Project background
Leading technical supplier of industrial electrical and electronic solutions Pacific Automation engaged ESI Tech Group to install and integrate heat trace cabling and control systems for a 1.6-kilometre bitumen pipeline for a port operator in Kwinana, Western Australia.
Heating bitumen over long distances requires precision and a coordinated approach. The client operates in an industrial marine environment, and deals with unique site restrictions, including the pipeline partially crossing over private land and a requirement for Hazardous Area T3 compliance at the wharf.
Hazardous Area T3 compliance refers to the maximum temperature any relevant part of the equipment that may be in contact with a flammable (explosive) gas can reach. In this case, it referenced the maximum allowable surface temperature of the bitumen pipeline.
Working in collaboration with Pacific Automation and its product partner, Thermon, the scope of work included:
- Project-specific heat trace cabling, control system and power distribution design and fit-for-project products (undertaken by Pacific Automation)
- Cable installation – underground and above-ground
- Dossier compilation & hazardous area inspections
- IS loop entity calculations
Project challenges
The project encompassed a range of challenges, including:
- The pipeline partially crossing over private land
- Long, complex piping with 4 circuits of heat trace cabling
- Large valves
- Working at height over water
- Temperature maintenance
- Tight timeframe
Bespoke solution
ESI Tech Group and Pacific Automation responded to these challenges by ensuring we had the right team and the right equipment for the job, and worked collaboratively, safely and efficiently.
This included:
- A team of qualified / certified technicians, with experience in working at height over water
- Bespoke, project-specific equipment
- Carefully managing each project stage to ensure the next stage could proceed seamlessly
- Collaboration with the project manager and other contractors
Reliability & continuity is key
Given that process equipment failure or malfunction will typically flow on to other areas of the operation, affecting timeframes, budgets and bottom lines, reliability is imperative for industrial operators.
Pacific Automation’s engineering team selected fit-for-project products and delivered the heat trace cabling, control and power distribution design, plus a remote monitoring set up via PLC.
They conducted a site assessment and recommended implementing Thermon‘s HTEK™ Series constant watt heating cable. Circuit lengths up to 3,658m can be energised from a single end, cutting down on power connection points.
Due to the size and scale of the project, alternative products for the main pipeline, such as self regulating cable, were deemed inefficient. With a much smaller run length possible between power connection points, a design using this cable would be unnecessarily complex.
The HTEK Series cable is built for high performance in demanding conditions, with a estimated service lifetime over two decades. Combined with the reductions in required power infrastructure and subsequent installation costs, it minimises issues for the design engineers and port maintenance team.
Streamlined installation
Our team conducted multiple on-the-job assessments and offered modifications and improvements throughout the installation.
They regularly met with the project managers on site and addressed concerns as they arose, resulting in a streamlined project delivery for the client.
Outcome
By working efficiently and collaboratively with our client and contractors, our team successfully installed the heat trace cable on time, on budget, and to high safety standards.
With a full suite of features, including low and high temperature alarms, programmable high-temperature trip functions and high ground / earth leakage alarms, the client now has a purpose-built solution for continuous monitoring and management of its heat tracing.
Paul Overton, Product Manager, Pacific Automation, said our attention to detail, and project-specific adjustments on-the-job and precise work resulted in a high-quality outcome for our client:
“The team at ESI Tech Group completed the job with an extremely high level of quality and attention to detail. We regularly use ESI Tech Group as a system integrator for heat tracing projects and can highly recommend them for anyone needing a heat trace installation.”
For more information about any of our heat trace installation services, email info@esi-techgroup.com.