Pipe Insert Heaters Guide | Industrial Dry Well Heaters
Pipe Insert Heaters Guide | Industrial Dry Well Heaters
Pipe Insert Heaters Guide | Industrial Dry Well Heaters

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Pipe Insert Heaters:

Screw Plug Heater
Screw Plug Type -
Pipe Insert Heaters
Pipe insert heater


Flange Style Pipe Insert
Heater Placed in Tank

Flanged immersion heaters


Flange Style -
Pipe Insert Heaters


PRODUCT DESCRIPTION


Indirect Heating of Tanks


Indirect heating uses a heat transfer medium to transfer the heat to the tank. Indirect methods can vary from external heating of the tank using the tank wall as the heating medium to utilizing a heat transfer medium to carry the heat to the tank. In addition, pipe insert heaters have been included in this category because they use an air space between the element and the process to convey the heat. There are various advantages to indirect heating. The biggest advantage is that the heater can typically be serviced without draining the tank. Second, indirect heating often allows watt density exposed to the process fluid to be lowered by spreading the heat over a larger surface. Finally, overheat conditions can be limited in many instances by simply limiting the temperature of the heat transfer medium. There are a few minor disadvantages to indirect heating that may be critical to your process. The primary disadvantage is the thermal lag caused by using a heat transfer medium to carry the heat. The delay is caused by the fact that the heater must first heat the heat transfer medium before the heat transfer medium can heat the process. If there is a large mass of heat transfer medium, larger heating capacities will be required to raise temperatures.




Pipe Insert Heaters Guide | Industrial Dry Well Heaters Pipe Insert Heaters - Specifications.pdf

Pipe Insert Heaters Guide | Industrial Dry Well Heaters How to Extend the Life of Your Immersion Heaters-2.pdf

Pipe Insert Heaters Guide | Industrial Dry Well Heaters Pipe Insert Heaters Wiring Diagrams-2.pdf

Pipe Insert Heaters Guide | Industrial Dry Well Heaters Pipe Insert Heaters-Installation, Operation and Maintenance Instructions.pdf



 

 

 

Pipe Insert Heaters


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. Consideration of element expansion both in length and in the element supports on the inner diameter must be considered when designing a pipe insert heater. The internal heaters of pipe insert heaters consist of screw plugs, flanged heaters, or open coil elements (OCE) inserted into a pipe. Pipe insert heaters must have a separate temperature controller mounted outside of the pipe to regulate the process temperature. An over temperature device should be installed and attached to the top of the pipe at the highest point. Packaged Systems offer a control panel with the necessary switchgear and temperature controls along with the heaters.

The Incoloy sheathed element(s) inside the pipe are carefully designed for this applicaton, and transfer their heat to the inside pipe wall by convection and radiation. The large surface area of the pipe in contact with your liquid greatly reduces the intensity making the pipe insert heater ideally suited for heating:

-Very viscous materials like Bunker C Fuel Oil
-Temperature sensitive materials like honey, glucose & liquid sugars
- Bulk storage of corrosive Material


Application:

Incoloy 800 is used for all pipe insert heating applications. Maximum sheath temperature 1400F. Watt densities of 10-30 W/Sq. in are mainly used.

Terminal Enclosures:



NEMA 1 Sheet Metal Housing (Intended for indoor use only)

NEMA 4 (Standard) Moisture Resistant Terminal Housing

NEMA 4X Epoxy Painted or Stainless Steel Moisture Resistant Terminal Housing

Pipe Insert Heaters Guide | Industrial Dry Well Heaters NEMA 7 Hazardous Location Terminal Housing

Thermostat Application

Since the thermostat will be located inside the pipe, it will be measuring the internal pipe temperature. The thermostat is intended for high limit purposes and is not suitable for process control. A separate temperature sensor, like a type “J” thermocouple will be required to control the process.

Complete Pipe Insert Heating Systems

Screw plug and Flanged assemblies are available complete with a pipe when installation of a pipe into the tank is not feasible or desirable. The pipe wells are 2” or 2 ” NPT schedule 40 carbon steel in the standard designs. Stainless steel pipes and connection fittings are available for chemical corrosion for or immersion into food products.

Installation Instructions

 

Before installing, check your pipe insert heater for any damage that may have occurred
    during shipment.

Check to insure that the line voltage is the same as that stamped on the nameplate.

Do not bend the heating elements. If bending is necessary, consult factory.

Pipe Insert Heaters Guide | Industrial Dry Well Heaters Important: Mount heater in the tank so that the liquid level will always be above the effective
    heated portion of the heater .If the heater is not properly submerged, it may overheat and
    damage the heating elements and create a possible fire hazard due to excessive sheath
    temperatures.

Where work will pass over or near equipment, additional protection such as a metal guard may
     be needed.

Heater must not be operated in sludge.

Install the heater using a high quality pipe sealing compound on the threads. Screw the heater
    into the opening. Tighten sufficiently with wrench applied on the hex portion of the screw plug.

 

Note: Locate Heater as low as possible for maximum liquid storage capacity. Heat does not move downward.

 

Warning: Hazard of Shock. Any installation involving electric heaters must be effectively grounded in accordance with the National Electrical Code.



Wiring

 

Pipe Insert Heaters Guide | Industrial Dry Well Heaters Electric wiring to heater must be installed in accordance with the National Electrical Code and
    with local codes by a qualified person as defined in the NEC. WARNING: Use copper
     conductors
only.

When element wattages are not equal, heaters must not be connected in series.

Electrical wiring to heater should be contained in rigid conduit or in sealed flexible hose to keep
     corrosive vapors and liquids out of the terminal housing.

If flexible cord is employed, a watertight connector should be used for entry of the cord into the
    terminal box. Outdoor applications require liquid-tight conduit and connectors.

Pipe Insert Heaters Guide | Industrial Dry Well Heaters Bring the power line wires through the opening in the terminal box. Connect line wires as shown
    in the wiring diagram.



Operation

 

Do not operate heaters at voltages in excess of that stamped on the heater since excess voltage
    will shorten heater life.

Always maintain a minimum of 2” of liquid above the heater to prevent exposure of the effective
     heated length. If the heater is not properly submerged, it may overheat and shorten heater life.
     Do not operate heater if tank is dry.

Be sure all trapped air is removed from a closed tank. Bleed the air out of the liquid piping
    system  and heater housing prior to energizing.
    Note: The tank or heating chamber in closed tank systems must be kept filled
    with liquid at all times.
 

Pipe Insert Heaters Guide | Industrial Dry Well Heaters Keep heating elements above sediment deposits.

Low Megohm Condition — The refractory materials used in electric heaters may absorb
    moisture during transit or when subject to a humid environment. This moisture absorption
    results in a cold insulation resistance of less than twenty megohms. Normally, this megohm
    value corrects itself after heatup and does not affect heater efficiency or life. A low megohm
    condition can easily be corrected by removing the terminal hardware and terminal enclosure
    and baking the heater in an oven at 350F for several hours, preferably overnight. Note: The
    lid must be removed from the housing. An alternate procedure is to energize the heaters at low
    voltage until the megohm reading returns to normal. When energizing heaters in air, the sheath
    temperature should not exceed 750F.


Maintenance

 

WARNING: Hazard of Shock. Disconnect all power to heater before servicing or replacing heaters.

 

Heaters should be checked periodically for coatings and corrosion and cleaned if necessary.

The tank should be checked regularly for sediment around the heater pipe insert as sediment
    can act as an insulator and shorten heater life.

Pipe Insert Heaters Guide | Industrial Dry Well Heaters Remove any accumulated sludge deposits from around pipe and from tank.

Check for loose terminal connections and tighten if necessary.

If corrosion is indicated in the terminal housing, check terminal box gasket and replace if
    necessary. Check conduit layout to correct conditions that allow corrosion to enter the terminal
    housing.

Clean terminal ends of all contamination



How To Order Pipe Insert Heaters

Quotation Request Form

(Please complete the fields below)



Specify ANSI Flange Size for Pipe Insert Heaters (standard is 3- 150 lb)
Specify ANSI Flange Rating or Pressure Class
Specify Pipe Insert Heaters Flange Material
Specify Non ANSI Flanges
Specify Pipe Insert Heaters Plug Sizes NPT
Specify Screw-plug Materials
Specify Pipe Insert Heaters Sheath Material
Specify Terminal Enclosure Type for Pipe Insert Heaters
Specify Pipe Insert Heaters Thermostat Power Ratings
Specify Thermostat Range
Specify Built in Temperature Sensor Options
Specify Complete Pipe Heating Assemblies
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Company Name Position
Address City/State/Province
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Toll Free Number Email
Web Site OEM Distributor Process User
Quotation Request Required Delivery Date
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Telephone: 905-859-8225        Facsimile: 905-859-4691

sales@nphheaters.com

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.