Industrial Process Heaters System Guide | Immersion Heaters
Industrial Process Heaters System Guide | Immersion Heaters
Industrial Process Heaters System Guide | Immersion Heaters

Industrial Process

Industrial Process Electric Heaters - Products Flanged Immersion Heaters Screw-Plug Heaters Duct Heaters Circulation Heaters Over-the-Side Heaters Finned Tubular Heaters Pipe Insert Heaters Tubular Heaters and Elements Temperature/Power Control Panels
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Heater System Guide

1) Define system to be heated (type of material to be heated, liquid, solid or gas; weight or gallons; flow rate if applicable; change in temperature, ?T, [delta T]; specific heat of material to be heated; heat-up time required; tank/container/vessel weight; insulated/non insulated tank etc.)

Process Application Index.pdf

2) Calculate heater wattage required (Allow for contingency factors

See fomulas below

To determine KW required for liquids and solids the following formulas apply:

KW = W x C x ?T KW = Kilowatts

3412 x hours

W = Weight of material in lbs.

C = Specific heat of material

?T = Change in temperature, F

(final temp. minus initial temp.)

3412 = Conversion factor, Btu to kWh

Hrs = Heat-up time, in hours (i.e. time required to reach set-point

For flowing water use the formula A) below:

A) KW = GPM x ?T x .16 GPM = Gallons per minute

?T = Change in temperature, F

For heating water in tanks or vessels use fomula B) below:

B) KW = Gallons of water x ?T (F)

325 x Heat-up Time (hours)

3) Determine appropriate heater watt density for material being heated see

Watt Density Value Chart.pdf

4) Determine suitable sheath material

Corrision Resistance of Different Materials.pdf

5) Select appropriate heater type

Guide for Selecting Heaters.pdf


Heater Determination Guide

Provide enough wattage with some contingency to allow for line

voltage fluctuations and other variables Add a factor of 20%

Make sure heater sheath watt densities do not exceed maximums

recommended for material heated see chart below

Watt Density Value Chart.pdf

Make sure heater sheath temperatures are well under maximums


Properties of Metals and NonMetallic Solids.pdf

Use lower operating voltages where choices are available (Regulate voltage

as close as possible to rated voltage. Do not exceed 110% of rated voltage.)

Protect against: Physical damage, termination contamination (including moisture), corrosion, and other conditions that could damage heater or other system components. Include an appropriate terminal housing

Immersion Heaters-Installation, Operation and Maintenance Instructions.pdf

Make sure suitable operating temperature control is included

in the final system

Sensor Placement In A Thermal System.doc

Make sure overheat safety device is included in the final system

Immersion Heaters-Installation, Operation and Maintenance Instructions.pdf

Install electrical wiring to all electrical standards and codes

Electrical Data and Wiring Diagrams.pdf

Make sure design construction and manufacture comply with Canadian Standards Association, CSA; Underwriters Labs (UL) or other regulations as required by specific application

National Plastic Heater,

Sensor and Control Inc.

Tel: 905-859-8225 Fax: 905-859-4691

Toll Free: 1-877-674-9744 ( Canada & USA )

Telephone: 905-859-8225        Facsimile: 905-859-4691

Toll Free: 1-877-674-9744

Our industrial process electric heaters...

Our industrial process electric heaters consist of the following product categories: flanged immersion heaters, screw-plug immersion heaters, over-the-side heaters, circulation heaters, duct or air process heaters, pipe insert heaters, tubular heaters , finned tubular heaters and Temperature Control Power Panels.

Industrial process heaters are available with adjustable thermostats, digital temperature controls; SCR, mercury relay or mechanical temperature control power panels with process and high limit thermocouples.

Industrial process heaters from National Plastic Heater, Sensor and Control Inc. are Hydro approved and CSA or C UL recognized. Terminal enclosures can be NEMA 1 (General Purpose), NEMA 4, ( Moisture resistant) NEMA 4X (Corrosion/Moisture Resistant), NEMA 7 (explosion proof) and NEMA 12 (Dust and Oil Resistant).

Industrial heater sheath materials like Titanium, Incoloy, Stainless Steel, Steel, and Copper can be used as required for specific applications. Standard Flanged Immersion Heaters have a 150 lbs flanges but 300, 600 and 1500 lbs flanges are also available.

Below a brief description of most of our industrial process heaters line-up:

Screw plug immersion heaters consist of hairpin bent tubular elements brazed or welded into a screw plug and provided with terminal boxes for electrical connections.

Screw plug immersion heaters are screwed directly through a threaded opening in a tank wall or through matching pipe coupling, half coupling or welding flange.

Circulation Heaters offer the following: High efficiency heat transfer, Pressure ratings to 600 lbs, ANSI Standard NPT or ANSI Class 150 connections, Heaters could be screw plug or flanged, Stainless steel construction with Canadian Vessel Registration, Various housing options available NEMA 4, 4X, explosion proof,

Suitable for steam, oils, chemicals, gases, corrosive solutions.

Heating using pipe insert heaters: A pipe insert heater uses an element inserted into a sealed pipe. The advantage to the pipe insert heater is that the element is isolated from the process. This allows the element to be removed without draining the tank, isolates hazardous or corrosive materials from deteriorating the element, and if sized properly may allow the heat to be distributed over a larger surface area reducing the watt density exposed to the process.

Over-the-side immersion heaters are designed for vessels where through the side immersion heaters cannot be conveniently installed. These heaters are installed through the top of the vessel with the heated portion of the unit along the side or at the bottom of the tank.

NPH Tubular heaters can be used in their straight form or bent into various shapes.

Tubular heaters can be used in free air, clamped to a surface, placed inside a groove or cast into metal.

Finned tubular heaters offer distinct advantages over open coil heaters: (a) they are safer to operate in that the risk of fire or electrical shock are minimized; (b) they have a much longer service life; and (c) they are more rugged requiring less maintenance than open coil heaters.

Duct heaters from National Plastic Heater are composed of, tubular, finned tubular or open coil heating elements that are either flanged or inserted in the duct. Duct air heaters are generally an assembly of tubular heating elements ready to mount into a duct but it can also be an open-coil resistance wire assembly mounted into a duct.

Temperature Control Power Panels, for a wide variety of applications are designed and engineered by National Plastic Heater, Sensor and Control Inc. Entire systems are available for the most complex process heating control applications that require electric heaters, temperature controls, and temperature sensors. Control power panels can be built with as little as one zone to as many as 36 or even more temperature control sensing points.