کابل هیت تریس خودتنظیم صنعتی FSS

Heat Trace FailSafe Super FSS Self-Regulating Heating Cable

Manufacturer: Heat Trace Ltd.

Industrial Self-Regulating Electric Heat Tracing Cable for High-Temperature Applications

Product Overview

The Heat Trace FailSafe Super (FSS) is an industrial-grade self-regulating electric heating cable designed for freeze protection and process temperature maintenance in pipework and vessels exposed to demanding operating conditions. With a maximum permissible exposure temperature of 225°C (437°F), FailSafe Super is suitable for selected high-temperature industrial heat-tracing applications.

The cable incorporates self-regulating heating technology that automatically adjusts its heat output in response to changes in pipe temperature. When the pipe temperature decreases, the heating cable increases its output to compensate for heat loss. As the pipe temperature rises, the cable reduces its output. This characteristic supports efficient heat delivery under changing ambient and process conditions.

A key feature of FailSafe Super is its inherently temperature-safe design. According to the manufacturer, the cable will not overheat or burn out, even when overlapped upon itself, provided that the specified operating limits and installation requirements are observed. Its maximum continuous exposure temperature in the energised state and maximum permissible exposure temperature in the de-energised state are both rated at 225°C (437°F).

FailSafe Super is available in nominal power outputs of 15, 30, 45, 60 and 75 W/m at 10°C. These ratings are specified at 230 V when the cable is installed on insulated metal pipes. Actual heat output varies according to pipe temperature, supply voltage and installation conditions.

The FSS range is designed for use in non-hazardous and selected hazardous areas, subject to the applicable product approvals, temperature classification and installation requirements. The FSS-CF version features a corrosion-resistant fluoropolymer outer jacket for applications requiring enhanced protection against corrosive environmental conditions.

The cable can be cut to the required length on site, making it adaptable to individual pipe runs and vessel configurations. Compatible termination, splicing and power connection components are available in dedicated accessory kits to support installation and system integration.

Key Features and Benefits

• Self-regulating heating technology that adjusts heat output in response to pipe temperature.
• Maximum continuous exposure temperature of 225°C (437°F) in the energised state.
• Maximum permissible exposure temperature of 225°C (437°F) in the de-energised state.
• Five nominal heating outputs: 15, 30, 45, 60 and 75 W/m at 10°C.
• Inherently temperature-safe design intended to prevent overheating under specified operating conditions.
• Suitable for industrial pipe and vessel freeze protection.
• Designed for process temperature maintenance in demanding industrial environments.
• 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 a corrosion-resistant fluoropolymer outer jacket in the FSS-CF version.
• Compatible termination, splicing and power connection accessories are available.
• Designed for straightforward installation without specialised cutting tools.
• Suitable for a range of industrial piping layouts and heat-tracing configurations.
• Supports reliable temperature maintenance under changing ambient conditions.
• Offers multiple power ratings to accommodate different calculated heat-loss requirements.

Technical Specifications

Industrial Applications

• Freeze protection of industrial process piping.
• Freeze protection of storage vessels and industrial equipment.
• Process temperature maintenance in high-temperature piping systems.
• Heat tracing for pipes carrying temperature-sensitive fluids.
• Heating applications in oil and gas facilities.
• Heat tracing in chemical and petrochemical processing plants.
• Temperature maintenance in power generation facilities.
• Industrial manufacturing and process engineering installations.
• Selected hazardous-area applications requiring appropriately certified heat-tracing equipment.
• Corrosive environments where the FSS-CF fluoropolymer-jacketed version is suitable.
• Industrial pipework exposed to low ambient temperatures.
• Vessels and equipment requiring reliable thermal maintenance within the cable's rated limits.

Self-Regulating Heating Technology

The FailSafe Super heating cable uses a self-regulating conductive heating matrix positioned between its electrical bus wires. The electrical characteristics of the heating matrix change with temperature, allowing the cable to adjust its local heat output in response to thermal conditions along the pipe or vessel.

When the pipe becomes colder, the cable increases its heat output to help compensate for greater heat loss. As the pipe warms, the cable reduces its output. This behaviour supports the changing heating requirements of industrial installations and helps avoid producing the same heat output continuously under all operating conditions.

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

Actual heating performance depends on the cable model, supply voltage, pipe temperature, insulation system and installation configuration. A heat-loss calculation is required to determine whether the selected power output can maintain the required process temperature.

Inherent Temperature Safety

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

The maximum exposure temperature is rated at 225°C (437°F) in both the energised and de-energised states. This characteristic makes FailSafe Super suitable for evaluating selected high-temperature applications where conventional self-regulating heating cables with lower exposure-temperature limits may not be appropriate.

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

FSS Power Ratings and Product Selection

The FailSafe Super range is available in five nominal power ratings to accommodate different heat-loss requirements. The appropriate model should be selected according to the calculated heat loss of the pipe or vessel, the required maintenance temperature, the minimum ambient temperature and the insulation characteristics.

The power ratings represent nominal output at 10°C under the manufacturer's specified reference conditions. They do not represent a constant heat output at every pipe temperature. Final selection must be based on heat-loss calculations and the manufacturer's output data for the intended operating conditions.

Hazardous Area Applications and Certifications

FailSafe Super is approved for selected hazardous-area applications as well as non-hazardous installations. The manufacturer lists ATEX and UKEX certification documentation for applicable FSS configurations.

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

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

FSS-CF Outer Jacket and Corrosion Resistance

The FSS-CF version features a corrosion-resistant fluoropolymer outer jacket. This construction is intended for applications where the cable may be exposed to corrosive environmental conditions and where the appropriate outer-jacket material is required.

The selection of the outer jacket should consider the chemicals present, operating temperatures, mechanical exposure, moisture conditions and applicable installation requirements. Chemical compatibility must be verified against the manufacturer's technical documentation before the cable is specified for a particular environment.

The published dimensions, bending radius, weight and cable gland information for the FSS-CF version should not automatically be applied to other configurations without confirmation from the relevant product documentation.

Installation and Mounting

FailSafe Super is designed for installation on industrial pipework and vessels. Its cut-to-length construction allows the cable to be adapted to the required piping layout, 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. For the FSS-CF version, the specified minimum bending radius 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 relevant environmental factors.

For hazardous-area installations, cable 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 FSS installations.
• BPS4 power seal kit for compatible FSS configurations.
• BES4 end seal kit for compatible FSS configurations.
• DESTU Seal No. 5, where specified for the selected installation arrangement.
• Commercial junction box with knockouts (CMJB), where suitable for the system design.
• Compatible cable glands and electrical connection components.
• Appropriate circuit protection devices selected according to the cable and electrical design.
• Temperature monitoring and control equipment, where required by the process design or applicable regulations.

Accessory selection must follow the manufacturer's current termination instructions and compatibility guidance. Confirm that the selected kit is approved for the exact FSS or FSS-CF configuration before ordering or installation.

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 heating cables can draw higher current during cold start-up, so these factors are essential when designing the electrical distribution system.

The manufacturer publishes maximum circuit-length data for individual FSS models at 230 V, based on specified circuit-breaker ratings and start-up temperatures. The permissible length must be selected from the applicable manufacturer's data for the exact cable model and installation conditions.

Circuit-breaker selection, supply cable sizing, protective earthing and any required residual-current protection must comply with the manufacturer's recommendations and applicable electrical standards. 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 and environmental exposure.

The selected FSS cable must provide sufficient heat output under the actual operating conditions. The designer must also verify the maximum exposure temperature, certified temperature classification, supply voltage, circuit length, start-up current and compatibility of 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 15, 30, 45, 60 or 75 W/m FSS model.
• Verify the cable's exposure-temperature rating 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 certificate conditions where applicable.
• Follow the manufacturer's testing, commissioning and maintenance instructions.

Product Summary

The Heat Trace FailSafe Super FSS is an industrial self-regulating heating cable developed for freeze protection and process temperature maintenance in pipes and vessels. Its self-regulating heating technology, inherently temperature-safe design and cut-to-length capability make it suitable for evaluating a range of demanding industrial heat-tracing applications.

The FSS range offers nominal power outputs of 15, 30, 45, 60 and 75 W/m at 10°C, with a specified supply voltage range of 12–277 V AC. Its maximum continuous exposure temperature in the energised state and maximum permissible exposure temperature in the de-energised state are both rated at 225°C (437°F).

The FSS-CF version provides a corrosion-resistant fluoropolymer outer jacket for compatible applications. With hazardous-area approvals available for applicable configurations and compatible termination accessories, FailSafe Super can be considered for industrial process plants, oil and gas facilities, chemical installations and other demanding environments.