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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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.