Heat tracing systems protect critical infrastructure by preventing freezing and maintaining process temperatures in piping, tanks, and instrumentation. When engineered and installed correctly, Heat Trace keep facilities operating safely, efficiently, and reliably – even in the harshest environments.
At RELCON, we design, install, and support heat tracing systems for industrial, commercial, and natural gas facilities across the Midwest. RELCON delivers strategic solutions through our expertise and experience being a Raychem value added representative and Honeywell Diamond Channel Partner.
With more than 65 years of experience, we help organizations reduce downtime, protect essential infrastructure, and maintain reliable thermal performance year after year.
What Is Heat Tracing?
Heat tracing systems protect critical infrastructure by preventing freezing and maintaining process temperatures in piping, tanks, and instrumentation. When engineered and installed correctly, Heat Trace keep facilities operating safely, efficiently, and reliably – even in the harshest environments.
We help our clients implement heat tracing systems for:
- Freeze protection for piping and valves
- Process temperature maintenance
- Chemical and fluid viscosity control
- Instrumentation protection
- Roof and gutter de-icing systems
- Snow melting for pavements and walkways
Heat tracing systems deliver reliable temperature control while minimizing energy consumption and maintenance requirements.
Our Heat Trace Services
At RELCON, we support heat tracing systems through their entire lifecycle: from engineering and design to installation, troubleshooting, and ongoing service. It’s why many of our clients know us as “The Heat Trace People.”
Heat Trace System Design and Engineering
RELCON evaluates application requirements, environmental conditions, and operational goals before recommending a solution.
Our engineering services include:
- Thermal analysis and heat loss calculations
- Heating cable selection and system sizing
- Control system integration
- Hazardous area compliance planning
- Energy efficiency optimization
By designing systems around real operating conditions, we help our clients avoid oversizing, energy waste, and performance issues later.
Heat Trace Installation Recommendations & Support
We provide heat trace installation recommendations & support, ensuring systems are installed correctly from the start.
Our installation services include:
- Heating cable installation standards
- Power distribution & controls integration
- System testing and commissioning
- Documentation and operator training
- Detailed installation drawings and specifications
Our goal is simple: deliver a system that performs reliably from day one and remains easy to maintain for years to come.
Heat Trace Troubleshooting & Repairs
Even well-designed systems occasionally require troubleshooting. When contacted, we work quickly to diagnose the issue and provide solutions.
Common issues we address include:
- Cold spots or uneven heating
- Damaged heating cables
- Control panel or thermostat failures
- Electrical faults or tripped circuits
- Sensor or monitoring system issues
Because we understand the full lifecycle of heat tracing systems, we’re able to identify root causes and implement long-term solutions.
Heat Trace System Audits & Optimization
Facilities are constantly expanding and keeping up with heat tracing needs. Without proper documentation and periodic inspections, future work can become timely.
Our heat trace audits evaluate:
- Heating cable condition and circuit integrity
- System documentation accuracy
- Energy consumption patterns
- Control system performance
- Safety and code compliance
This helps us identify opportunities to improve reliability, reduce energy costs, simplify maintenance, and prevent costly repairs.
Freeze Protection & Winterization
For many facilities across the Midwest, winterization is one of the most important applications of heat tracing. RELCON help clients prevent freezing and disruptions.
This often includes:
- Identifying vulnerable systems
- Freeze protection system verification
- Instrument winterization
- Roof and gutter de-icing systems
- Snow melting solutions for pavements and walkways
Proactive winterization helps prevent pipe bursts, facility structure/equipment damage, employee/customer injuries, and costly disruptions.
Heat Tracing for Tanks & Vessels
In industrial environments, tanks and vessels require precise temperature control to maintain product quality and process stability.
Typical tank heat tracing applications include:
- Freeze protection for low viscosity fluids (water or ammonia)
- Temperature maintenance for medium-viscosity fluids (oils and resins)
- Condensation prevention in silo systems
The result is a system that protects both your infrastructure and the materials inside it, from one facility to another.
Industries We Serve
Heat tracing systems support critical infrastructure across many industries.
Chemical plants, refineries, pharmaceutical manufacturers, and power generation facilities rely on heat tracing to maintain process temperatures and prevent freezing in critical systems.
Commercial buildings, data centers, hospitals, and universities depend on heat tracing to protect piping systems and maintain safe roof drainage during winter conditions.
Natural gas utilities use heat tracing to protect pressure regulation systems, instrumentation, and pipeline equipment exposed to extreme environments.
Why Facilities Partner With Relcon
Decades of experience, vertically integrated solutions, and proven performance in demanding environments have earned us the reputation as “The Heat Trace People.”
- 65+ Years of Experience: Our team brings more than 65 years of experience designing and supporting heat tracing systems for complex industrial and infrastructure applications.
- Vertically Integrated Solutions: At RELCON, we take a fully integrated approach. We engineer, supply material, and support the complete system, reducing the coordination challenges that often arise when multiple vendors are involved.
- Proven Reliability: Our systems are designed for demanding environments where safety, uptime, and regulatory compliance are critical.
- Extended Warranty Protection: To provide additional peace of mind, Chemelex offers optional extended warranty coverage of up to 10 years on qualifying systems.
- Long-Term Service Support: We don’t walk away after project completion. Our team remains available to provide troubleshooting, audits, and lifecycle support.
Frequently Asked Questions About Heat Trace Systems
What is the purpose of heat tracing?
Heat tracing prevents pipes and equipment from freezing while maintaining temperatures required for industrial processes.
How long do heat trace systems last?
When properly installed and maintained, most systems last 20 to 40 years.
What industries use heat tracing systems?
Industries including chemical processing, oil and gas, power generation, natural gas utilities, data centers, food processing, and commercial infrastructure commonly rely on heat tracing.
How often should heat trace systems be inspected?
Most facilities benefit from annual inspections, particularly before winter conditions.
Can existing heat trace systems be upgraded?
Yes. Many older systems can be modernized with improved controls, monitoring systems, and more efficient heating cables.
What factors affect heat trace system performance?
Key factors include insulation quality, cable type, environmental conditions, system controls, and installation practices.
What should I consider when installing a heat trace and insulation system?
Proper heat trace installation requires balancing heat output with heat loss while protecting the insulation system. Key considerations include accurate heat loss calculations, selecting the right heating cable type, proper cable placement, insulation quality, moisture protection, and testing the system before and after installation to ensure safe, reliable performance. INSULATION MUST BE USED FOR HEAT TRACE SYSTEM PERFORMANCE.
How do I choose the right heat trace control panel for my facility?
Choosing the right heat trace control panel depends on your facility’s power supply, number of heating circuits, and the level of monitoring required. Important factors include matching the panel to your voltage and phase, ensuring it has enough circuit capacity for current and future zones, supporting the total heating load, and providing proper safety features like ground fault protection. For more complex systems, panels may also include line sensing, advanced control logic, and integration with building management or SCADA systems for remote monitoring and control.
What is electric tracing?
Electric tracing, also called heat tracing, uses electrical heating cables attached to pipes, tanks, or equipment to maintain or raise temperatures. It is commonly used for freeze protection, temperature maintenance, and process control in industrial, commercial, and utility systems.
How does heat line freeze protection work in cold climates?
Heat line freeze protection systems use self-regulating heating cables installed along pipes to automatically adjust heat output based on surrounding temperatures. When temperatures drop, the cable increases heat to prevent freezing; when temperatures rise, it reduces output to conserve energy.
How does glass tape improve heat trace insulation and protection?
Glass tape, such as fiberglass or glass cloth tape, is commonly used to secure heat trace cables to pipes and equipment while improving system durability. It helps maintain proper cable contact for efficient heat transfer, protects the cable from abrasion and environmental exposure, and withstands high temperatures without degrading.
Work With RELCON On Your Next Heat Trace Project
At RELCON, we work closely with our clients to design and support heat tracing systems that deliver safe, reliable, and efficient performance. It’s the experience and expertise that have earned us the reputation as “The Heat Trace People.”
If you’re evaluating a new heat tracing system, looking to improve an existing one, or have any questions, get in touch with our team today.