Modernise existing heat tracing systems
Upgrade Existing Systems
New process conditions, ageing controls or changed pipe routes can require a system upgrade. Pro Therm assesses the existing installation and plans targeted modifications. Reuse and replacement decisions follow technical suitability, condition and project objectives.
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Start with an existing-system assessment
We assign existing circuits, cable types, supply, sensors and controllers to the affected plant areas. Drawings are compared with the actual installation. Missing type …
We assign existing circuits, cable types, supply, sensors and controllers to the affected plant areas. Drawings are compared with the actual installation. Missing type information and unclear assignments are identified before design, providing a reliable basis for the intended upgrade.
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Reuse suitable components
A complete replacement is not always necessary. Reuse nevertheless requires suitable technical data, adequate condition and appropriate interfaces. With mixed products, …
A complete replacement is not always necessary. Reuse nevertheless requires suitable technical data, adequate condition and appropriate interfaces. With mixed products, connection and system compatibility are assessed. Manufacturer independence allows open selection, rather than universal interchangeability.
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Coordinate modifications with operations
Access, outage windows and the sequence of removal, installation and insulation affect execution. Pro Therm coordinates the agreed scope with the operator and other …
Access, outage windows and the sequence of removal, installation and insulation affect execution. Pro Therm coordinates the agreed scope with the operator and other trades. Its own teams can implement electric heat tracing modifications on site, including international projects.
We can offer required insulation work with partner companies. Where cabling between our control panels and the power-feed and control boxes needs modification, we can undertake that work if cable routes are already available. Existing conditions, usable routes and connection boundaries are agreed before the retrofit.
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Compare options over their service life
Repair, partial retrofit and complete replacement can disrupt operation in different ways. Compare materials, installation, shutdown requirements, insulation changes and …
Repair, partial retrofit and complete replacement can disrupt operation in different ways. Compare materials, installation, shutdown requirements, insulation changes and documentation together. The least expensive individual component does not automatically produce the least expensive retrofit.
Future support also matters: are type data available, can spare parts be identified and are faults reported clearly? Pro Therm compares suitable options on a common technical basis. An economic advantage is assessed from the actual data rather than promised without knowing the existing plant.
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Frequently asked questions
Does the entire system need replacement? Not necessarily. Condition, technical suitability and interfaces determine which components can be reused. Can circuit length …
Does the entire system need replacement?
Not necessarily. Condition, technical suitability and interfaces determine which components can be reused.
Can circuit length simply be changed?
Changing length can affect output, cold start and protection. Permissible modifications depend on the specific technology.
How does retrofit differ from repair?
A repair addresses a fault. A retrofit intentionally adapts the system to new requirements, components or operating conditions.
Can another manufacturer be used?
Yes, subject to technical suitability and system compatibility. We consider preference and budget without universal interchangeability claims.
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Related topics
Maintenance and repair → Testing and commissioning → Controls and monitoring → Engineering and design → Energy optimisation → Heat loss and insulation →
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Reassess the revised heating duty
A change in maintenance temperature, insulation or pipe length can affect output and permissible temperatures. Starting conditions and the available supply are also …
A change in maintenance temperature, insulation or pipe length can affect output and permissible temperatures. Starting conditions and the available supply are also reassessed. A previously functioning arrangement is not automatically retained when the process imposes new requirements.
04
Improve controls and alarms
Ageing controllers can be replaced by suitable alternatives where sensors, supply and output functions are compatible. Setpoints, alarm limits and plant control signals …
Ageing controllers can be replaced by suitable alternatives where sensors, supply and output functions are compatible. Setpoints, alarm limits and plant control signals are clearly defined. The upgraded operation should be understandable to staff and match the actual operating conditions.
06
Document the upgraded arrangement
After modification, circuit schedules, identification, electrical information and agreed test records are aligned with the new arrangement. Changed setpoints and …
After modification, circuit schedules, identification, electrical information and agreed test records are aligned with the new arrangement. Changed setpoints and components remain identifiable. This supports future maintenance and avoids selecting replacements from obsolete information.
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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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Plan an upgrade from the existing records
Send existing drawings, type data, test reports and a description of the intended change. Include outage windows and budget expectations. We assess what can remain and …
Send existing drawings, type data, test reports and a description of the intended change. Include outage windows and budget expectations. We assess what can remain and what requires a new design.
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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.
Reassess the revised heating duty
A change in maintenance temperature, insulation or pipe length can affect output and permissible temperatures. Starting conditions and the available supply are also reassessed. A previously functioning arrangement is not automatically retained when the process imposes new requirements.
Standards reference (checked 14 October 2026): IEC/IEEE 62395-2:2024 addresses system design, installation, maintenance and repair outside hazardous areas. DIN EN 62395-2:2014-12 remains the current German national edition. Record the agreed edition in the project documentation.
Reuse suitable components
A complete replacement is not always necessary. Reuse nevertheless requires suitable technical data, adequate condition and appropriate interfaces. With mixed products, connection and system compatibility are assessed. Manufacturer independence allows open selection, rather than universal interchangeability.
Standards reference (checked 14 October 2026): Equipment repair is distinct from installation inspection. Within their respective scopes, IEC 60079-19:2025 and the current German DIN EN IEC 60079-19:2021-07 address repair of Ex equipment. Permitted procedures, competence and manufacturer documentation are assessed for the actual device.
Improve controls and alarms
Ageing controllers can be replaced by suitable alternatives where sensors, supply and output functions are compatible. Setpoints, alarm limits and plant control signals are clearly defined. The upgraded operation should be understandable to staff and match the actual operating conditions.
Coordinate modifications with operations
Access, outage windows and the sequence of removal, installation and insulation affect execution. Pro Therm coordinates the agreed scope with the operator and other trades. Its own teams can implement electric heat tracing modifications on site, including international projects.
We can offer required insulation work with partner companies. Where cabling between our control panels and the power-feed and control boxes needs modification, we can undertake that work if cable routes are already available. Existing conditions, usable routes and connection boundaries are agreed before the retrofit.
Document the upgraded arrangement
After modification, circuit schedules, identification, electrical information and agreed test records are aligned with the new arrangement. Changed setpoints and components remain identifiable. This supports future maintenance and avoids selecting replacements from obsolete information.
Standards reference (checked 14 October 2026): IEC 60364-6:2016, including its 2017 corrigendum, provides the international installation-verification reference. For initial verification in Germany, DIN VDE 0100-600:2017-06 applies. Product testing, installation verification and thermal operating evidence are documented separately.