Pipe Freeze Protection

nVent Thermal Management offers complete heating systems for Frost protection to meet the diverse requirements of many different industries: oil and gas, utilities, petrochemicals, specialty chemicals, pulp and paper, and pharmaceuticals. Pipe-Freeze-Protection-Industrial.jpg

Water, and fluids containing significant water, expand as they freeze. This expansion can cause the pipe to break—leading to property damage or production loss, or jeopardizing personnel safety.

  • A frozen water pipe leading to a critical process—like a frozen pipe in waste water treatment plant or cooling tower can shut down the operation causing multi-million dollars of losses.
  • A frozen pipe to safety showers can jeopardize personnel safety in the event of hazardous chemical exposure.

We offer various systems of pipe freeze protection using different technologies, suitable for use in hazardous and non-hazardous areas.

Pipe Freeze Protection – Easy to use products or a Complete Heat Management System Approach

nVent Thermal Management offers pipe freeze protection as a complete heat management system which includes the selection of appropriate pipe heating cable technologies and advanced control system technologies, in addition to turnkey services.

Heat Trace System
  • Electric heat trace cables – heat trace cables that maintain the temperature of non-flowing fluids by replacing the heat lost through the thermal insulation on pipes, vessels and associated equipment.
  • Advanced control systems –help maintain the temperature of the fluid through a heat traced pipe.
  • Components and accessories – items for making electrical connections and properly completing the installation, such as end terminations, glass tape and warning labels.


Reliable Pipe Frost Protection System

A heat traced pipe replaces the heat lost through the insulation to maintain the pipe and fluid at temperatures above the freezing point.  Thus, heat tracing is critical for freeze protection of pipes that are expected to have stagnant fluids for prolonged durations.
nVent RAYCHEM self-regulating systems have been reliably specified by many engineers around the world and favoured for their ease of use by as many installation contractors.

Premiere Heat Management System Services

A properly designed heat management system is complicated. Let our heat trace experts provide you with turnkey solutions and project management through all phases of your pipe heat tracing project to ensure that you stay on schedule and have an optimal heat trace system that will provide you with many worry-free hours of operation

Global Experience

nVent Thermal Management is a global organization with a complete line of heat tracing systems, superior technical support, proven project execution strategies, and high safety standards, making us an ideal partner for our customers worldwide who benefit from our expertise, products, and services to meet their heat management system needs.

Self-Regulating Technology

nVent RAYCHEM self-regulating electric heat trace cables automatically adjust their power output to compensate for temperature changes of the pipe. These cables:

RAYCHEM Heating Cables:


  • Can be used for complex piping, plastic pipes and for pipes with/without steam cleaning
  • Offer maximum design flexibility and reliability for heat-tracing applications with line lengths of up to 250m and maintain temperatures of up to 150°C.
  • Result in more uniform pipe temperatures
  • Are fundamentally safe with their unconditional T-ratings
  • Can be cut to length on site
  • Can be overlapped at valves, flanges, and instruments for ease of installation
  • Do not require the collection of a hot work permit
  • Include hi-tech RAYCHEM installation kits that are simple to install

Power-Limiting Technology

RAYCHEM power-limiting systems for Pipe Frost Protection provide higher power outputs at elevated temperatures than self-regulating systems and can be exposed to higher temperatures.

RAYCHEM Power-Limiting Cables


  • For line lengths of up to 250 m
  • For maintain temperatures of up to 230°C.
  • Can be used at voltages up to 480V
  • Can be cut to length
  • Vary their power output depending on the pipe temperature
  • Can be overlapped once for ease of installation
  • Include RAYCHEM installation kits that are simple to install and do not necessitate hot work permits
  • Do not require RTV silicones, which can be hazardous during installation

RAYCHEM Polymer Insulated technology
  • RAYCHEM polymer insulated (PI) series heating systems are especially suitable for longer heating circuits (e.g. >250 m)
  • For continuous temperatures up to 260°C and intermittent exposure temperatures up to 300°C.
  • Depending on the application, they typically require more sophisticated control systems.

Mineral Insulated (MI) Technology

nVent PYROTENAX mineral insulated (MI) series heating systems are recommended for high-temperature applications of up to 800°C. Suitable for the harshest of industrial environments they are offered in a choice of constructions each with a complete range of compatible components and accessories.

PYROTENAX Mineral Insulated Cables


  • Provide up to 61W/ft (200W/m) of power output
  • Are pre-terminated, allowing for simplified installation
  • Are approved for use in non-hazardous and hazardous locations
  • Can be used at voltages to 600 V
  • Are especially suited for harsh environments
  • Provide a maximum application temperature of 550°C and a maximum exposure temperature of 650°C
  • Can be customized for higher temperatures by special order

Constant-wattage parallel technology

RAYCHEM constant-wattage parallel heating systems offer an economical alternative while maintaining the advantages of cut to length cables. Because of their constant power output, circuit breaker sizes may be reduced compared to self-regulating heating systems.

  • For line lengths of up to 200m
  • For maintain temperatures of up to 200°C.

Depending on the application, they typically require more sophisticated control systems.

Advanced Control Systems

Our advanced control systems from RAYCHEM offer state-of-the-art control solutions designed exclusively for use with pipe freeze protection systems.

RAYCHEM Monitoring and Control Products
  • Include electronic and mechanical thermostats for simple on/off switching control
  • Can detect ambient temperatures and are intended to control individual circuits, or provide control for a heat-tracing power distribution system (HTPG which will activate a number of critical circuits.
  • Include refined NGC controllers that offer monitoring of circuit performance, integrity, and ground fault current and protection.

How We Control and Monitor your Pipe Freeze Protection System
  • Distributed Systems – This is a multi-circuited panel system that is strategically placed around a plant for the purpose of gathering EHT circuits. The strategic locations of these panels help to reduce the overall cost of the system by reducing cable lengths. In turn, this will reduce the voltage drop and material requirements of the project.
  • Centralized Systems – This system uses a single control monitoring location that is able to regulate an entire group of heat tracing circuits on its own. These systems are ideal when the activation of a multiple circuit system from one location is needed.
  • Local Systems - This device system is devoted to a single circuit located somewhere near the heat trace power connection. These devices can control or monitor the heat trace system based upon the ambient temperature of that location.
Optimized Heat Management System Reduces Costs at Ethanol Production Facility
Key Challenges

Bridgeport Ethanol is a green-field 40-million gallons/year ethanol production facility in Nebraska. Their heat-tracing application needed to be modified to include pipe freeze protection for water lines, tank heating and process temperature maintenance of syrup, silage and caustic lines. They brought in nVent Thermal Management’ nVent TRACER Turnkey Solutions team in May 2008 for the project.


The TRACER Turnkey Solutions team completely engineered, procured and installed the necessary heat management systems (HMS) at Bridgeport Ethanol. The team leveraged a complex and diverse range of nVent RAYCHEM control and monitoring solutions to reduce the number of necessary circuits to 35. And in doing so, the team was able to reduce the total cost of the heat management system at Bridgeport Ethanol.


Products used included the RAYCHEM 200NG with proportional ambient sensing control (PASC) for the pipe freeze protection and broad temperature maintenance applications. In PASC, the power to the heat tracing is proportioned based upon on the ambient temperature.

The TRACER Turnkey Solutions team also selected a combination of the RAYCHEM 920 and HTPG local control system to control and monitor remote circuits for tank heating as well as pipe freeze protection of the water lines. These areas were respectively 800 feet and 450 feet away from the centralized control panels and would have required 2/0 power wires due to the voltage drop.

Additionally, the team chose the RAYCHEM 200NI with line sensing control for the critical temperature maintenance applications. To reduce the RTD wiring costs, we used the RAYCHEM power line interface technology (PLI) and Smart End Seals (SES) to transmit temperature and continuity data over the heating cable conductors.


The project was successfully completed in November 2008. With the use of PASC algorithm, the TRACER Turnkey Solutions team was able to reduce Bridgeport Ethanol’s operating costs by 75 percent from that of the standard ambient sensing controller. The conduit and wiring costs were also greatly reduced by using a local control system, and the use of RAYCHEM power line interface (PLI) technology eliminated the estimated $40,000 of RTD wiring costs.

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