Process Heating January 2012

www.process-heating.com | January 2012 | Volume 19, Number 1

Ensuring compliance with tthe EPA’s new boiler rules requires a new mindset.

Periodical Class

20 Compare Heat Transfer Fluid Specs 26 Selecting and Specifying an Oven

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These heaters will be fully assembled and checked at our factory before delivery.

Get a complete heater package Need a new heater? Get a complete heater package from Heatec. A complete package eliminates hassles, saves you time and saves you money. Our package includes design, manufacturing, factory assembly, on-site setup and startup. We also offer maintenance contracts and provide free phone support. Heaters have many components from a variety of manufacturers. It’s always best to mate these components with the heater and adjust them before the heater is shipped to you. This eliminates most compatibility problems. Our goal is that setup of our heater at your plant will be trouble free, without undue rework. Most setups should only require re-assembly of parts dismantled

for shipping, plus connection of electrical power and piping. Complete factory assembly eliminates last-minute fieldwork that can cause startup delays. It also eliminates buck passing if things don’t go right. Moreover, if a problem develops later, you won’t have to wrangle with a variety of component suppliers to fix it. So, when you buy a new heater, always choose a manufacturer that provides a complete package. Heatec has this capability, which sets us apart from others. Call today and let us answer any questions you have about our heater packages.

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January 2012 Volume 19 • Number 1

www.process-heating.com WEB EXCLUSIVES: READ MORE AT WWW.PROCESS-HEATING.COM Q Online Compliance Assistance

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Features 18

The plate test helps users accurately assess the maximum sheath temperature of mineral insulated heat tracing cables. Are you familiar with this tool?

Equipment Overview: Heat Transfer Fluids Heat Transfer Fluid Guide Selecting the heat transfer fluid is the most important decision to make in specifying a system because the fluid’s properties have to be matched to the process requirements, and the equipment has to be matched to the fluid properties. Use our Equipment Overview to learn more about a fluid’s properties and narrow the field.

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Q What Not to Do When Specifying an Oven As an over builder, we find there are three general categories of customers: the clueless messenger, the overprepared messenger, and an educated buyer. Oven buyers will get the best result by putting the educated buyer in direct contact with the oven manufacturer.

Q Sheath Impacts Design

Heat Tracing A Proper Assessment

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One manufacturer has set up an educational website to make it easier for facility managers to understand and comply with the EPA’s new rules for boilers.

Ovens

Before making electric heat tracing design decisions, engineers should confirm with their cable manufacturers that the sheath temperature data provided for their cables is the result of using the plate test.

UPDATED DAILY Q New Products Q Archives Q Calendar of Events Q Drying Files columns

Quick links point the way: www.process-heating.com/connect Q Go Mobile

Heat Exchangers Increasing Heat Transfer Efficiencies Adding economizers to existing boilers can help heat processing operations get the most out of every BTU they buy. Is it time to look at improving energy efficiency at your facility?

Boilers A Whole New (Boiler) Ballgame In 2011, the EPA enacted the Area Source Rule, making it mandatory for many commercial, institutional and manufacturing facilities to monitor fuel usage on a monthly basis and conduct biennial tuneups. Some facilities also are required to conduct a one-time energy assessment, and others must regularly meet emissions limits. Ensuring compliance with the EPA’s new boiler rules requires a new mindset.

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Heat Processing Focus Manufacturing Spotlight Enlighten yourself on the latest heat processing technology with this special section of products, tips and application ideas.

Columns & Departments 6 10 17 47

Editor’s Page Inner Workings Calendar Free Literature

Q Digital Editions Q Buyers Guide Q Archived Webinars

NETWORK WITH PROCESS HEATING!

Having a good idea of what you are looking for in an oven is the best way to get what you need.

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Q Energy Notes column Q Equipment Overviews Q Heating Highlights

Check out our redesigned site with more frequent updates and web exclusives!

Selecting & Specifying an Oven

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Q Industry News

ALWAYS ONLINE

48 49 49 50

Classified Directory Advertiser Index Subscription Form Places & Faces

Use your smart phone to read Process Heating, wherever you are! Simply visit http://gettag.mobi/ with your phone’s browser to install the Microsoft Tag app. Then, point your phone’s camera at the tag below to be taken to our current issue online — instantly. The reader works on most current smart and advancedd ffeature phones, includh i l d ing Windows Mobile (5.5 and above), iPhone, Blackberry, Symbian and J2ME.

About the Cover A large corn oil and ethanol producer uses four boilers from Precision Boilers LLC (www.precisionboilers.com) to base load the plant at more than 400,000 lb/hr of steam during nine months of the year. In the hottest summer months, says the Morristown, Tenn.-maker of boilers and steam generators, the ethanol producer typically runs 50 percent of the time based on electric rates due to high summer heat and air-conditioner loading at the utility. For more information about boilers, turn to page 31.

PROCESS HEATING (ISSN 1077-5870) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2012, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: PROCESS HEATING, P.O. Box 2146, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to PROCESS HEATING, P.O. Box 2146, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

www.process-heating.com • J a n u a r y 2 0 1 2

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New Ways to Handle Old Business

By Linda Becker

Commentary

Gimme Gadgets If you get the chance, tune in to the History Channel’s 101 Gadgets that Changed the World, a program the network compiled in conjunction with the editors of Popular Mechanics. It’s a fascinating look at history in all new ways. For instance, the show suggests that the audio cassette tape was instrumental in the fall of the Shah of Iran in 1979, and that wristwatches helped make it possible for the Allied troops to be successful on D-Day. Certainly, obvious game-changers such as the iPod, the calculator and the personal computer made the list. Still others, like the wristwatch, surprised me, though their influence on history is made clear on the show. Among the top 10 are the light bulb, the alarm clock, the rotary phone and portable air-conditioning, and even a cursory thought about your work day makes clear how different life would be without them. At the top of the list — the gadget that most changed the world — was a smartphone. As a device that combines so many other gamechanging gadgets — the personal computer, the Internet, radio, the telephone, Wi-Fi, and a calculator, to name a few — a smartphone is certainly useful. Yet I was unconvinced until two key points were asserted. First, as anyone who has ever owned one can attest, once you adjust to having a smartphone at your disposal, it’s almost impossible to live

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without one. Second, the smartphone will continue to be a gadget that changes lives because it has created an app-driven world. Now, it is no longer necessary to buy a dedicated device or even a full, multi-function computer program. Instead, “There’s an app for that!” Whether you want to play a game, listen to music, create music, share files — you name it — there is likely an app already offered for most smartphone platforms. Do you have a smartphone? Do you use it for work? There are some apps that can help. For instance Munters AB, Kista, Sweden, has released PsychroApp, a psychrometric calculation tool that allows users to determine the thermodynamic properties of air on an iPhone or iPod Touch. App developers also have begun to introduce engineering tools for smartphones. Check out some of those currently offered in iTunes or the Android market, such as HeatXchanger, Steam, Gas Rating Calculator, Building Engineer’s Formulator or Gas Rate & Heat Input Calculator. Each costs $0.99 or more, but if after a careful review you decided to buy, you can put an effective tool in your pocket.

Linda Becker, Associate Publisher and Editor, [email protected]

Inner Workings

Gasifiers Reduce Fossil-Fuel Use A biomass energy equipment company has the ability to produce renewable electricity from scrap wood chips using a clean thermo-chemical process. PHG Energy, LaVergne, Tenn., developed the process — called gasification — to produce a fuel much like natural gas, and then processed and purified that gas so it can be used to run a 1 MW Caterpillar generator. A successful implementation of the technology was installed and recently demonstrated at a Boral Bricks Inc. plant in Gleason, Tenn.

Gasification equipment from PHG fires brick kiln burners during a demonstration of the technology at Boral Bricks.

“We have trialed our gasification equipment producing fuel gas to fire large brick kilns here in Gleason as well as at two other manufacturing facilities in Georgia and Alabama,” says Tom Stanzione, PHG president. “We have more than 40,000 hours of successful gas production from waste biomass products on these gasifiers.” Boral uses six PH-8 downdraft gasifiers that convert wood chips to producer gas. The gas is piped directly into brick kiln burners for firing, with 2 percent biochar residue. According to PHG’s website, the gasification equipment uses wood chips with 25 percent moisture content. Feedstock input capacity is 48 tons/day and the producer gas output capacity is 24 million BTU/hr. “This ongoing application of our gas generation system has been focused on accomplishing just what we did today, cleaning and cooling the fuel gas 10

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J a n u a r y 2 0 1 2 • Process Heating

in order to generate power directly in a reciprocating engine generating set and putting that renewable power on the grid,” Stanzione says. PHG’s gasification equipment can utilize many biomass feedstocks such as wood chips or foresting wastes, and it can take advantage of recycled waste materials from industrial and manufacturing operations. “Our new generation of gasification equipment is truly industrial-grade,” Stanzione says. “It brings our customers the ability to reduce their use of fossil fuels, thereby their carbon footprint, and perhaps more importantly cut their fuel costs by 50 percent or better.” The project to produce electricity has been supported over the past year through collaborative contributions and funding from the U.S. Department of Energy as part of the ARES Program, which includes Caterpillar Inc., Peoria, Ill., and Boral Bricks, headquartered in Roswell, Ga. PHG notes that Boral’s Gleason site has realized the following benefits: • Fuel Cost Savings. The project uses $2 million BTU producer gas from dry $30/ton wood chips vs. $8 million BTU natural gas cost. • Reduced Reliance on Fossil Fuels. There is a projected 65 percent reduction in natural gas use. • Good Capitalization. With quality feedstock, projected payback is less than four years through fuel cost savings. For more information, go to www.phgenergy.com.

Thermcraft, Electrotherm Partner Two makers of heat processing equipment have formed a joint partnership to better serve their North American customers. Thermcraft Inc., Winson-Salem, N.C., a manufacturer of ovens and furnaces, and Electrotherm Industry, Migdal HaEmek, Israel, will work together to

provide products and services for industrial heat processing. Thermcraft manufactures thermal processing equipment such as laboratory and production furnaces, recirculating ovens, vacuum formed ceramic fiber heaters, cast heaters, heater coils, air heaters, ovens, kilns and diffusion heaters. Electrotherm Industry designs, develops, manufactures and markets precision forging and heat treatment furnaces for the aerospace, medical and energy industries. Electrotherm focuses on developing systems that meet stringent precision process requirements, NADCAP quality standards and AMS-2750D. As a part of the partnership, Scott Miller will join the team as sales manager in the United States. Working from an office in St. Louis, Miller can be reached by at (314) 726-4743 or via e-mail at [email protected].

Tweeting Combustion Alerts Anyone working with combustion equipment now can receive via Twitter information on important safety and risk events occurring throughout the world. CEC Combustion Safety, Cleveland, offers the service to keep those people involved with boilers, ovens, furnaces, thermal oxidizers and fuel delivery systems, including natural gas pipelines, fully informed when incidents happen, even those occurring outside the United States. If you want to know when there is a plant explosion, boiler blowup or factory fire, sign up for CEC’s service. Knowing details about an event can help you avoid the same fate. According to CEC, besides end-users of combustion equipment, the following groups could benefit from the service: insurance industry risk managers, environmental health and safety managers, corporate executives and plant personnel. CEC also will tweet important equipment-related issues such as safety recalls and warnings about potential problems related to gas valves, pressure switches, flame safety devices and other critical safety components. To subscribe, visit twitter.com and enter “CombustSafety” in the “Find People” search area. Those that do not already have an account can create one

Did you know that 90% of heat transfer fluid breakdowns are caused by equipment issues? If you just check your hot-oil on a regular basis you could practically eliminate unplanned shutdown or loss of production. The easy way to do this is by conducting a Fluid Analysis. Because Fluid Analysis isn't just to check your fluid; it's to test your system. When we test your fluid (we suggest annually or more frequently for demanding service) the values we get from boiling range, viscosity, and acidity tell us what's going on in there. Better yet, together with a one-to-one system review with you, those same test results can help pinpoint emerging issues with oxidation, overheating, or possible mismatches in those interrelated components that could lead to a downtime-causing problem. This can help you keep the system up when it's supposed to be up, and know in advance if any corrections are needed for when you do have scheduled downtime. Your system runs better, your fluid lasts longer, and your process earns its keep. Our Fluid Services Program team of engineers can get deep into your process with you from the design stage, customizing maintenance plans, process expansions or, in cases where the Fluid Analysis and system review suggests it, just a good cleanout

of your system with one of Paratherm's three specialized system cleaners. Paratherm's nine heat transfer fluids are designed to cover a broad temperature range as well as a range of compatibility and performance criteria. The fluid chart below can give you a feel for their specifications, but to narrow it down to the right product for your application all it takes is a short conversation with one of Paratherm's sales engineers. Eliminate the downside risk and call Paratherm today or check us out on the web.

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Inner Workings at no charge. CEC notes that it will tweet as it becomes aware of publicly released and important events. After getting a Twitter account, type “CombustSafety” to visit the company’s Twitter feed page, and then click on “follow” to receive CEC’s tweets in your Twitter feed. You also can view @CombustSafety on Twitter with a mobile device.

Facility Expansion Completed A $10.5 million facility expansion at Fulton provides efficiencies that are already allowing for increased response to customer demands, according to company officials. While introducing the recently completed project, Mark Hilton, Fulton’s vice president of manufacturing, noted, “The new facility will also provide the opportunity to expand Fulton’s product lines.” At the Pulaski, N.Y.-based facility, the expansion’s manufacturing space is already fully functioning; office space transitions have begun and are

expected to be complete in the first quarter of 2012. According to the company, an additional $3.5 million will be spent to complete project interior and equipment needs. All told, the project is expected to provide: • 10,000 ft2 of new research and development space. • 82,000 ft2 of new manufacturing space. • 20,000 ft2 of additional office space. • 70 tons of additional lifting capacity at Pulaski, N.Y., headquarters. Guests will be encouraged to visit and see firsthand the innovative technologies employed for heating and cooling, lighting and customized energy

recovery. Some of them include: • Heating. The heating system for the office space uses a 12-zone in-floor radiant hydronic system that can be heated using waste heat from the manufacturing processes or the factory’s research and development facilities. • Cooling. The office space is divided up into 43 zones with a chilled beam system mounted in the ceilings to efficiently distribute cooling to the building occupants. Cooling towers are incorporated to manage the energy balance of the overall system. For example, when waste heat exceeds the energy required by the system, excess energy can be rejected to the cooling towers. The system

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Inner Workings

Gas Burner Products

also has the potential to utilize gas absorption heat pumps and retention ponds as an energy source. The expansion also provided an opportunity for Fulton’s affiliate, Synex Controls, to integrate a custom energymanagement system to centralize and manage the facility’s heating, cooling, fresh air, humidification and lighting. Video and project background can be viewed online at www.fulton.com.

• • • • •

e-Distributor Gets Dow Glycol Fluids

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Dow Chemical Co., Midland, Mich., has expanded its relationship with ChemPoint.com, an e-distributor of fine and specialty chemicals, to include Dowfrost and Dowtherm glycol-based heat transfer fluids. ChemPoint will provide marketing, sales, order fulfillment and expanded technical support for customers in the food, beverage, radiant, geothermal, pharmaceutical and HVAC industries in the United States. Contact ChemPoint at www.chempoint.com.

Oxidizers Recover Energy Regenerative thermal oxidizers are abatement systems for volatile organic compounds and hazardous air pollutants. Regenerative thermal oxidizers from Catalytic Products

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Inner Workings International, Lake Zurich, Ill., use a ceramic heat exchange media for high thermal efficiency, and the exhaust temperature is 75 to 100°F (41 to 55°C) higher than the inlet temperature. In ambient temperature applications, there is not a lot of heat left over in the regenerative thermal oxidizer’s stack to allow for efficient secondary heating. According to CPI, it has developed a system that can affect the oxidizer’s thermal efficiency, raising the stack temperature to provide efficient heating. In certain applications, says the company, energy derived from VOCs is sufficient to offset the lower efficiency, and the net result is savings that otherwise might have been lost up the stack. The most common form of energy recovery is hot air delivered back to the process. Other options include heating, makeup air, hot water or other heating fluids. For more information about air pollution control and energy conservation from CPI, visit www.cpilink.com.

Metso Signs 2 Boiler Installation Contracts Biomass boilers from Metso, Helsinki, are scheduled for installation in two diverse applications. A biomass-fired steam boiler equipped with Metso’s DNA automation system will be installed in 2013 at Helsinki-based Valio Ltd.’s Lapinlahti, Finland, milk-production facility. The other biomass-fired boiler will be installed at a pulp and paper mill owned by Arkhangelsk, headquartered in Novodvinsk, Russia. The boiler plant destined for the milk-production facility will generate the steam and heat needed by the processing plant. The plant will be fueled by wood chips and peat. Wood chips are expected to be used at 100 percent eventually, but in the initial stage, they will account for 50 to 60 percent of the fuel mix, with a gradual increase, according to Metso. “Valio is investing in the development

The boiler plant destined for the milkproduction facility will generate the steam and heat needed by the processing plant.

of its energy-generation structure and in the recovery of waste energy streams, with the goal of improving energy efficiency, achieving lower emissions and increasing its use of domestic fuels,” says Esa Mäkipelto, Valio’s technical manager. The annual operation of the new plant will be around 8,500 hr and its process steam output will total approximately 140 GWh/a. The boiler is based on Hybex bubbling fluidized-bed combustion technology, patented by Metso, that allows the use of a range of fuels.

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J a n u a r y 2 0 1 2 • Process Heating

Inner Workings The boiler output is 20 MWth and that of the auxiliary boiler, also included in the delivery, is 12.4 MWth. The pulp and paper mill’s bubbling fluidized-bed biomass-fired boiler has a completion date of 2014. It will replace an existing power boiler and is expected to increase the mill’s energy independence and cut electricity costs. Bark and sludge will be used as fuel in the boiler, which has a capacity of 60 MWth. By replacing old coal boilers with a new biomass boiler, the Arkhangelsk mill will obtain an additional amount of steam and electricity.

EDL Adds Shopping Cart to Site An online shopping cart has been added to Danville, Va.-based EDL Inc.’s website. Now visitors can purchase temperature-related products with payments processed through EDL’s secure site using all major credit cards or a PayPal account.

Also on the site, visitors can download a temperature product catalog or request a hard copy; read product details; learn about the calibration laboratory and service; or sign up for eNews bulletins. See the site at www.edl-inc.com.

Study Outlines Promising Powder Coating Markets A new powder coating study based on surveys and interviews with U.S. companies has identified 21 market segments that spell opportunity for powder coaters. “Project Expand,” commissioned by the Powder Coating Institute in The Woodlands, Texas, and conducted by Chemmark Consulting Group Inc., Southern Pines, N.C., indicates that the segments carry a total potential value of more than $4 billion. Of the 21 segments that hold the most promise, five are within the markets that powder coatings currently serve, four are adjacent to the typical or

current areas, and 12 are in markets not previously penetrated by conventional powder coating systems. The 142-page report is available as a CD or hard copy. Cost depends on the type of PCI membership the purchaser has, but the report also is being sold to nonmembers. To order the study, go to www.powdercoating.org and click on the “Project Expand” logo.

Sizing Software for Valve Module Gets New Features As a part of its product sizing and selection software library, Spirax Sarco, Blythewood, S.C., has released Phase 1 of its pressure-reducing valve. The addition to the sizing software allows directacting products to be selected. Sizing charts no longer are necessary because the visual product-range selection option allows viewing of full product descriptions and code numbers. Users can access the software at http://prs.spiraxsarco.com.

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CALFLO AF delivers longer fluid life and better equipment protection. And more savings to you. We put CALFLO AF and leading competitors to the test in a challenging Severe Oxidative Stability Test and the results are clear. CALFLO AF provides better oxidative stability for longer fluid life and enhanced equipment protection. That means more savings in operations and maintenance costs. And less worry. Test CALFLO AF, or another product in our line of CALFLO heat transfer fluids, in your operation. And see the results for yourself.

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Calendar of Events January 23-25 — AHR Expo (held in conjunction with ASHRAE Winter Meeting), McCormick Place, Chicago. Hosted by co-sponsors ASHRAE and ARI. Call (203) 221-9232 or visit www.ahrexpo.com. 24-26 — International Poultry Expo, Georgia World Convention Center, Atlanta, Georgia. Hosted by U.S. Poultry & Egg Association. Call (770) 493-9401 www.internationalpoultryexposition.com. 24-26 — Elster Hauck Asphalt Product Maintenance Seminar, Customer Technical Center, Hauck Manufacturing Co.. Lebanon, Pa. Other dates available. Call (717) 272-3051 or visit www.hauckburner.com.

Exhibition, Las Vegas. Hosted by Water Quality Association. Call (630) 505-0160 or visit www.wqa-aquatech.com. 11-15 — Pittcon Conference and Expo, Orange County Convention Center, Orlando, Fla. Hosted by Pittsburgh Conference on Analytical Chemistry and

Applied Spectroscopy Inc. (Pittcon). Call (412) 825-3220 or visit www.pittcon.org. 13-15 — Composites Manufacturing Conference, Phoenix Marriott Mesa, Mesa, Ariz. Hosted by Society of Manufacturing Engineers. Call (800) 7334763 or visit www.sme.org/composites.

Lower production costs for snack expansion. AeroExpanderTM provides continuous hot air expansion of pelleted snack products with exceptional texture and appearance. Unmatched uniformity with 100% pellet expansion is achievable on a wide variety of products. Develop the industry’s next better-for-you snack with Buhler Aeroglide.

February 5-8 — Biodiesel Conference and Expo, Orlando, Fla. Call (800) 841-5849 or visit www.biodiesel.org.

Buhler Aeroglide 100 Aeroglide Drive, Cary NC 27511 USA Tel +1 919 851 2000, Fax +1 919 851 6029 [email protected], www.buhlergroup.com/aeroexpander

5-9 — Cooling Technology Institute (CTI) Annual Meeting, Hilton Hotel, Houston. Call (281) 583-4087 or visit www.cti.org. 8-13 — Hydraulic Institute Annual Meeting, Renaissance Vinoy, St. Petersburg, Fla. Call (973) 267-9700 or visit www.pumps.org. 14-16 — Plastec West, Anaheim Convention Center, Anaheim, Calif. Hosted by Canon Communications. Call (310) 445-4200 or visit www.canontradeshows.com/expo/plastecshows/. 28-March 1 — IPC APEX Expo, Convention Center, San Diego. Call (847) 615-7100 or visit www.ipc.org.

March 6-7 — Safety Standards Seminar for Industrial Ovens and Furnaces, Hilton Garden Inn O’Hare, Rosemont (Chicago), Ill. Hosted by Industrial Heating Equipment Association (IHEA). Call (859) 356-1575 or visit www.ihea.org.

Innovations for a better world.

6-9 — Aquatech USA Conference and www.process-heating.com • J a n u a r y 2 0 1 2

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Heat Tracing

A Proper Assessment By Blair McGrath and Sudhir Thorat, Tyco Thermal Controls

E

ngineers have many considerations when designing a heat tracing installation, especially if the area where it is located is defined as a hazardous location — a location where flammable gases may be present. It is vital that engineers assess all their equipment and ensure that it is up to code to protect the safety of personnel, the installation and its equipment. For example, an electric heat tracing cable can be accurately tested — provided that accurate assessment methods are used — to ensure the maximum sheath tem-

• Required temperature to maintain the fluid in the pipes. • Ambient temperature where the tracing system will be installed. • Heat loss from the fluid to ambient. • Maximum pipe temperature to which the heating cable will be exposed.

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• Autoignition temperature of the hazardous gases that may be present in the area.

Heat Trace Panel (May Include Circuit Breakers, Controllers and Alarms)

The plate test helps users accurately assess the maximum sheath temperature of mineralinsulated heat tracing cables. Are you familiar with this method? perature attained by the cable will not be so high as to cause harm to the installation through autoignition of hazardous gases present in the area. An electric heat tracing system may be used in an installation’s pipe system to compensate for heat losses and to maintain a minimum temperature. This often is important to ensure the proper viscosity of the process fluid in the pipe, or to prevent water or steam lines from freezing. Prior to designing and installing an electric heat tracing system, an engineer must carefully evaluate the application the system is serving. Important items to check include:

In applications where the heating cables will be installed in hazardous areas, there are additional design inputs that need to be considered, including the:

Transformer

Lighted End Seal

Remote Configuration and Monitoring Insulation Systems RTD Temperature Measurement Separate Wiring Run to Panel (Shown) Power Connection Heating Cable

An electric heat tracing system can be used in an installation’s pipe system to compensate for heat losses and to maintain a minimum temperature. This often is important to ensure the proper viscosity of the process fluid in the pipe, or to prevent water or steam lines from freezing. Prior to designing and installing an electric heat tracing system, an engineer must carefully evaluate the application the system is serving.

Solid Conductors

Magnesium Oxide Insulation

Seamless Metal Sheath

• Area temperature rating of the physical location of the installation. • Highest sheath temperature that the heating cable will reach during operation. The sheath temperature — the temperature of the outermost heat trace cable jacket — must not exceed the area temperature rating and is an extremely important part of electric heat tracing system design. Suppliers of heat tracing cables are required to predict the maximum sheath temperature that the cable will reach. However, given the varied methods used to measure and predict maximum sheath temperatures of mineral-insulated (MI) heating cables, there is confusion in the industry about the best approach. Two common methods have been evaluated and identified in IEEE 515, Standard for the Testing, Design, Installation, and Maintenance of Electrical Resistance Trace Heating for Industrial Applications. IEEE 515 requires that manufacturers verify their ability to predict sheath temperatures using either the pipe test or the plate test.

Benefits of the Plate Test vs. the Pipe Test Many pipe and plate experiments were performed to determine the maximum sheath temperature of various mineral-insulated cables from the same manufacturer, ranging in size from 0.12 to 0.43" (3 to 11 mm). Pipe Test. The pipe test consists of a 2" dia., L-shaped pipe sculpture with a valve located along the horizontal section and various flanges located along the length of the pipe. The heating cable is installed on the surface of the pipe according to the manufacturer’s instructions. Thermocouples are located at anticipated hot spots and attached to the heating cable

There is some confusion in the industry as to the best approach to measure and predict maximum sheath temperatures of mineral-insulated heating cable (shown in a cutaway view).

sheath, with another thermocouple located on the pipe itself in close proximity to the thermocouple on the heating cable sheath. After several of these thermocouple pairs are located along the length of the pipe, the entire assembly is insulated with 2" fiberglass insulation. The heating cable is energized at the required wattage and the pipe temperature is allowed to stabilize. After stabilization, the heating cable sheath temperature is recorded from all thermocouples, and the highest recorded temperature is the maximum sheath temperature of the cable at the given operating conditions. With the pipe test, it was difficult to obtain reproducible temperatures, and the hottest spot on the pipe varied from test to test and pipe to pipe. After reviewing the variations in the results, it was concluded that the pipe test was not a suitable method for consistently and accurately determining the maximum cable sheath temperature. Considering the implications for hazardous areas where a fire or explosion may occur, it is critical to have accurate sheath temperatures. Plate Test. The plate test uses a metal plate that is air cooled, electrically heated and well insulated. In the procedure, the cable is laid on the plate over a trough to simulate a common field condition where the heating cable is not in direct contact with the pipe. Thermocouples are located on the cable sheath at the center of the trough to measure the sheath temperature and also on the plate itself to measure the plate temperature. The plate temperature is monitored and controlled by the heating and cooling channels throughout the test. The assembly is insulated on all sides and on the top and bottom. After many trials, it was determined that the plate test produced more accurate and repeatable results with several benefits. It provides a simple, consistent method to

Heat Tracing install the cable and removes the installerrelated variability from the test. The cable sample simply is placed on the plate over a predetermined location and clamped down, without any bending or manipulation of the cable required. The trough depth of ~0.20" (5 mm) between the cable and the plate is highly controlled, represents the worst case condition, and is not dependent on the technique of the installer. In the authors’ opinion, the plate test proved to be a more repeatable, cost effective and reliable method of predicting maximum sheath temperature and ensuring the intent of the industry standards is met. In conclusion, engineers can rest assured that most heat tracing equipment manufacturers take a conservative approach to prevent hazards. For instance, the area temperature ratings and the temperature at which a fire can occur often are intentionally understated by the industry to build precaution into electrical installation designs. Additionally, even if the maximum temperatures are reached, the required insulation and cladding around the heating cables offer another layer of protection. The plate test has proven effective in predicting maximum sheath temperatures for mineral-insulated cable in an accurate and repeatable manner. Adoption of the plate test within industry standards as the single acceptable test method is the most logical next step to ensure consistency across the industry. PH Blair McGrath and Sudhir Thorat are product managers with Tyco Thermal Controls, Menlo Park, Calif. For more information from the manufacturer of heat tracing, call (800) 5456258 or visit www.tycothermal.com.

WEB EXCLUSIVE Sheath Impacts Design Before making electric heat tracing design decisions, engineers should confirm with their cable manufacturers that the sheath temperature data provided for their cables are the results of using the plate test. READ MORE @ WWW.PROCESS-HEATING.COM

www.process-heating.com • J a n u a r y 2 0 1 2

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Equipment Overview | Heat Transfer Fluids

W

Thermal Conductivity** (BTU/hr-ft-˚F @ 600˚F)

* *

* *

* *

0.46 0.67 0.43 0.7 0.71

*

0.072 0.069 0.07 0.006 0.076 0.072

0.065 0.065 0.0611 0.074 0.067

*

0.675 0.609 0.667 0.63 0.605 0.611

* *

* *

* *

* *

0.78 1 1.5 0.95 0.63 0.34 0.39

0.41 0.22 0.7 0.43 0.42

0.061 0.06 0.07 0.06 0.07 0.08 0.08

0.053 0.05 0.06 0.051 0.06

0.56 0.67 0.61 0.61 0.65 0.65 0.62

42.4 42.5 42.5 42.4 38.8

1.37 1.41 1.44 1.46 0.82

0.7 0.7 0.7 0.7 0.51

0.077 0.077 0.074 0.077 0.072

0.074 0.073 0.07 0.074 0.067

0.6 0.6 0.6 0.6 0.65

*

1.1 0.46 0.84 0.88 0.29 0.89 2 2 2 0.84

*

0.07 0.064 0.07 0.061 0.048 0.061 0.077 0.077 0.073 0.0725

*

0.61 0.53 0.63 0.53 0.61 0.51 0.6 0.6 0.6 0.65

42 49.6 46 49.25 47.6 49.6

46.7 40.2 44.9 44.2 44.1

*

* *

* *

0.64 0.96 1.5 0.93 1.5 1.52 150-200 @ 40°C, cSt 100 @ 40°C, cSt

10%: 600FA 10%: 565A 10%: 730A 10%: 650A 10%: 600A 10%: 355A 10%: 290A

51 47 47 47 43 39.1 40.1

46 43 42 42 41

41.2 41.1

-75 -40 0 -51 -44 5 50 50

10%: 613 90%: 637 10%: 638 90%: 730 10%: 760 90%: 930 10%: 583 90%: 930 10%: 704 90%: 904

430

n/a n/a n/a n/a n/a n/a n/a

Firepoint (ASTM D92, ˚F)

Autoignition (ASTM E 659-78, ˚F)

Density** (lb/ft3 @ 600˚F)

* *

Density** (lb/ft3 @ 400˚F)

* *

Distillation Range (ASTM D1160, ˚F)

* *

Pour Point (ASTM D97, ˚F)

38.9

45.70 45.63 46.00 45.70 46.38 54.94 52.07 42.70

670 650 490 670 690 690 550 630 390 180

444 435 302 440 530 615 511 329 210 120

472 464 327 466 582 636 543 370 240 140

693 680 625 682 740 818 704 675

500 600 600 600 550 550 180 550

550 640 650 630 600 600

310 340 440 330 455 442 >350 >392

335 385 500 345 520 505

* * * 650 675 670

* *

* *

650 600 600 550 550 400

700 650

Specific Heat** (BTU/lb-˚F @ 400˚F)

Thermal Conductivity** (BTU/hr-ft-˚F @ 400˚F)

* *

Viscosity** (ASTM D445, cSt @ 600˚F)

0.066

0.60 0.60 0.63 0.60 0.57 0.47 0.55 0.65

Viscosity** (ASTM D445, cSt @ 400˚F)

0.074 0.074

0.54

0.077 0.077 0.075 0.077 0.077 0.054 0.080 0.072

0.73 0.71

10%: 727 90%: 902 10%: 715 90%: 886 10%: 481 90%: 851 10%: 769 90%: 930 10%:769 90%:930 10%: 922 90%: 1255 10%: 694 90%: 957 10%: 613 90%: 784 10%: 356 90%: 546 10%: 181 90%: 546

630 600 450 620 640 650 500 600 350 150

choose a fluid that can take the heat — and move it to wherever you need it to go. You also can conduct your search online at www.process-heating.com. The online version includes advanced searching capabilities to make it even easier to find the fluid that is right for your process. You set the criteria

1.46 1.39 0.70 1.46 1.76 8.47 2.32 0.84

-1 14 -49 1 15 -87 -40 -72 -70 -130

Flashpoint (ASTM D92, ˚F)

Company and Fluid Name

Film, Maximum Temperature, ˚F

You also can conduct your supplier search online! www.process-heating.com Click on Equipment Overview, then on heat transfer fluids.

Bulk, Maximum Temperature, ˚F

hen choosing which heat transfer fluid to use for your process, data such as density, film coefficient, viscosity, pour point and thermal conductivity need to be taken into consideration. In Process Heating’s annual Equipment Overview on Heat Transfer Fluids, we have compiled all the data you need to

Duratherm Extended Life Fluids • www.heat-transfer-fluid.com Duratherm 630 Duratherm 600 Duratherm 450 Duratherm FG (Food-Grade) Duratherm HF (High FlashPoint) Duratherm S Duratherm G Duratherm LT (Low Temperature) Duratherm XLT -50 Duratherm XLT -120

MultiTherm LLC • www.multitherm.com MultiTherm 503 MultiTherm PG-1 MultiTherm IG-4 MultiTherm FF-1 (flushing fluid) MultiTherm OG-1 MultiTherm IG-1 MultiTherm PSC MultiTherm PSC Plus

Paratherm Corp. • www.paratherm.com Paratherm HR Paratherm NF Paratherm HE Paratherm GLT Paratherm MR Paratherm LR Paratherm CR

Petro-Canada • www.calflo.com Petro-Therm Calflo AF Purity FG Calflo HTF Calflo LT

* *

* *

600 600 450 400

330 340 465 360 330 N/A N/A

599 600 619 619 550

617 617 650 650 550

437 437 459 448 349

473 464 480 473 372

666 649 669 666 613

0 -44 0 0 -81

10%: 709 90%: 880 10%: 689 90%: 887 10%: 721 90%: 892 10%: 705 90%: 889 10%: 604 90%: 734

46.8 46.8 46.8 46.8 43.4

572 680 600 662 572 653 620 600 620 500

617 716 640 716 608 698 650 650 650 617

432 288 385 421 147 374 439 430 408 343

468 295 410 475 158 401 462 446 457 372

617 842 626 842 770 716 687 650 669 613

10 -26 -76 -29 -130 -27.4 5 -44 0 -81

10%: 650 90%: 880 10%: 532 90%: 540 10%: 630 90%: 750 10%: 730 90%: 740 10%: 355 90%: 365 10%: 650 90%: 670 10%: 738 90%: 932 10%: 693 90%: 900 10%: 720 90%: 928 10%: 624 90%: 752

45 53 47 57 44 55 46 45.8 45 43

*

*

>780F

* * *

* * * * 500

*

41.2 41.89 51.82

*

* *

*

0.73 0.81 3.37

*

* *

*

0.074 0.073 0.042

*

* *

Chem Group Chem Group / Marlotherm FP Chem Group / Marlotherm LH Chem Group / Marlotherm N Chem Group / Marlotherm SH Chem Group / Marlotherm X Chem Group / Thermaflo 660 Chem Group / Calflo HTF Chem Group / Calflo AF Chem Group / Calflo FG Chem Group / Calflo LT

47

*

52

*

50 41 40.8 41 38

0.29

*

0.41

*

0.42 0.73 0.73 0.72 0.72

0.056

*

0.053

*

0.059 0.074 0.073 0.07 0.07

*Contact Manufacturer for Specifics | **Values provided for Density, Viscosity, Thermal Conductivity and Specific Heat were determined at 400°F and 600°F (204 and 316°C) unless otherwise indicated for a specific fluid | NR=Not Reported | AData is from a Gas Chromatograph (ASTM D2887). | BFor fired heaters. All other heat sources are 30°F higher | †Thermal Conductivity Liquid (mW/(m)(K) @ 25°C) | ‡Thermal Conductivity Vapor (m/W/(m)(K) @ 25°C)

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J a n u a r y 2 0 1 2 • Process Heating

and let the search engine work for you. In addition, hyperlinks will take you directly to manufacturers’ web sites. If you would like a list of contact information for heat transfer fluid manufacturers listed in our Equipment Overview, Process Heating can help. Call or e-mail editor Linda Becker for the phone number, address and contact name of the companies in which you are interested: (847) 405-4020 or e-mail [email protected].

* * 0.62 0.81 0.71 0.69 0.7

*

0.06 0.05