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Heat Trace FailSafe Ultimo FSU and FSUw Self-Regulating Heating Cable

Manufacturer: Heat Trace Ltd.

Industrial High-Temperature Self-Regulating Electric Heat Tracing Cable

Product Overview

The Heat Trace FailSafe Ultimo FSU and FSUw are industrial-grade self-regulating electric heating cables developed for high-temperature heat-tracing applications. They are designed to provide freeze protection for pipes and vessels and to maintain process temperatures in demanding industrial environments. The product range combines high thermal performance, inherent temperature safety and flexible installation options for process-critical heating systems.

FailSafe Ultimo automatically adjusts its heat output in response to changes in pipe temperature. As the pipe temperature decreases, the cable increases its heat output; as the temperature rises, its output decreases. This self-regulating characteristic helps deliver heat according to changing thermal requirements and supports reliable operation under varying process and ambient conditions.

A key feature of the FailSafe Ultimo range is its inherent temperature-safe design. According to the manufacturer, the heating cable will not overheat or burn out, even when overlapped upon itself, when operated within its specified ratings and installation requirements. Both the maximum continuous exposure temperature in the energised state and the maximum permissible exposure temperature in the de-energised state are rated at 250°C (482°F).

The standard FSU range is available in nominal power outputs of 15, 30, 45, 60 and 75 W/m at 10°C, while the wider FSUw version provides a nominal output of 100 W/m at 10°C. These outputs are specified at 230 V when installed on insulated metal pipes. Actual heat output varies with pipe temperature, supply voltage and installation conditions.

FailSafe Ultimo is suitable for use in non-hazardous and hazardous areas, subject to the applicable product variant, certification, temperature classification and installation requirements. Optional corrosion-resistant fluoropolymer outer jackets are available in the FSU-NF and FSUw-NF versions to support installations requiring enhanced resistance to corrosive environments.

Key Features and Benefits

• Self-regulating heating technology that automatically adjusts heat output in response to pipe temperature.
• High-temperature resistance with a maximum continuous exposure temperature of 250°C (482°F), both energised and de-energised.
• Nominal power outputs of 15, 30, 45, 60 and 75 W/m for the FSU range.
• High power output of up to 100 W/m at 10°C for the FSUw wide-cable version.
• Inherently temperature-safe design intended to prevent overheating under specified operating conditions.
• Suitable for freeze protection of industrial pipework and vessels.
• Designed for process temperature maintenance in demanding industrial applications.
• Can be cut to the required length on site in accordance with the manufacturer's instructions.
• Suitable for selected hazardous and non-hazardous area installations, subject to applicable approvals.
• Available with optional corrosion-resistant fluoropolymer outer jackets.
• Supports installation in industrial facilities, process plants, energy installations and other demanding environments.
• Compatible termination, splicing and power connection accessories are available.
• Designed for straightforward installation without the need for specialised cutting tools.
• Offers a choice of standard and wide cable profiles to meet different heating output requirements.

Technical Specifications

Industrial Applications

• Freeze protection of industrial process piping.
• Freeze protection of storage vessels and process equipment.
• Process temperature maintenance in high-temperature industrial systems.
• Heat tracing for pipes carrying temperature-sensitive fluids.
• Heating systems in oil and gas facilities.
• Heat tracing in chemical and petrochemical processing plants.
• Temperature maintenance in energy generation and industrial manufacturing facilities.
• Selected offshore and marine installations, subject to the applicable product approvals.
• Heating applications in classified hazardous areas requiring certified heat-tracing equipment.
• Corrosive industrial environments where the appropriate fluoropolymer-jacketed cable is specified.

Self-Regulating Heating Technology

The FailSafe Ultimo heating cable incorporates a self-regulating conductive heating matrix between its electrical bus wires. The electrical resistance of the heating matrix changes with temperature, allowing the cable to adjust its local heat output as thermal conditions change along the pipe or vessel.

When the pipe becomes colder, the cable produces more heat to help compensate for increased heat loss. As the pipe warms, the cable reduces its output. This characteristic helps accommodate changing ambient temperatures and process conditions without requiring the heating element to produce the same output continuously along its entire length.

The self-regulating construction also allows the cable to be cut to the required installation length, subject to the manufacturer's design rules and maximum circuit-length limitations. This simplifies adaptation to individual pipe sections, branches and equipment layouts.

Inherent Temperature Safety

FailSafe Ultimo is designed to provide inherent temperature safety by reducing its heat output as its temperature increases. The manufacturer states that the cable will not overheat or burn out, even when overlapped upon itself, within its specified operating limits.

The 250°C maximum exposure rating applies in both the energised and de-energised states. This capability makes the product suitable for selected high-temperature applications where conventional self-regulating cables with lower exposure-temperature limits may not be appropriate.

Inherent temperature safety does not eliminate the need for correct circuit protection, appropriate hazardous-area design, compliant installation and verification of process temperatures. The selected cable must remain within its certified electrical, thermal and environmental limits.

FSU and FSUw: Product Selection

The FSU and FSUw versions provide different nominal heating outputs to accommodate different thermal requirements. The standard FSU range offers five nominal outputs, while the FSUw wide version provides a higher nominal output for applications with greater heat-loss requirements.

The table provides nominal output ratings rather than guaranteed output at every operating temperature. Final selection requires a heat-loss calculation and verification of the actual cable output under the intended operating conditions.

Hazardous Area Applications and Certifications

FailSafe Ultimo is approved for selected hazardous-area applications as well as non-hazardous installations. The manufacturer lists ATEX and UKEX certifications for the FSU and FSUw ranges, with additional DNV type approval listed for the FSU range.

Hazardous-area suitability depends on the exact product variant, nominal output, supply voltage, gas or dust classification, temperature class, installation method and applicable certificate conditions. The cable must be selected and installed in accordance with the relevant certification documents and hazardous-area regulations.

For projects involving flammable gases, vapours or combustible dust, the design must consider the maximum permitted surface temperature, process temperature, electrical protection, cable termination and environmental conditions. The product's maximum exposure temperature alone must not be used to determine its suitability for a classified area.

Outer Jacket and Corrosion Resistance

FailSafe Ultimo is available with an optional corrosion-resistant fluoropolymer outer jacket. The FSU-NF and FSUw-NF versions provide jacketed cable configurations for installations where resistance to corrosive environmental conditions is an important selection factor.

The appropriate jacket and cable configuration should be chosen according to the chemicals present, operating temperatures, mechanical exposure, moisture conditions and applicable hazardous-area requirements. Chemical compatibility should be verified against the manufacturer's technical documentation before installation.

Installation and Mounting

FailSafe Ultimo is designed for practical installation on industrial pipework and vessels. Its cut-to-length construction allows the heating cable to be adapted to the required pipe route, while compatible connection and termination kits support power connection, splicing and end termination.

The cable must be installed in accordance with the manufacturer's instructions, including requirements for attachment, bending radius, thermal insulation, circuit design, cable spacing and electrical connections. The minimum specified bending radius for the FSU-NF and FSUw-NF versions is 35 mm.

Where thermal insulation is used, it must be suitable for the required process temperature and environmental conditions. Heat-loss calculations should account for pipe diameter, pipe material, insulation thickness, ambient temperature, required maintenance temperature and any applicable environmental factors.

For hazardous-area installations, all glands, junction boxes, termination kits and associated components must be compatible with the selected cable and approved for the applicable area classification. Installation, inspection, testing and commissioning should be performed by suitably qualified personnel.

Recommended Accessories

• UTK 344 termination kit for compatible FSU configurations.
• UTK 555 termination kit for compatible FSUw configurations.
• BPS4 power seal kit for compatible FSU installations.
• BPS5 power seal kit for compatible FSUw installations.
• BES4 and BES5 end seal kits, selected according to the cable and termination arrangement.
• DESTU Seal No. 5, where specified for the selected installation.
• Commercial junction boxes with knockouts (CMJB), where suitable for the system design.
• Compatible cable glands, junction boxes, connection components and electrical protection devices.
• Appropriate temperature monitoring and control equipment, where required by the process design or applicable regulations.

Accessory selection must follow the manufacturer's termination method matrix and installation instructions. Not every accessory is suitable for both FSU and FSUw configurations, so compatibility must be confirmed before ordering.

Circuit Length and Electrical Protection

The maximum permissible heating-circuit length depends on the selected cable output, supply voltage, circuit-breaker rating and expected start-up temperature. Self-regulating cables can draw higher current during cold start-up, making these factors essential when designing the power distribution system.

The manufacturer publishes maximum circuit-length data for different FSU and FSUw models at 230 V, based on specified circuit-breaker ratings and start-up temperatures. These values must be taken from the current product specification for the exact cable reference and installation conditions.

Circuit-breaker selection, supply cable sizing, protective earthing, residual-current protection where applicable, and coordination with other electrical protection devices must comply with the manufacturer's recommendations and applicable electrical standards. The nominal wattage alone is not sufficient to determine the permissible circuit length.

Design and Installation Considerations

Correct heat-tracing design begins with determining the required maintenance temperature and calculating the heat loss from the pipe or vessel. The calculation should consider the process temperature, minimum ambient temperature, pipe dimensions, insulation material, insulation thickness, environmental exposure and any additional heat losses.

The selected FSU or FSUw cable must provide sufficient heat output under the actual operating conditions. The designer must also verify the cable's maximum exposure temperature, hazardous-area temperature classification, supply voltage, circuit length, start-up current and compatibility with the selected accessories.

• Calculate pipe and vessel heat loss before selecting the cable output.
• Confirm the required process temperature and minimum ambient temperature.
• Select the appropriate FSU or FSUw nominal power rating.
• Verify the cable's maximum exposure temperature and certified temperature classification.
• Check supply voltage, circuit-breaker ratings and permissible circuit length.
• Observe the specified minimum bending radius during installation.
• Select compatible termination kits, cable glands and junction boxes.
• Verify chemical compatibility and outer-jacket requirements for corrosive environments.
• Confirm hazardous-area certification and installation conditions where applicable.
• Follow the manufacturer's testing, commissioning and maintenance instructions.

Product Summary

The Heat Trace FailSafe Ultimo FSU and FSUw are high-temperature industrial self-regulating heating cables developed for freeze protection and process temperature maintenance on pipes and vessels. Their self-regulating heating technology, inherent temperature-safe design, cut-to-length capability and maximum exposure-temperature rating of 250°C make them suitable for evaluating a wide range of demanding industrial heat-tracing applications.

The standard FSU range provides nominal outputs of 15, 30, 45, 60 and 75 W/m, while the FSUw version offers 100 W/m at 10°C. The range operates with a specified power supply of 12–277 V AC and offers optional corrosion-resistant fluoropolymer outer jackets for compatible configurations.

With hazardous-area approvals available for applicable variants and a range of compatible termination accessories, FailSafe Ultimo can be considered for industrial process plants, chemical facilities, energy installations, offshore applications and other demanding environments. Final product selection must be based on heat-loss calculations, operating conditions, certified temperature classification, electrical design and the manufacturer's current technical documentation.