Systematic heating

Global support availability Product campaign initiated

It is becoming more and more challenging to meet the demands placed on technical systems used for the extraction, transportation and processing of fossil fuels. This is in part due to the fact that these fuels are increasingly extracted from regions that are subject to extreme temperatures. Heating systems play a decisive role in reliably ensuring process security: When certain links in the process chain are broken, it is more than an extreme financial setback – safety becomes an issue, too. Consequences of either type must be avoided reliably.

At Achema 2018, BARTEC, the global market leader in explosion protection, presents its advanced heating system technology in three augmented-reality scenarios (AR): a petrochemical plant, a chemical plant and a loading station. BARTEC plays a key role as a systems supplier for these highly complex facilities. “We collaborate with all noteworthy EPC providers (Engineering, Procurement and Construction) around the world on these kinds of projects. As a turnkey, fullservice provider we cover all the relevant stages of design, manufacturing, assembly and maintenance, depending on customer needs. We can prepare specifications and engineering designs, procure and manufacture to the highest standards, assemble and construct, handle the commissioning and, of course, the maintenance”, says Tobias Dold, Head of Heating Technology at BARTEC.

Recently, a South Korean construction company, who was building a pipeline to transport liquid sulphur in the the Middle East, gave BARTEC the order to design and construct the heat tracing system. This is an especially challenging project that requires constant monitoring to ensure the fluidity of the sulphur, which of course requires system redundancy.

“We have subsidiaries around the world so that we can react quickly and flexibly. Most importantly, we always stay close to the customers so that we can offer them our services at reasonable costs. That way we can meet the expectations of our clients”, says Dold of the BARTEC philosophy. The demanding project in the Middle East was a good example of this: The project engineering was carried out in India and Singapore, while the project was managed from Germany, where most of the components of the Skin Effect Heating System originated from. This method is an ideal match for pure frost protection, temperature regulation or for heating materials as they are transported through up to 25-kilometre-long pipelines. It does not matter whether the pipes are located under or above ground or in the water. In most cases, a sophisticated energy distribution system is indispensable due to the total length and any given geographical access restrictions to such heat tracing systems.

When addressing the technical risks of such complex systems, it is also necessary to consider the commercial demands of the procurement process. BARTEC has the financing resources necessary to pre-finance projects of this size and offer this clear advantage to customers.

Maintenance gains importance

According to Dold, the Maintenance, Repair and Operations (MRO) branch of the business is gaining importance. In general, newly built systems are reviewed after their first year of operation. After three years, necessary modifications are made. After five years, the first major revision takes place.

More and more operators are starting to give this work to external qualified service providers like BARTEC. This field is therefore thought to hold a lot of potential. However, BARTEC only maintains the systems of its direct customers in order to ensure high-quality service. The goal here is to conclude more long-term agreements.

Installation-friendly and high- performing

At ACHEMA, BARTEC is starting a product campaign to continue to live up to its ideal of offering easy-to-install and maintain systems that meet the latest standards. As a result, the portfolio has been limited and streamlined.

The PBM/PBS terminal system is a convincing compact and installation-friendly unit with a foot and a single or multi-port. This simplifies and shortens the installation process and reduces possible risks associated with the improper installation of individual components. The connection between the heat circuit and the external electricity is made through a robust box with an Ex e-spring terminal for cables with a diameter of 6 mm²; the installation-friendly boxes are intended for use with operating environments of minus to plus 55 °C. They are fire resistant in accordance with the standard EN 60079-0, as well as impact resistant. BARTEC offers comprehensive accessories for both terminal housings, such as a control lamp that shows the operational status.

The electronic temperature and limiting device ESTM/ESTML is specifically designed for use within processes that are so critical that they cannot be interrupted under any circumstances. The on-site and in-the-field functionalities are impressive: configured redundantly, it is an absolutely fail-safe system that can also be used in operating environments of minus to plus 55 °C. It facilitates non-stop functional monitoring of up to three temperature parameters, such as minimum, maximum and current operating temperature, and it can be controlled via Bluetooth on mobile devices for tasks such as setting parameters. Furthermore, it offers longer heat circuits with up to 30 A breaker capabilities, and it is certified to the latest heat tracing standards in Europe and the USA (IEEE/IEC 60079-30-1). Self-limiting heating tape can be directly connected within the controller.

The output-limiting heating cable BPL is being launched specifically for the European market. It is particularly suited to applications where the maximum service temperature is much higher than the operating temperature. The advantages can be found in the parallel design, similar to self-limiting heating tape, and the temperature resistance of up to 425 °C. The latter makes it possible in many cases to completely or partially avoid mineral-insulated heating lines that resist heats of up to 1,000 °C. Heat circuits can be more rapidly constructed, delivered and installed, because – like self-limiting heating cables – they can be sized and mounted at the construction site rather than in the factory. This makes the system much more flexible and simplifies its configuration.

Manufacturing to the highest standards

Nothing is so good that it cannot be improved. This applies equally to products and processes. That’s why BARTEC has invested heavily in its heating cable production equipment to clearly optimise production quality. “We want to our offer our customers optimal system solutions with reliable, premium-quality products”, says Tobias Dold. When used in hazardous environments, heat tracing systems and components must live up to very high standards of quality and reliability. Due to the new harmonised standards for North America and Europe, a new and expanded testing procedure was introduced to ensure product reliability. BARTEC was the first supplier to obtain a model test certificate for the new standard IEEE/IEC 60079-30-1.

Unplanned downtime due to component failures creates costs. This means that reliability and quality are top priorities, ensured through strict quality controlling. BARTEC, the global market leader in explosion protection, can offer its full experience to benefit clients. The quality associated with ‘Made in Germany’ is still very important to customers. That’s why the main production plant for heating cable is located in Gotteszell in southern Germany. “But we also manufacture worldwide so that we can optimally meet the specific local requirements.” The Group sets itself far apart from the competition with ist comprehensive support services.