HomeMy WebLinkAboutTab 1 - Watlow 80kw CIP HeaterW A T L O W
339 Flange HeatersTubular andProcess AssembliesFlange Immersion HeatersWatlow flange heaters are easy toinstall and maintain. Designed forheating liquids and gases in tanksand pressure vessels, flangeimmersion heaters are ideal forapplications requiring higherkilowatts.Watlow flange heaters are madewith WATROD or FIREBAR®tubularelements brazed or welded to aflange. Stock flange heaters areequipped with a general purpose(NEMA 1) terminal enclosure.Flange heaters, with FIREBARelements, also answer the need forliquid immersion applicationsrequiring high kilowatts in smalltanks. The FIREBAR element’sunique flat surface geometry packsmore power in a smaller bundle,with lower watt density, making itespecially well suited for petroleum-based liquid heating applications.
Performance Capabilities
• Watt densities to 100 W/in
2
(15.5 W/cm2)
• Wattages to one megawatt
•UL®and CSA component
recognition to 480VÅ(ac) and
600VÅ(ac) respectively
• Incoloy
®sheath temperatures to
1600°F (870°C)
• Passivated 316 stainless steel
sheath temperatures to 1200°F
(650°C)
• 304 stainless steel sheath
temperatures to 1200°F (650°C)
• Steel sheath temperatures to
750°F (400°C)
• Copper sheath temperatures to
350°F (175°C)
Features and Benefits
•ANSI and ANSI compatible 2,
21⁄2, 3, 4, 5, 6, 8, 10, 12 and 14
inch flanges provide appropriate
heater size-to-application and fit.
•Flange sizes up to 24 inches
available on made-to-order units.
•Element sheath and flange
materials to meet application
needs.
•Integral thermowells provide
convenient temperature sensor
insertion and replacement without
draining the fluid being heated.
•A standard, general purpose
(NEMA 1) terminal enclosure
offers easy access to wiring.
•Element support(s)provide
proper element spacing to
maximizing heater performance
and life.
•To facilitate lifting, drilled andtapped holes come supplied foreye bolts on 10 inch and larger
flange heaters.
•All units are inspected and/or
tested to ensure element-to-
flange pressure seals do not leak.
•Four or six inch FIREBAR
flange heaters pack more
kilowatts in smaller bundles—in
liquid immersion applications, a
conventional 10 inch round
tubular element flange can be
replaced with a six inch FIREBAR
flange.
•WATROD hairpins are
repressed (recompacted)to
maintain MgO density, dielectric
strength, heat transfer and life.
•Branch circuits meet NEC with
48 amps per circuit maximum.
•UL®and CSA component
recognition under file numbers
E52951 and 31388 respectively.
See pages 268-271 for details.
WATROD Heating Element
Incoloy®is a registered trademark of
Special Metals Corporation.
UL®is a registered trademark of
Underwriter's Laboratories.
ThermowellFIREBARHeating ElementFlangeConduit Opening Terminal EnclosureOn stock chart units:• Three to five working days on most heaters• 10 working days on special voltages and/orwattages• 15 working days on special element lengthsFlange Final 11/22/00 10:43 AM Page 339
340
Tubular andProcess AssembliesFlange Immersion HeatersApplications• Water:DeionizedDemineralizedCleanPotableProcess • Industrial water rinse tanks• Vapor degreasers• Hydraulic oil, crude, asphalt• Lubricating oils at API specified watt densities• Air and gas flow• Caustic solutions • Chemical baths• Process air equipment• Boiler equipment• Freeze protection of any fluid• Anti-freeze (glycol) solutions• ParaffinOptionsTerminal EnclosuresGeneral purpose terminal enclosures, without thermostats, arestandard on all flange immersionheaters. Optional terminal enclosures include:• General purpose (NEMA 1) with asingle or double pole thermostat.• Moisture resistant (NEMA 4–steel). Available with or without asingle or double pole thermostat.• Corrosion resistant (NEMA 4X).Available with or without a single
or double pole thermostat.
• Explosion resistant (NEMA 7)
class 1 groups C and D.
Available with or without a single
or double pole thermostat.
• Explosion/moisture resistant(NEMA 7/4) combinations.Available with or without a singleor double pole thermostat.• For class 1, group B enclosures, consult your Watlow representative.Enclosure Enhancements• Enclosure heater to solve condensation and freeze problems.• Power distribution blocks to
facilitate power feed line wiring.
Prior to ordering, refer to the
terminal enclosure dimensions on
page 341. Order by adding the
appropriate suffix letter(s) to the
base flange heater code number, as
shown on the Build-a-Code chart.Heater code numbers and suffix letters are depicted on the Stockand Options charts, pages 345 to362. Specify class and group, ifapplicable.CautionExplosion-resistant terminal enclosures are intended to provideexplosion containment in the
electrical termination/wiring
enclosure only. No portion of the
assembly outside of this enclosure
is covered under this NEMA rating.
NEMA rating effectiveness may be
compromised by abuse or
misapplication.
Stand-off Terminal Enclosures
Stand-off terminal enclosures
provide an air-insulating barrier
between the flange and terminal
enclosure by mounting the
terminations and wiring away from
the flange. Stand-off terminal
enclosures are recommended
whenever a process operating
temperature exceeds 400°F
(205°C). This helps minimize
terminal enclosure temperatures.
To order, specify stand-off terminal
enclosure.
CSA Certified Enclosures
CSA certified moisture and/or
explosion resistant terminal
enclosures protect wiring in
hazardous gas environments.
These terminal enclosures, covered
under CSA file number 61707, are
available on all WATROD and
FIREBAR flange heaters. For
additional information, consult your
Watlow representative.
To order, specify CSA certified
enclosure, process temperature
(°F), maximum working pressure of
application (psig), media being
heated and heater mounting
orientation (horizontal or vertical)
and flange size.
Stand-off
Terminal
Enclosure
Ref. 6"
(150 mm)
Stand-off
Height
ANSI
FlangeConduit
Openings
Flange Final 11/22/00 10:43 AM Page 340
General 2➀1 1⁄2 (38) 3 3⁄8 (86) — — — — — — — —Purpose 21⁄2➀2 1⁄8 (54) 4 (102) — — — — — — — —(NEMA 1) 3 3 13⁄16 (97) 4 5⁄8 (117) 9 3⁄8 (238) 7 (178) 9 3⁄8 (238) 7 (178)49 3⁄8 (238) 7 (178) 9 3⁄8 (238) 7 (178) 9 3⁄8 (238) 7 (178)57 1⁄16 (179) 7 (178) 7 1⁄16 (179) 7 (178) 7 1⁄16 (179) 7 (178)67 1⁄16 (179) 8 (203) 7 1⁄16 (179) 8 (203) 7 1⁄16 (179) 8 (203)87 1⁄16 (179) 10 1⁄32 (255) 7 1⁄16 (179) 10 1⁄32 (255) 7 1⁄16 (179) 10 1⁄32 (255)
10 7
1⁄16 (179) 11
5⁄8 (295) 7
1⁄16 (179) 11
5⁄8 (295) 7
1⁄16 (179) 11
5⁄8 (295)
12 7
1⁄16 (179) 13
1⁄2 (343) 7
1⁄16 (179) 13
1⁄2 (343) 7
1⁄16 (179) 13
1⁄2 (343)
14 7
1⁄16 (179) 15
1⁄8 (384) 7
1⁄16 (179) 15
1⁄8 (384) 7
1⁄16 (179) 15
1⁄8 (384)
Moisture 22 5⁄8 (67) 3
1⁄2 (89) — — — — — — — —
Resistant 2 1⁄2 2 5⁄8 (67) 3
1⁄2 (89) — — — — — — — —
(NEMA 4) 3 2
1⁄8 (54) 4 (102) 9
3⁄8 (238) 7 (178) 9
3⁄8 (238) 7 (178)
49 3⁄8 (238) 7 (178) 9
3⁄8 (238) 7 (178) 9
3⁄8 (238) 7 (178)
57 1⁄16 (179) 7 (178) 7
1⁄16 (179) 7 (178) 7
1⁄16 (179) 7 (178)
67 1⁄16 (179) 8 (203) 7
1⁄16 (179) 8 (203) 7
1⁄16 (179) 8 (203)
87 1⁄16 (179) 10
1⁄32 (255) 7
1⁄16 (179) 10
1⁄32 (255) 7
1⁄16 (179) 10
1⁄32 (255)
10 7
3⁄4 (197) 13
3⁄4 (349) 7
3⁄4 (197) 13
3⁄4 (349) 7
3⁄4 (197) 13
3⁄4 (349)
12 7
3⁄4 (197) 15
7⁄8 (403) 7
3⁄4 (197) 15
7⁄8 (403) 7
3⁄4 (197) 15
7⁄8 (403)
14 7
3⁄4 (197) 17
1⁄4 (438) 7
3⁄4 (197) 17
1⁄4 (438) 7
3⁄4 (197) 17
1⁄4 (438)
Explosion 23 1⁄16 (78) 3
3⁄4 (95) — — — — — — — —
Resistant 2 1⁄2 3 1⁄16 (78) 3
3⁄4 (95) — — — — — — — —
(NEMA 7) 3 7
1⁄8 (181) 5
3⁄4 (146) 7
1⁄8 (181) 5
3⁄4 (146) 7
1⁄8 (181) 5
3⁄4 (146)
Class 1, 4 7
1⁄8 (181) 5
3⁄4 (146) 7
1⁄8 (181) 5
3⁄4 (146) 7
1⁄8 (181) 5
3⁄4 (146)
Groups 5 7
7⁄8 (200) 8
7⁄8 (225) 7
7⁄8 (200) 8
7⁄8 (225) 7
7⁄8 (200) 8
7⁄8 (225)
C and D 6 7
7⁄8 (200) 9
7⁄8 (251) 7
7⁄8 (200) 9
7⁄8 (251) 7
7⁄8 (200) 9
7⁄8 (251)
Consult 8 7
7⁄8 (200) 12
1⁄8 (308) 7
7⁄8 (200) 12
1⁄8 (308) 7
7⁄8 (200) 12
1⁄8 (308)
Factory 10 7
7⁄8 (200) 14
5⁄8 (371) 7
7⁄8 (200) 14
5⁄8 (371) 7
7⁄8 (200) 14
5⁄8 (371)
for 12 7
7⁄8 (200) 15
7⁄8 (403) 7
7⁄8 (200) 15
7⁄8 (403) 7
7⁄8 (200) 15
7⁄8 (403)
Group B) 14 7
7⁄8 (200) 19
3⁄8 (492) 7
7⁄8 (200) 19
3⁄8 (492) 7
7⁄8 (200) 19
3⁄8 (492)
W A T L O W
341 Flange HeatersTubular andProcess AssembliesFlange Immersion HeatersWithout Thermostat With ThermostatEnclosure Flange Single Pole Double PoleType Size E Dimension K Dimension E Dimension K Dimension E Dimension K Dimensioninch inch (mm) inch (mm) inch (mm) inch (mm) inch (mm) inch (mm)Terminal Enclosure Dimensions
➀Terminal enclosure is octagonal, not round.
OptionsK E K E K E EK4-8 inches NEMA 1 and NEMA 4 10-14 inches NEMA 1 10-14 inches NEMA 4 4-14 inches NEMA 7 Flange Final 11/22/00 10:43 AM Page 341
342
Tubular andProcess AssembliesFlange Immersion HeatersOptions ThermostatsTo provide process temperaturecontrol, Watlow offers optional single pole, single throw (SPST) anddouble pole, single throw (DPST)thermostats.Unless otherwise specified, thermostats are mounted inside theterminal enclosure. For details and ordering information, refer toThermostats on pages 423 to 425.Please verify that the thermostat’ssensing bulb O.D. is compatible withthe flange heater’s thermowell I.D.ThermocouplesASTM Type J or K thermocouplesoffer more accurate sensing ofprocess and/or sheath tempera-tures. A thermocouple may beinserted into the thermowell orattached to the heater’s sheath.Thermocouples are supplied with120 inch (3050 mm) leads (longerlead lengths available). Unless otherwise specified, thermocouplesare supplied with temperature
ranges detailed on the
Thermocouple Types chart.
Using a thermocouple requires an
appropriate temperature and power
control. These must be purchased
separately. Watlow offers a wide
variety of temperature and power
controls to meet virtually all
applications. Temperature controls
can be configured to accept
process variable inputs, too.
Consult your Watlow representativefor details.To order, specify Type J or Kthermocouple and lead length.Indicate if the thermocouple is forprocess temperature sensing orheater sheath high-limit protection.Please specify if the flange heaterwill be mounted vertical or horizon-tal in the tank. If vertical, specify if
the housing is on top or bottom.If the flange heater is part of an in-line circulation heating application, indicate flow directionrelative to the heater’s enclosure.RTDsIf your process requires greater temperature sensing accuracy thanis possible with thermocouples,Watlow can also supply RTDs in DINor JIS calibrations. Consult Watlow
for details.
Wattages and Voltages
Watlow routinely supplies flange
immersion heaters with 240 to
480VÅ(ac) as well as wattages from
150 watts to one megawatt. If
required, Watlow will make heaters
with voltage up to 600VÅ(ac) and
wattage beyond one megawatt. For
more information on special voltage
Branch Circuits
Branch circuits are subdivided by
National Electrical Code (NEC)
requirements to a maximum of
48 amps per circuit. Consult factory
for circuit requirements other than
those listed in the stock charts.
➀Type J and Type K thermocouples are rated 32 to 1382°F and 32 to 2282°F (0-750°C and
0-1250°C), respectively. Watlow does not recommend exceeding temperature ranges
shown on this chart for the tubular product line.
Alumel®and Chromel®are registered trademarks
of the Hoskins Manufacturing Company.
Recommended➀
ASTM Conductor Characteristics Temperature Range
Type Positive Negative °F (°C)
J Iron Constantan 0 to 1000 (-20 to 540)
(Magnetic) (Non-magnetic)
K Chromel
®Alumel®0 to 2000 (-20 to 1100)
(Non-magnetic) (Magnetic)
Thermocouple Types
and wattage configurations, consult
your Watlow representative.
Flange Final 11/22/00 10:43 AM Page 342
W A T L O W
343 Flange HeatersTubular andProcess AssembliesFlange Immersion Heaters Standard 150 lbMade-to-Order 300 lb600 lb
Over 600 lb➁
Standard Sheath MaterialsWATRODIncoloy®316 stainless steelSteelCopperFIREBARIncoloy®Made-to-Order Sheath MaterialsWATROD304 stainless steelMonel®FIREBAR 304 stainless steelOptionsSheath MaterialsThe following sheath materials areavailable on WATROD and FIREBARflange heaters:External FinishingPassivationDuring the manufacturing process,particles of iron or tool steel maybecome embedded in the stainlesssteel or alloy sheath. If not removed,these particles may corrode, produce rust spots and/orcontaminate the process. For critical sheath applications, passivation will remove free ironfrom the sheath. To order, specifypassivation.Other FinishesSimple belt polishing and glassbeading are available to meet cosmetic demands. Consult factoryfor details.FlangesFlange Sizes and StylesStandard: 2➀, 21⁄2➀, 3, 4, 5, 6, 8, 10,12 and 14 inch ANSI raisedface/blind flanges.
Made-to-Order: 16, 18, 20 and 24
inch in any recognized
configuration, as well as customer
specified. Over 24 inch, consult
Watlow Process Systems.
Flange Materials Pressure Classes
Gaskets
Rubber, asbestos-free and spiral
wound gaskets are available for all
flange sizes. Order by specifying
gasket type, flange size/rating,
process operating temperature and
pressure.
To make the correct selection, see
the Gasket Selection chart.
It provides a recommended gasket
type and effective temperature
rating.
To use this chart, multiply operating
temperature by the operating
pressure to arrive at “Maximum
PSIG X °F.” This is listed in the
chart’s first column.
Baffles
For forced circulation applications,
baffles can be arranged on the
heating element bundle to enhance
and/or modify fluid or gas flow for
better heat transfer.
For open tank or convection heating
applications, standard element
supports will be supplied.
To order, specify baffles.
Direction of Flow
➀ANSI compatible only.
➁Consult Watlow Process Systems in
Troy, Missouri.
Gasket
Maximum Temperature
PSIG X °F °F Gasket Type
Up to 15,000 300 Rubber
Over 250,000 700 Asbestos-Free
Over 250,000 ➂Spiral Wound
Gasket Selection
➂Depends on metal gasket material.
Monel®is a registered trademark of
Special Metals Corporation.
Exotic Sheath MaterialsConsult your Watlow representativefor details and availability.Standard Carbon steel316 stainless steel304 stainless steel
Made-to-Order Exotic materials to
meet specific
application needs➁
Flange Final 11/22/00 10:43 AM Page 343
344
Tubular andProcess AssembliesFlange Immersion HeatersApplication Hints• Select the recommended heatingelement sheath material and wattdensity for the substance beingheated. Use the SupplementalApplications Chart on pages263 to 266. If unable to determine the correct heating element sheath material and type,consult your Watlow representative.• Extend the element no-heat section completely into the fluidbeing heated to help prevent premature heater failure. Seeaccompanying illustration forproper no-heat section placement.• Locate flange heater low in thetank, but above the sludge level.• Choose a FIREBAR element whenyour application requires a smaller system package or lowerwatt density.• Ensure wiring integrity by keepingterminal enclosure temperaturebelow 400°F (205°C).• Keep electrical connectionsclean, dry and tight.• Minimize problems associatedwith low liquid level conditions by using low liquid level sensor orsheath temperature high-limitcontrol.• Periodically remove the flangeassembly to inspect and cleanthe heating element(s). This preventive maintenance willreduce premature failure andoptimize heater performance.• Refer to the Installation andMaintenance Instructions for correct orientation of FIREBARelements. This is important in airapplications with customersupplied circulation tanks.Correct element orientation toflow minimizes pressure drop,increases buoyancy force andheater performance.
C
D
E
F
A
No-Heat Section
K
B
Immersed Length ± 1%
H
Bundle
150 lb Flange Conduit Opening
WATROD Element
Thermowell for 0.375" (10 mm) Diameter Bulb
WATROD 2➀3⁄4 (19) 4 — — 2 (51) 4
3⁄4 (121) 6 (152)
9⁄16 (14) 2 (51) 3 3
WATROD 2
1⁄2➀3⁄4 (19) 4 — — 3 (76) 5
1⁄2 (140) 7 (178)
3⁄8 (10) 2
1⁄4 (57) 3 3
WATROD 3
3⁄4 (19) 4 12 (305) 4 (102) 6 (152) 7
1⁄2 (191)15⁄16 (24) 2
3⁄4 (70) 3 6
WATROD 4
3⁄4 (19) 8 12 (305) 4 (102) 7
1⁄2 (191) 9 (229)
15⁄16 (24) 3
7⁄8 (98) 6 6
WATROD 5
7⁄8 (22) 8 12 (305) 4 (102) 8
1⁄2 (216) 10 (254)
15⁄16 (24) 5 (127) 6 9
WATROD 6
7⁄8 (22) 8 12 (305) 4 (102) 9
1⁄2 (241) 11 (279) 1 (25) 6 (152) 12 15
WATROD 8
7⁄8 (22) 8 18 (457) 6 (152) 11
3⁄4 (298) 13
1⁄2 (343) 1
1⁄8 (29) 7
13⁄16 (198) 18 24
WATROD 10 1 (25) 12 18 (457) 6 (152) 14
1⁄4 (362) 16 (406) 1
3⁄16 (30) 9
3⁄4 (248) 27 36
WATROD 12 1 (25) 12 18 (457) 6 (152) 17 (432) 19 (483) 1
1⁄4 (32) 11
3⁄4 (298) 36 54
WATROD 14 1
1⁄8 (29) 12 18 (457) 6 (152) 18
3⁄4 (476) 21 (533) 1
3⁄8 (35) 12
3⁄4 (324) 45 72
Flange Immersion Heater Dimensions
➀Thermowells are not provided on two and 21⁄2 inch units. 150 lb rating is not available on two and 21⁄2 inch stock units.
Note: The number and size of conduit openings will comply with the National Electrical Code standards.
➀➁No-HeatSection
Flange
Element Flange Mounting Hole Thermowell Number of
Type Size Size Number Length A Dimension C Dimension D Dimension F Dimension H Dimension Elements
in in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) Std Max
Flange Immersion Heater
For terminal enclosure
dimensions (K and E) see
page 341.
Flange Final 11/22/00 10:43 AM Page 344
Application: Clean Water60 W/in2 50 213⁄4 (553)FRC721N3➁3 FRC721N11 3 FRC721N5 2 118 (54)Steel Flange 75 293⁄4 (756)FRC729N3➁6 FRC729N5➁2 126 (58)18-Copper 100 371⁄4 (946)FRC737E3➁6 FRC737E5 3 130 (59)(9.3 W/cm2) 125 451⁄4 (1149)FRC745E3➁6 FRC745E5➁6 132 (60)150 523⁄4 (1340)FRC752N5➁6 137 (63)175 603⁄4 (1543)FRC760N5➁6 144 (66)200 681⁄4 (1734)FRC768E5➁6 149 (68)Application: Process Water48 W/in2➄50 253⁄4 (654)FRN725N3➁3 FRN725N11➁3 FRN725N5➁2 121 (55)Steel Flange 75 353⁄4 (908)FRN735N3➁6 FRN735N5➁2 130 (59)18-Incoloy®100 441⁄4 (1124)FRN744E3 6 FRN744E5 3 132 (60)(7.5 W/cm2) 125 5411⁄16 (1389)FRN754M3➁6 FRN754M5➁6 140 (64)150 6311⁄16 (1617)FRN763M5➁6 145 (66)175 733⁄16 (1859)FRN773D5 6 151 (69)200 8211⁄16 (2100)FRN782M5➁6 157 (72)48 W/in2 67 263⁄16 (665)FRN726D3X➁4 FRN726D11X➁3 FRN726D5X➁2 129 (59)Steel Flange 100 363⁄16 (919)FRN736D3X➁8 FRN736D5X➁4 142 (65)24-Incoloy®133 44
11⁄16 (1135)FRN744M3X➁8 FRN744M5X➁4 147 (67)
(7.5 W/cm2) 167 54
11⁄16 (1389)FRN754M3X➁8 FRN754M5X➁8 158 (72)
200 63
11⁄16 (1618)FRN763M5X➁8 166 (76)
233 73
3⁄16 (1859)FRN773D5X 8 175 (80)
267 82
11⁄16 (2100)FRN782M5X➁8 184 (84)
Application: Forced Air and Gases, Caustic Solutions, Degreasing Solutions
23 W/in2➄➅30 32
3⁄4 (832)FRNA32N10➁3 FRNA32N3➁2 FRNA32N11➁2 FRNA32N5➁1 130 (59)
Steel Flange 40 43
1⁄4 (1099)FRNA43E3➁3 FRNA43E11➁2 FRNA43E5➁2 132 (60)
18-Incoloy®50 51
11⁄16 (1313)FRNA51M3 3 FRNA51M11 3 FRNA51M5 2 137 (63)
(3.6 W/cm2)
23 W/in2 40 33
3⁄16 (843)FRNA33D10X➁4 FRNA33D3X➁4 FRNA33D11X➁2 FRNA33D5X➁2 142 (65)
Steel Flange 53 43
11⁄16 (1110)FRNA43M3X➁4 FRNA43M11X➁3 FRNA43M5X➁2 147 (67)
24-Incoloy®67 51
11⁄16 (1313)FRNA51M3X➁4 FRNA51M11X➁3 FRNA51M5X➁2 154 (70)
(3.6 W/cm2)
W A T L O W
357 Flange HeatersTubular andProcess AssembliesFlange Immersion Heaters8" 150 lb ANSI Flange—WATROD ElementWATROD Immersed Code No. Est. Ship.Description kW B Dimension 240VÅ(ac) No. of 240VÅ(ac) No. of 480VÅ(ac) No. of 480VÅ(ac) No. of Weightinch (mm) 1-Phase Circuits 3-Phase Circuits 1-Phase Circuits 3-Phase Circuits lbs (kg)
All flange immersion heaters are Assembly
Stock unless otherwise noted.
Availability
Stock: Same day shipment
Assembly Stock: Five to seven working days
Standard: 10 working days, depending on
size
Truck Shipment only
b Standard
e 240VÅ(ac) 3-phase can be rewired wye to
produce 1⁄3 more kW and watt density when
operated at 480VÅ(ac) 3-phase.
➅Can be rewired wye to produce 1⁄3 of the
original kW and watt density
(3-phase only).
CONTINUED
Flange Final 11/22/00 10:43 AM Page 357