around a pipe, vessel, or equipment. The cable generates heat that compensates for heat lost to the environment, either to prevent freezing or to maintain a specific temperature.

The basic principle:

1. Heat loss occurs naturally from pipes and equipment to the surrounding air
2. Heating cable is installed along the pipe to replace that lost heat
3. Insulation is applied over both the pipe and cable to reduce heat loss
4. Temperature control maintains the desired temperature automatically

Trace heating works due to ohms law, Current equals voltage divided by resistance . Therefore,  if the resistance of the cable changes the current output will change providing designed heat.

1. Heating Cable

The heat-generating element. Available in self-regulating, constant wattage, or mineral-insulated (MI) types.

2. Temperature Sensor (typically PT100)

Monitors the pipe or process temperature and sends feedback to the controller.

3. Control Panel & Thermostat

Switches the heating on and off to maintain the set temperature. Includes circuit protection 

4. Power Connection & Terminations

Electrical connections that are weatherproof and compliant.

5. Insulation

Thermal insulation (lagging) over the pipe and heating cable to minimize heat loss and improve efficiency.

How it works: The cable automatically adjusts its heat output based on the surrounding temperature. As the pipe gets colder, the cable produces more heat. As it warms up, heat output decreases, due to the change in the resistance. 

Advantages:

• Energy efficient (only heats where needed)
• Can be cut to length on site
• Reduced risk of overheating
• Lower running costs

Best for: Freeze protection, long pipe runs, winterization, water pipes

Typical applications: Domestic water lines, fire suppression systems, roof and gutter de-icing

How it works: Produces a fixed heat output per meter, regardless of temperature. Requires precise design and temperature control.

Advantages:

• Higher heat output per meter
• Suitable for higher temperature maintenance
• Precise temperature control

Best for: Process temperature maintenance, long pipe runs with consistent heat requirements

Typical applications: Chemical processing, maintaining viscosity in oil or bitumen lines

How it works: Heating element inside a copper or stainless steel sheath, insulated with magnesium oxide powder. Extremely robust and capable of very high temperatures.

Advantages:

• High temperature capability (up to 600°C)
• Extremely durable and impact-resistant
• Suitable for hazardous areas (ATEX)
• Long service life

Best for: High-temperature applications, harsh environments, heavy-duty industrial use

Typical applications: Steam lines, hot oil systems, petrochemical plants, power generation

The problem: Water pipes, fire sprinkler lines, and instrumentation freeze in cold weather, causing damage and downtime.

The solution: Self-regulating trace heating cable maintains pipes above 0°C (typically 3-5°C) to prevent ice formation.

Where it's used:

• External water pipes
• Fire sprinkler systems
• Condensate lines
• Instrument air lines
• PRV kiosks and meter chambers

The problem: Materials like oils, chemicals, or food products solidify or become too viscous if they cool down.

The solution: Constant wattage or MI heating cables maintain the exact process temperature required.

Where it's used:

• Bitumen and asphalt lines
• Chemical processing pipes
• Food and beverage (chocolate, syrups)
• Molten sulfur lines
• Hot oil systems

The problem: Steam condensate lines can freeze or cool excessively, causing system inefficiency.

The solution: Trace heating maintains condensate at the right temperature for proper drainage.

The problem: Petrochemical and process industries need heating in potentially explosive atmospheres (ATEX zones).

The solution: Certified trace heating systems designed to IEC 60079-30-1 standards for safe operation in Zone 1 and Zone 2 areas.