Thorne & Derrick: Your Partner in Solving Challenges in Heat Tracing Applications

Published 07 May 2025

Heat Tracing Solutions

Competitive Pricing | UK Heat Trace Stockist & Supplier | Industrial & Hazardous Areas

At Thorne & Derrick, we understand that heat tracing plays a critical role in many industries, ensuring the safety and efficiency of processes by preventing freezing, regulating temperatures, and safeguarding equipment. However, like any industrial system, trace heating can present its challenges, ranging from improper installation and poor maintenance to energy inefficiencies and safety risks. Fortunately, with our comprehensive range of products and expert services, we’re well-equipped to address these challenges head-on.

In this blog, we’ll walk you through some of the most common challenges in heat tracing applications—and how our solutions help clients overcome them to ensure maximum performance and reliability.

1. Improper Installation

Improper installation of heat tracing systems is one of the most frequent challenges. Incorrect cable placement, poor terminations, or choosing the wrong type of system can lead to uneven heat distribution, overheating, or system failure.

How We Help:

• Product Selection Support: We provide expert advice to ensure that the right products—whether cables, controllers, or accessories—are selected based on your specific needs. Our team works closely with you to make sure the system is tailored to your application.

• Training & Installation Guidance: Our experts offer on-site support and training to your installation teams, ensuring cables are spaced correctly, terminations are properly done, and all connections are safe and secure.

2. Poor Maintenance and Inspection

Regular maintenance and inspection are key to keeping trace heating systems running smoothly. Over time, heat trace cables can become damaged, and components may degrade, which can impact the overall performance of the system.

How We Help:

• Spare Parts & Components: We provide a wide variety of high-quality replacement parts such as cables, thermostats, and sensors, so you can quickly address any issues and ensure the reliability of your systems.

• Preventive Maintenance Kits: We offer tools and diagnostic equipment to help you carry out regular inspections and proactive maintenance, minimizing the risk of system failure before it impacts operations.

3. Overheating and Underheating

If your trace heating system is either overheating or underheating, it can lead to equipment damage or operational inefficiencies. Overheating can cause insulation degradation, while underheating may fail to protect pipes from freezing in colder conditions.

How We Help:

• Advanced Temperature Controllers: Our precise control systems allow for accurate regulation of your trace heating system, ensuring temperatures remain within the desired range and preventing overheating or underheating.

• Self-Regulating Cables: We offer self-regulating cables that adjust their heat output based on the temperature of the surface they are attached to, ensuring consistent and energy-efficient heating.

4. Control System Failures

Heat Trace Systems rely on sensors and thermostats to regulate temperature. When these components malfunction, your entire system can be thrown off balance.

How We Help:

• Integrated Control Solutions: We offer advanced control panels and monitoring systems to keep your trace heating system running smoothly. These solutions prevent failures by providing real-time monitoring, enabling immediate action if something goes wrong.

• Remote Monitoring & Alerts: For added convenience, our remote monitoring solutions allow you to track the performance of your trace heating system from anywhere, ensuring that potential issues are caught before they lead to system downtime.

5. Energy Efficiency and Cost

These systems are often energy-intensive. Without optimisation, they can drive up operational costs, leading to higher electricity bills.

How We Help:

• Energy-Efficient Products: We provide energy-efficient solutions, such as self-regulating cables and smart controllers, to help reduce energy consumption and lower your operational costs.

• Cost-Effective Solutions: With a wide range of trace heating products available, we ensure that you can find the most cost-effective solution that meets your performance needs and fits within your budget.

6. Corrosion and Environmental Factors

Trace heating systems in harsh environments—such as offshore platforms or chemical processing plants—can be exposed to corrosive elements, aggressive weather, or chemicals. These factors can degrade the cables and components over time.

How We Help:

• Corrosion-Resistant Products: We supply trace heating cables and components made from durable materials designed to resist corrosion, ensuring your systems last longer in harsh conditions.

• Hazardous Area Equipment: For applications in explosive or hazardous environments, we offer certified trace heating solutions that meet ATEX and IECEx standards, ensuring both safety and durability.

7. Regulatory and Safety Compliance

They must comply with various safety regulations and standards. Non-compliance can lead to safety hazards or costly legal issues.

How We Help:

• Safety-Certified Products: All of our trace heating products meet the latest industry standards and regulations, including ATEX and IECEx certifications, ensuring that your systems are both safe and compliant.

• Documentation & Certification: We provide full product certification and installation documentation to help you meet regulatory requirements with ease.

8. Freezing and Blockages

In cold environments, systems are often used to prevent freezing in pipes and vessels. If these systems fail to maintain the required temperature, it can lead to costly damage, downtime, and even safety risks.

How We Help:

• Freeze Protection Systems: We offer specialised solutions designed to prevent freezing in pipes, keeping your systems operational even in extreme temperatures.

• Flow Assurance: Our heating solutions help prevent blockages caused by solidified fluids, ensuring smooth operation and minimising downtime.

9. Complexity in Retrofitting Existing Systems

When retrofitting older systems, compatibility issues can arise, especially when trying to integrate new components with legacy infrastructure.

How We Help:

• Retrofit Solutions: We offer flexible trace heating products that are easy to integrate into existing systems. Whether upgrading or expanding, our solutions are designed to work with your legacy equipment.

• Custom Solutions: Our team can customise to meet the unique requirements of your existing infrastructure, making the retrofit process easier and more efficient.

10. System Integration and Compatibility Issues

Integrating trace heating with other industrial systems, like HVAC or process heating, can sometimes lead to compatibility problems, affecting the overall performance of your operation.

How We Help:

• Custom Integration Solutions: We specialise in providing systems that integrate seamlessly with other systems, ensuring smooth operation and minimising disruptions.

• Expert Guidance: With our extensive industry experience, we offer expert advice to ensure that your trace heating system is compatible with existing processes and automation systems.

11. Environmental Impact

As businesses continue to focus on sustainability, reducing the environmental impact of industrial operations is more important than ever.

How We Help:

• Sustainable Solutions: Our energy-efficient trace heating products are designed to help reduce energy consumption, making your operations more sustainable and cost-effective.

• Recyclable Materials: We offer trace heating components made from recyclable materials, helping your business reduce its carbon footprint.

12. Cost of Materials and Components

The cost can be a concern, especially for large-scale installations or retrofitting projects.

How We Help:

• Competitive Pricing: We offer products at competitive prices, ensuring that you can find the right solution within your budget.

• Long-Term Value: Our high-quality, durable products are designed to minimise the need for frequent replacements, providing excellent long-term value.

Conclusion

At Thorne & Derrick, we understand the complexities and demands of certain heat tracing applications and are dedicated to helping our clients overcome challenges with confidence. Trace heating systems are essential to the safety, efficiency, and reliability of operations across numerous industries—but only when installed, maintained, and managed correctly.

Whether you’re planning a new installation, upgrading legacy infrastructure, or looking to optimise performance, our team is ready to help you unlock the full potential of your trace heating system.

Get in touch with us today to discover how we can help you achieve safer, more efficient, and compliant operations.