High-Temperature Electric Heat Tracing
High-Temperature Heating
Self-regulating heating cable is not the right solution for every industrial process. High maintain temperatures, elevated exposure temperatures or high power requirements often require engineered resistance or mineral insulated heating systems.
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When high-temperature systems are required
Design starts with a complete temperature profile: required maintain temperature, maximum temperature during normal operation, external heat during cleaning, and cooling …
Design starts with a complete temperature profile: required maintain temperature, maximum temperature during normal operation, external heat during cleaning, and cooling and restart conditions. Duration, frequency and whether the heater is energised matter for each exposure.
Together with heat loss, available voltage and installation conditions, this defines the combination of heating cable, sheath material, power density and controls. Pro Therm selects suitable systems independently of manufacturer, taking the customer specification and budget into account.
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Resistance heating cables
In a series resistance heater, output, conductor resistance, length and supply voltage are directly related. The heated length is therefore based on the actual routing, …
In a series resistance heater, output, conductor resistance, length and supply voltage are directly related. The heated length is therefore based on the actual routing, including valves and other heated components.
Changing that length requires a fresh electrical and thermal assessment. Heat transfer, local power density and available electrical supply are considered at the same time. Selection follows the heating duty and installation conditions.
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Control and temperature limitation
Control sensors, control strategy and, where required, independent temperature limitation are selected from process and protection requirements. The measurement point …
Control sensors, control strategy and, where required, independent temperature limitation are selected from process and protection requirements. The measurement point must make clear which temperature is being measured and whether it represents the critical operating condition.
Hazardous-area design considers permissible surface temperatures and requirements for the actual assembly. Transitions, cold leads, terminations, fixings and insulation must also suit the temperatures at their respective locations.
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Account for thermal movement and transitions
Hot pipes and vessels change dimensions. Cable routing and fixings must accommodate the intended movement without overstressing the heater or its joints. Bending radii …
Hot pipes and vessels change dimensions. Cable routing and fixings must accommodate the intended movement without overstressing the heater or its joints. Bending radii and installation temperatures come from the selected product instructions.
Heated-to-cold transitions and the route to the electrical connection deserve particular attention. The highest permitted process temperature is not automatically permissible at every termination. Drawings should therefore identify temperature zones, moving areas and accessible connection locations.
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Frequently asked questions
When is self-regulating cable not suitable? Resistance or mineral insulated systems may be preferred when temperature, exposure temperature, power demand or circuit …
When is self-regulating cable not suitable?
Resistance or mineral insulated systems may be preferred when temperature, exposure temperature, power demand or circuit length exceeds the suitable range of self-regulating technology.
What is a mineral insulated heating cable?
It is a robust heating cable typically using a metallic sheath and inorganic electrical insulation, making it suitable for high-temperature industrial service.
Can Pro Therm install high-temperature heat tracing worldwide?
Yes. High-temperature heat tracing is part of Pro Therm’s international industrial heat tracing scope.
Is the maximum datasheet temperature enough for selection?
No. Energised operation, external heat exposure, exposure duration and all connection components must also be assessed.
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Related topics
Hazardous-area heat tracing → Finished soldered MI assemblies → Controls and monitoring → Worldwide installation → Chemical and petrochemical plants → Heat loss and …
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Mineral insulated heating cables
Mineral insulated heating cables have a metallic sheath and inorganic electrical insulation. They can be considered for demanding temperature profiles when the specific …
Mineral insulated heating cables have a metallic sheath and inorganic electrical insulation. They can be considered for demanding temperature profiles when the specific cable and completed assembly suit the application.
Pro Therm manufactures MI heating assemblies with soldered cold leads to specification. Heated length, conductor resistance, voltage and power are defined together; cold leads and terminations are selected for their installation locations. Temperature limits are assessed for the complete assembly.
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Typical applications
Typical duties include temperature maintenance on hot process piping, tanks and reactors, and heating in chemical plants, energy facilities and bitumen or heavy-oil …
Typical duties include temperature maintenance on hot process piping, tanks and reactors, and heating in chemical plants, energy facilities and bitumen or heavy-oil processes. Valves, filters and pumps may have different heat losses and installation constraints from straight pipe.
Access, removable equipment and existing insulation are identified early. A temperature-resistant cable alone does not replace the design of a complete heating system.
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Cleaning, shutdown and restart
Cleaning or steam-out can produce the highest external temperature while the heater is switched off. This exposure is specified separately from the maintain temperature …
Cleaning or steam-out can produce the highest external temperature while the heater is switched off. This exposure is specified separately from the maintain temperature and the temperature experienced with the heater energised. Short-term and continuous exposures are distinguished as well.
Restart assessment considers starting temperature, operating permissions and any required heat-up time. Accessible connections and clear identification of each circuit, sensor and controller support subsequent testing and maintenance.
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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.
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Review a high-temperature duty
Provide the maintenance temperature, maximum exposure with the heater on and off, cleaning cycles, fluid, supply and hazardous-area requirements. We assess suitable …
Provide the maintenance temperature, maximum exposure with the heater on and off, cleaning cycles, fluid, supply and hazardous-area requirements. We assess suitable technologies, including finished soldered MI assemblies where appropriate.
Discuss a high-temperature project →
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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.
Mineral insulated heating cables
Mineral insulated heating cables have a metallic sheath and inorganic electrical insulation. They can be considered for demanding temperature profiles when the specific cable and completed assembly suit the application.
Pro Therm manufactures MI heating assemblies with soldered cold leads to specification. Heated length, conductor resistance, voltage and power are defined together; cold leads and terminations are selected for their installation locations. Temperature limits are assessed for the complete assembly.
Standards reference (checked 14 October 2026): For heating cables and assemblies outside hazardous areas, IEC/IEEE 62395-1:2024 is the international reference for general requirements and testing. Germany still lists DIN EN 62395-1:2014-10 as the current national edition.
Resistance heating cables
In a series resistance heater, output, conductor resistance, length and supply voltage are directly related. The heated length is therefore based on the actual routing, including valves and other heated components.
Changing that length requires a fresh electrical and thermal assessment. Heat transfer, local power density and available electrical supply are considered at the same time. Selection follows the heating duty and installation conditions.
Typical applications
Typical duties include temperature maintenance on hot process piping, tanks and reactors, and heating in chemical plants, energy facilities and bitumen or heavy-oil processes. Valves, filters and pumps may have different heat losses and installation constraints from straight pipe.
Access, removable equipment and existing insulation are identified early. A temperature-resistant cable alone does not replace the design of a complete heating system.
Control and temperature limitation
Control sensors, control strategy and, where required, independent temperature limitation are selected from process and protection requirements. The measurement point must make clear which temperature is being measured and whether it represents the critical operating condition.
Hazardous-area design considers permissible surface temperatures and requirements for the actual assembly. Transitions, cold leads, terminations, fixings and insulation must also suit the temperatures at their respective locations.
Standards reference (checked 14 October 2026): DIN EN 60519-10:2014-01 remains the current German standard for safety of industrial and commercial resistance trace heating. Its application is coordinated with the selected heating system and electrical-installation requirements. 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.
Cleaning, shutdown and restart
Cleaning or steam-out can produce the highest external temperature while the heater is switched off. This exposure is specified separately from the maintain temperature and the temperature experienced with the heater energised. Short-term and continuous exposures are distinguished as well.
Restart assessment considers starting temperature, operating permissions and any required heat-up time. Accessible connections and clear identification of each circuit, sensor and controller support subsequent testing and maintenance.