Electric Heat Tracing for Hazardous Areas
Hazardous-Area Heat Tracing
Electric heat tracing is widely used in chemical, petrochemical, oil and gas and other facilities with hazardous locations. In these applications, thermal design, electrical safety, explosion protection and installation must be treated as one system.
01
Hazardous area heat tracing is a system
A hazardous-area-rated heating cable alone does not create a complete compliant system. Power connections, end terminations, sensing, controls, temperature limitation, …
A hazardous-area-rated heating cable alone does not create a complete compliant system. Power connections, end terminations, sensing, controls, temperature limitation, protection devices, documentation and installation must also be suitable for the application.
03
Temperature class and surface temperature
Maximum permissible surface temperature is a key design consideration. Heater output, process conditions, ambient temperature and temperature limitation therefore need …
Maximum permissible surface temperature is a key design consideration. Heater output, process conditions, ambient temperature and temperature limitation therefore need to be evaluated together.
Permissible temperatures are assessed for the actual operating conditions, including shutdown and external heating. Depending on the system, a stabilised design or a controlled and limited concept may be required. The appropriate method and evidence follow the specific manufacturer's documentation and project requirements.
05
Engineering and documentation
Engineering should transparently document the design basis, selected components and protection concept. Project requirements, certificates and technical documentation …
Engineering should transparently document the design basis, selected components and protection concept. Project requirements, certificates and technical documentation are assembled for the actual application.
07
Check special conditions and the scope of evidence
Selection considers the full Ex marking, the associated certificate documents and any special conditions of use. A certificate suffix or reference to additional …
Selection considers the full Ex marking, the associated certificate documents and any special conditions of use. A certificate suffix or reference to additional instructions must not be lost when replacing a component. It also matters whether the evidence covers equipment, a component or a defined heater assembly.
IEC/IEEE 60079-30-2:2025 excludes applications requiring EPL Ga or Da. Suitability for Zone 0 or Zone 20 cannot therefore be inferred from a general reference to that standard. The specific project assessment remains decisive.
09
Frequently asked questions
Is an ATEX heating cable enough for a hazardous-area heat tracing system? No. The complete system, including connections, controls, temperature limitation, protection …
Is an ATEX heating cable enough for a hazardous-area heat tracing system?
No. The complete system, including connections, controls, temperature limitation, protection concept and installation, must be suitable for the application.
Why does temperature class matter?
The permitted surface temperature must be controlled under relevant operating and fault conditions, so heater selection and temperature limitation are engineered together.
Does Pro Therm install heat tracing in hazardous areas worldwide?
Yes. Hazardous-area heat tracing installation is part of Pro Therm’s international industrial heat tracing services.
Is an Ex approval valid worldwide?
Required evidence depends on the country and project. ATEX or IECEx documentation does not automatically replace all local requirements or assessment of the specific application.
11
Related topics
Electric heat tracing → Worldwide installation → Engineering and design → Finished soldered MI assemblies → Controls and monitoring → Chemical and petrochemical plants → …
02
ATEX, IECEx and project requirements
Depending on the project, components with relevant approvals and certifications are selected. The correct configuration depends on area classification, gas or dust …
Depending on the project, components with relevant approvals and certifications are selected. The correct configuration depends on area classification, gas or dust group, temperature class, environmental conditions and customer specification.
Selection depends on the specific area classification, gas or dust atmosphere, temperature requirements and ambient conditions. Connections, cable glands, sensors and controllers must also fit the protection concept. A cable certificate alone does not establish the suitability of all other components or the complete installation.
04
Heating technology selection
Self-regulating heating cables suit many freeze protection and temperature maintenance duties. Resistance or mineral insulated systems may be better for higher …
Self-regulating heating cables suit many freeze protection and temperature maintenance duties. Resistance or mineral insulated systems may be better for higher temperatures, long circuits or increased power requirements.
06
Evidence must match the installation
A heating cable certificate does not automatically cover any combination of connection box, controller and accessories. The actual system scope and conditions of use are …
A heating cable certificate does not automatically cover any combination of connection box, controller and accessories. The actual system scope and conditions of use are decisive. Product identification, markings, permitted temperatures and the approved design are brought together for assessment. A change of product, circuit length or process conditions requires a review. Hazardous-area documentation should describe the installation as built, rather than merely collect unrelated certificates.
08
Standards and technical basis
Our knowledge section explains how the standards relate to the heating task, product selection and project design. Open the standards overview →
Our knowledge section explains how the standards relate to the heating task, product selection and project design.
10
Agree hazardous-area requirements early
Please provide the area classification, relevant gas or dust data, temperature class or permissible surface temperature, country and customer specification. We assess …
Please provide the area classification, relevant gas or dust data, temperature class or permissible surface temperature, country and customer specification. We assess suitable system components and the necessary documentation from these inputs.
Discuss a hazardous-area project →
12
References & projects
Explore our project reports for electric heat tracing and frost heave protection. View references & projects →
Explore our project reports for electric heat tracing and frost heave protection.
ATEX, IECEx and project requirements
Depending on the project, components with relevant approvals and certifications are selected. The correct configuration depends on area classification, gas or dust group, temperature class, environmental conditions and customer specification.
Selection depends on the specific area classification, gas or dust atmosphere, temperature requirements and ambient conditions. Connections, cable glands, sensors and controllers must also fit the protection concept. A cable certificate alone does not establish the suitability of all other components or the complete installation.
Standards reference (checked 14 October 2026): IEC/IEEE 60079-30-1:2025 and IEC/IEEE 60079-30-2:2025 are international references for resistance trace heating in hazardous areas. Germany still lists DIN EN 60079-30-1:2018-04 and DIN EN 60079-30-2:2018-04 as current national editions. Equipment group, permitted EPL, protection concept and evidence for the actual assembly determine suitability.
Temperature class and surface temperature
Maximum permissible surface temperature is a key design consideration. Heater output, process conditions, ambient temperature and temperature limitation therefore need to be evaluated together.
Permissible temperatures are assessed for the actual operating conditions, including shutdown and external heating. Depending on the system, a stabilised design or a controlled and limited concept may be required. The appropriate method and evidence follow the specific manufacturer's documentation and project requirements.
Heating technology selection
Self-regulating heating cables suit many freeze protection and temperature maintenance duties. Resistance or mineral insulated systems may be better for higher temperatures, long circuits or increased power requirements.
Engineering and documentation
Engineering should transparently document the design basis, selected components and protection concept. Project requirements, certificates and technical documentation are assembled for the actual application.
Standards reference (checked 14 October 2026): IEC 60079-14:2024 addresses design, selection, installation and initial inspection of electrical Ex installations. Its German adoption is DIN EN IEC 60079-14:2026-02. It supplements general electrical-installation requirements.
Evidence must match the installation
A heating cable certificate does not automatically cover any combination of connection box, controller and accessories. The actual system scope and conditions of use are decisive. Product identification, markings, permitted temperatures and the approved design are brought together for assessment. A change of product, circuit length or process conditions requires a review. Hazardous-area documentation should describe the installation as built, rather than merely collect unrelated certificates.
Standards reference (checked 14 October 2026): IEC 60079-17:2023, adopted in Germany as DIN EN IEC 60079-17:2024-10, addresses inspection and maintenance of electrical Ex installations. IEC/IEEE 60079-30-2:2025 adds guidance specific to trace heating systems.