October 2017 Volume 24, Number 10

Heaters
Help Deliver
FOOD
PACKAGING
SAFETY

Follow us on:

www.process-heating.com
 Reliability
that comes at
no extra
charge.
Choosing the right burner is key in maximizing boiler performance.
Recognized for reliable, efficient operation, Industrial Combustion
burners are engineered with more standard features
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Our versatile MTH Series burners offer a
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W h e re R e l i a b i l i t y C o m e s S t a n d a rd
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 OCTOBER 2017 Volume 24 Number 10

18
Features
Online Exclusives
12 Thermal Fluid Heaters
The Importance of Expansion and Drain Structure Hurricane Harvey Moves Turbomachinery Meeting to December
in Hot Oil Systems The 46th Turbomachinery and 33rd International Pump Users Symposia (TPS
Preplanning during design can save time and money during 2017) will now be held December 12-14, with short courses held December
11. The conference and exposition, sponsored by the Turbomachinery Lab
planned or unplanned shutdowns.
at Texas A&M University, was delayed when Hurricane Harvey hit Houston.
18 Heaters Partnership Improves Awareness of Need for Industrial
Heaters Help Deliver Packaging for Food Safety Cybersecurity
and Consumer Acceptance The International Society of Automation (ISA) formed a global
Packaging innovations such as heat-sealed packages, tamper- partnership with Siemens to improve awareness of the need for
resistant bottles and shrink wrap are all a result of evolution industrial cybersecurity. The alliance specifically focuses on broadening
in process heating technologies. Though process heating is understanding and adoption of industrial automation security standards.
essential to many effective packaging solutions, too often, it is Acquisition of BJM Pumps Completed
an afterthought. Private equity firm May River Capital completed its acquisition of BJM
Pumps LLC, which provides submersible pumps for demanding applications
22 Portable Chillers in industrial and municipal/wastewater environments.
How Variable-Speed Portable Chillers Can Help
An alternative for process cooling applications, variable-
speed compressors coupled with advanced PLCs continuously
Always Online
Archives Energy Notes column Digital Editions
monitor the heat load and adjust the compressor speed for
Calendar of Events Equipment Overviews Buyers Guide
peak efficiency and temperature control. Drying Files columns Heating Highlights Archived Webinars
26 Combustion New Products Industry News

Improved NOX Limitation Standard to Reflect Check out our redesigned site with more frequent updates and web exclusives!
Combustion Efficiency
In many locations throughout North America, nitrogen oxide Quick links point the way:
(NOX) emissions of gas-heated furnaces and ovens are limited www.process-heating.com/connect
by code or law. This is typically the case in urban areas or in
places where special topographical characteristics intensify the Go Mobile
Use your smart phone to read Process Heating, wherever you are! Point
negative local and regional effects of NOX emissions. your phone or tablets camera at the image
at right to scan the QR code with your mobile
30 Temperature Sensors phone or tablet. Your device will display the
Temperature Measurement Flexibility Helps Quality mobile version of the current issue of Process
and Validation Heating instantly!
Understanding different sensor types helps create better Your mobile service provide may charge for
temperature profiles. data transmission usage. Contact your mobile
provider for details on your data plan and limits.
34 Equipment Overview
Industrial Heat Exchangers
An apples-to-apples comparison of the capabilities of
industrial heat exchanger manufacturers, our Equipment About the Cover
Overview will help you narrow the field of potential suppliers. Packaging innovations such as heat-sealed
October 2017

packages, tamper-resistant bottles and Volume

24, Number 10

Columns & Departments shrink wrap are all a result of evolution in

process heating technologies, notes Jeff
4 Commentary 45 Advertiser Index Myatt of Osram (www.osram-americas. Heate
Help Deliversr

6 Inner Workings 45 Classified Directory com). Learn more about heat processing FO
PACKAGINOD
G
10 Calendar 46 Places & Faces technologies for food packaging and SAFETY
38 Product Highlights 46 Contact Us other processes in the article beginning
44 Front & Center on page 18. Follow us
on:

www.p rocess-
heating .com

PROCESS HEATING (ISSN: Print 1077-5870 and Digital 2328-9996) is published 12 times annually, monthly, by BNP Media, Inc., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to
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www.process-heating.com OCTOBER 2017 3

Commentary
Learn about Heat Transfer Fluids
for Process Heating
As fate would have it, the first article I
ever worked on for Process Heating related
to heat transfer fluids. Check Your Fluid
Before It Checks Production appeared in
our May/June 1995 issue, and it focused on
the common tests that are performed on
industrial heat transfer fluids to determine
whether a fluid changeout was needed By Linda Becker
in a system. (Unfortunately, PH content
published prior to 1998 was lost in the great Mac
hard-drive crash of 1997. If youd like to read Check
Your Fluid Before It Checks Production, Ill post a
PDF to this column on our site.)
You may be thinking, if we covered heat transfer
fluids in 1995, has much changed? Is there anything
new to learn? Absolutely! Standards are developed
and changed, and materials developments drive fur-
ther equipment enhancements.
In this issue, The Importance of Expansion and
Drain Structure in Hot Oil Systems is a prime
example. The article, written by the engineering team
at Sigma Thermal, explains the design principles
that must be considered when designing a thermal
fluid heating system. Learn key design principles for
expansion tanks and the drain structure, and under-
stand how these systems play a part of the overall
thermal heating system.
This fall, Process Heating and our sister publication,
Process Cooling, will present two hour-long webinars
on heat transfer fluids.
On October 12 at 2 p.m. ET, Process Cooling and
experts working daily with low temperature heat
transfer fluids will present Using Glycol Heat Trans-
fer Fluids for Effective Process Cooling. The unique
collaborative event means that you can gain honest
insights into low temperature heat transfer fluids and
how they can best perform in your plant. During the
webinar, you will:
Understand the regulatory needs for a given
application and location.
Understand why the heat transfer fluid freezing
point affects system operation.
Learn about effective corrosion control when using
glycol fluids.
Glycol-based heat transfer fluids, which have low
4 OCTOBER 2017 Process Heating
Heat
Processing
Technologies
for these
freezing points, are particularly well suited
9 Industries
for food processing applications, breweries
and wineries, and refrigerated warehouse
as well as commercial applications such as Chemicals/
supermarkets and ice rinks. Petrochemicals
Are you struggling with these common
problems related to using glycol-based
fluids:
Food Processing
Overdilution of glycols, biofilm fouling and scale
formation?
Short fluid lifetime?
Air entrainment and foaming? Finishing
Our speakers Kevin Connor of Dow, Kevin
Coscia of Dynalene Inc. and Alfonso Sira of Hough-
ton Chemical will offer key insights during this
Plastics/Rubber
one-hour event. Register for this event at http://bit.
ly/glycolfluidswebinar and watch it live or on demand.
On December 5 at 2 p.m. ET, Process Heating and
experts working daily with mineral oil and silicone
heat transfer fluids will present An Insiders Guide Pharmaceuticals
to Fluid System Maintenance. In the final episode
of Process Heatings heat transfer fluids webinar series,
our panel goes beyond the basics to deliver practical
Pulp/Paper/
tips from those working with heat transfer fluids
Wood/Converting
every day. Learn the insiders tips for preventive main-
tenance for thermal fluid heating, including:
How to pipe in a nitrogen system. Ethanol/
Design elements in system filtration. Biodiesel
How to remove water and deal with water
contamination.
How to deal with water contamination. Packaging/
Printing
All of the webinars in the Process Heating heat
transfer fluids series are available for on-demand
viewing. To register for the December 5 event or
watch past episodes, visit http://bit.ly/2xgckEA.
Electronics
Visit www.process-heating.com
to read industry-focused content
as well as thousands of articles
Linda Becker, Associate Publisher and Editor, covering industrial heat
processing equipment.
BeckerL@bnpmedia.com
DESIGN THE
PERFECT PRODUCT
Customize our thermal processing ovens and furnaces
to fit your application needs, in any environment.

Call our Engineering

Design Center
570-538-7200
Or email
info@thermalproductsolutions.com

Applications
Military and aerospace
Consumer product testing
Clean room applications
Explosive environments
Inert gas atmospheres
High temps and vacuums
Small footprint designs
Robotic load/unload
Web-based management
Pollution control

Aftermarket service
Start-up and training
Installations
Temperature uniformity
Preventative maintenance
Retrofits
Refurbished equipment
Rental equipment

Address: 2821 Old Route 15 | New Columbia, PA 17856 | USA

Phone: (570) 538-7200 | Fax: (570) 538-7380

www.thermalproductsolutions.com
Inner Workings

Powder Coating Show Returns to Indianapolis

The 2018 Powder Coating Technical
Conference will be held March 12-15
at the J.W. Marriott in Indianapolis.
The four-day event, produced by the
Powder Coating Institute (PCI), will
include a tabletop exhibition.
The event begins with the
conference and exhibition on March
12-13, closing on the morning of
March 14. Attendees can learn
about powder coating during
general sessions and by attending
a concurrent technical program.
The tabletop display area will allow
attendees to interact with powder
coating manufacturers and get
hands-on experience with powder
coating application equipment. Other
exhibitors include system houses,
chemical suppliers and various service
providers for the powder coating
CSB Advises Caution for
Chemical, Oil Facilities in
Wake of Hurricane Harvey
In the wake of Hurricane Harvey, oil
and chemical facilities in the Gulf Coast
region will begin restarting facilities
shut down to weather the storm.
The U.S. Chemical Safety and Hazard
Investigation Board (CSB) issued
a safety alert urging them to take
special precautions. The CSB notes that
startup of major processes at chemical
facilities is a hazardous phase. Facilities
should pay particular attention to
process safety requirements during
this critical period to ensure a safe
return to normal operations.
The safety alert outlines specific
procedures to help ensure safe
restarts, including:
Use appropriate management-of-
change (MOC) processes before
modifying any startup procedures,
equipment or staffing arrangements
due to the impact of the hurricane.
Make sure that adequate staffing
and expertise are available before
starting up. Recognize that human
performance may be compromised
due to crisis conditions.
Use up-to-date startup procedures
and ensure that the available staff
are trained in how to execute them.
Evacuate nonessential personnel,
including personnel in trailers, from
the vicinity of process units that are
starting up.
Images courtesy of U.S. Geologic Survey

industry.
Following the technical conference,
PCIs Powder Coating 101: Basic
Essentials Hands-On Workshop will be
offered on March 14-15. The workshop
covers the basics of powder coating
operations and concludes with hands-
on training demonstrations at an area
powder coating facility. Hurricane Harvey made landfall on the Gulf Coast of Texas as a Category 4
Visit www.powdercoating.org for hurricane on the night of August 25, 2017. It then stalled over southeastern Texas
more information. as a tropical storm and continued to creep northeast over Louisiana.

6 OCTOBER 2017 Process Heating

 Inner Workings

Additional safety protocols require
checking bulk storage tanks for
evidence of floating displacement
or damage, notes the CSB. The
safety board also reminds facilities
to examine insulation systems,
sewers, drains, furnace systems,
electric motors and other equipment,
including warning systems, to make
sure they are fully functional.
You can download the safety alert
at CSBs website (www.csb.gov).
are linked to a back-end digital
monitoring system and a master
data management system. According
to the company, the networking
of production processes has
evolved into an intelligent lifecycle
management platform designed to
Industry 4.0 principles.
Thermal Fluid Maker Adds
Refurbished Heaters,
Refurbishing Services
For processors that need a quick-ship
thermal fluid heater, Fulton Thermal
Corp., Pulaski, N.Y., is offering used,
refurbished thermal fluid heaters
from stock.

Ohio Plant Produces

2 Million Jeep Wrangler
Body-in-Whites
Thermal Fluids that
go beyond precise
temperature control
Working closely with equipment manufacturers and our customers, weve
gained an intimate and unrivaled understanding of real-world concerns for
heat transfer fluids. Our full range of environmentally responsible thermal
KUKA Toledo Production Operations
fluids and unique and innovative system cleaners make Duratherm a single
(KTPO) celebrated the completion of
its two millionth Jeep Wrangler body- source for all aspects of heat transfer fluid applications.
in-white.
The wholly owned subsidiary of
KUKA Systems North America LLC
has built the body-in-white of all Operating range -84C to 338C (-120F to 640F)
Wranglers sold worldwide both Non-toxic/non-hazardous
two-door and four-door models
since beginning operations in 2006. Complete engineering data
It took seven years for the company
to build the first million but only four OEM system design collaboration
to make the second million because
it expanded output to keep up with Online thermal fluid calculators
demand for the vehicle. Body-in-white 24/7 technical support
is the stage of vehicle manufacturing
where a car body's sheet metal Free fluid analysis
components have been welded
together but no moving parts have Fast response to all inquires
been assembled to the frame.
With a fleet of 259 robots, KTPO
produces 828 body-in-whites per
day over three daily shifts in its
330,000 ft2 body shop. Assembling 1 800 446 4910
the body-in-white involves welding www.durathermfluids.com
the underbody, windshield and 2016 Duratherm.

closures together. The plant's

robotic fleet and 60,000 other inputs

www.process-heating.com OCTOBER 2017 7

Inner Workings
The used heater stock program
allows processors experiencing
production losses to restart processes
with minimal downtime by buying
used equipment. Used heaters offer
the same capabilities as standard,
newly built Fulton coil heaters and can
be used many process applications.
The thermal fluid heaters have a
90-day warranty and standard Fulton
factory and engineering support.
In other company news, Fulton
Thermal will offer refurbishment and
retrofit services for existing heater
installations via its Fulton Service
Solutions. Services include pump
rebuilds, low emission retrofits, burner
repair and replacement, refractory
repair and replacement, valve
replacement, coil leak testing and
repainting.
PLC from Honeywell
First to Receive ISASecure
Level 2 Certification
Honeywells ControlEdge
programmable logic controller
(PLC) received ISASecure Embedded
Device Security Assurance (EDSA)
Level 2 certification by exida, the ISO
17065-accredited certification body
8 OCTOBER 2017 Process Heating
that conducted the assessment.
The certification recognizes the
integrity of both the PLC and its
development lifecycle. It includes
communication-robustness testing
as well as functional and software
development security assessments.
The ISASecure program has been
developed by the ISA Security
Compliance Institute (ISCI) with a goal
to improve cybersecurity for industrial
automation and control systems.
According to ISA, the ControlEdge
PLC is the first of its kind to be
awarded the ISASecure Level 2
certification. The Level 2 certification
builds on Level 1 capabilities by
providing additional security features
such the detection of unauthorized
changes and additional protection
against denial-of-service attacks.
The controller is used in balance-
of-plant control applications such as
water treatment, pump systems and
material handling.
manufacturing and test facility.
Aerospace Parts
Manufacturer Purchases
Aging Oven
Wisconsin Oven Corp. shipped
an electrically heated aluminum
aging oven to an aerospace parts
manufacturer. It will replace an
antiquated oven that was having
difficulties meeting AMS 2750E Class 2
specifications.
With a maximum temperature
rating of 650F (344C), the oven
is constructed with tongue-and-
groove panel assemblies that include
Wisconsin Ovens high efficiency
panel seams and provide better
insulating efficiency. The recirculation
system utilizes combination airflow
to maximize heating rates and
temperature uniformity of the
product.
This will be the third industrial
oven supplied to this company by
Wisconsin Oven. It was fully factory
tested and adjusted prior to shipment.
Boiler Provider Adds
Maintenance Facility
in Oklahoma
Nationwide Boiler Inc. extended its
network of storage and maintenance
facilities for rental and stock boiler
equipment.
Located in in Broken Arrow, Okla.,
the site is owned by Applied Global
Cogeneration (AGC), a cogeneration
system supplier with a 112,000 ft2
The Fremont, Calif.-based
Nationwide Boiler has seven other
storage and maintenance facilities
in Alabama, Iowa, Michigan, Ohio,
Pennsylvania and South Carolina.
 Inner Workings

Oven Cures Paint on Steel,

Aluminum Test Coupons

Process Heating Equipment

Thermal Fluid Systems

Water - Glycol Systems

Indirect Bath Heaters

A gas-heated cabinet oven is being used for curing paint on Electric Process Heaters
steel and aluminum test coupons at a manufacturers facility.
Manufactured by Grieve Corp., Round Lake, Ill., the oven Direct Fired Heaters
has 100,000 BTU/hr installed in a modulating gas burner, and
a 600-cfm recirculating blower provides horizontal airflow to Waste Heat Recovery
the workload.

Conveyor Oven Provides Process

Pro Skid Packages
Automated Batch Process
An air purifying systems manufacturer received shipment of Systems Service & Parts
a Gruenberg indexing conveyor oven.
The oven, which has a maximum temperature rating of
450F, will provide an automated batch process. The system
consists of an oven module and a 30 wide by 18 long
conveyor.
The design is for index positions within the oven chamber.
A set loading position is determined by physical stops 1-866-923-6121
that will allow the manufacturers product to be placed in info@sigmathermal.com
the same position each time to alleviate the potential for Georgia, USA
vertical-lift door crashes. Five products are loaded on the
load conveyor, indexed into the chamber, soaked for 15 to 40
www.sigmathermal.com
minutes, and indexed out.

www.process-heating.com OCTOBER 2017 9

Calendar Events

October 27-29 Drying Theory Put to 30 Fundamentals of Industrial

Practice Seminar, Raleigh, N.C.
3-5 Industrial Combustion Presented by Bhler Aeroglide.
Workshop, Rockford, Ill. Presented Call 919-278-2864 or visit
by Honeywell Combustion Safety. www.buhlergroup.com/drying.
Call 216-749-2992 or visit
www.combustionsafety.com. 27-29 Boiler and Pressure
Vessel Repair Seminar (RO),
8-11 ASTM Committee C16 on Columbus. Presented by
Thermal Insulation Fall Meeting, National Board of Boiler and
Sheraton New Orleans. Pressure Vessel Inspectors.
Call 610-832-9678 or Call 614-888-8320 or visit
visit www.astm.org. www.nationalboard.org.
Process Heating Online Course
(course begins; continues for six
weeks). Presented by Industrial
Heating Equipment Association.
Visit www.ihea.org.
31-Nov. 2 Chem Show,
Javits Center, New York.
Call 203-221-9232 or visit
www.chemshow.com.
November

10-12 Vapor Control Course,
Tulsa, Okla. Presented by
John Zink Institute.
Call 918-234-5710 or visit www.
johnzinkinstitute.edu.
12 Using Glycol Heat Transfer
Fluids for Effective Process
Cooling Webinar, 2 p.m. ET.
Register or learn more at
webinars.process-cooling.com.
23-24 Hydraulic Institute
Fall Conference, Renaissance
Worthington, Fort Worth, Texas.
Produced by the Hydraulic Institute
(HI). Call 973-267-9700 or visit
www.pumps.org.
24-26 The Quality Show, Donald
E. Stephens Convention Center,
Rosemont, Ill. Call 844-644-7449 or
visit www.qualityshow.com.
6-9 ISA Process Control and
Safety Symposium and Exhibition,
Houston Marriott Westchase,
Houston. Presented by International
Society of Automation. Call 919-
549-8411 or visit www.isa.org.
6-9 International
Instrumentation Symposium
(IIS), co-located with ISA Process
Control and Safety Symposium and

ARI Valves can take the heat

Theres no margin of error when it comes to reliability of the valves
in your system. While you may not have to protect against lava ow,
we can solve your problems up to 800F! ARI Valves are the choice of
industrial professionals. Our quality assurance system is in accordance
with DIN ISO 9001. You can trust our bellows-seal valves to perform
under adverse conditions and never need to replace stem packing.

ARI Valves are in Heat Transfer Service Around the Globe. So if you are
responsible for the security and safety of your companys system, make
certain that ARI Valves are the choice. When things get hot, you should
specify ARI Valves for Thermal Transfer Fluid Applications.

ARI ValvesThe Obvious Choice

60

ARI Valve Corporation

1738 Sands Place, S.E. Marietta, Georgia 30067 U.S.A.
Fax: (770) 933-8846 Phone: (770) 933-8845
www.arivalve.com

10 OCTOBER 2017 Process Heating

 Calendar Events

Exhibition, Houston. Presented by
International Society of Automation.
Call 919-549-8411 or visit
www.isa.org.
6-9 Fabtech Expo, McCormick
Place, Chicago. Cosponsored by AWS,
FMA, SME, PMA and CCAI.
Call 888-394-4362 or visit
www.fabtechexpo.com.
7-9 Drying Theory Put to
Practice Seminar, Joinville, Brazil.
Presented by Bhler Aeroglide.
Call 919-278-2864 or visit
www.buhlergroup.com/drying.
7-10 Fired Process Heater
Course, Tulsa, Okla. Presented by
John Zink Institute.
Call 918-234-5710 or visit
www.johnzinkinstitute.edu.
15-16 Automation Fair, George R
Brown Convention Center, Houston.
Presented by Rockwell Automation.
Visit www.rockwellautomation.com.
December
5 Insiders Guide to Fluid
System Maintenance Webinar, 2
p.m. ET. Register or learn more at
webinars.process-heating.com.
12-14 Turbomachinery
& Pump Symposia,
George R. Brown Convention Center,
Houston. Rescheduled due to
Hurricane Harvey.
Visit tps.tamu.edu/updates.
January 2018
22-24 AHR Expo, McCormick
Place, Chicago. Call 203-221-9232
or visit www.ahrexpo.com.
30-Feb. 1 International
Production & Processing Expo,
Georgia World Convention Center,
Atlanta. Call 770-493-9401 or visit
www.ippexpo.com.
February
4-8 Cooling Technology
Annual Conference,
Hilton Houston North, Houston.
Call 281-583-4087 or visit
www.cti.org.
12-14 National Ethanol
Conference, JW Marriott San
Antonio, Hill Country Resort &
Spa, San Antonio, Texas.
Hosted by the Renewable Fuels
Association (RFA).
Call 832-653-4046 or visit
www.nationalethanolconference.com.
21-22 Food Processing Expo,
Sacramento Convention Center,
Sacramento, Calif. Call 916-640-8150
or visit www.clfp.com/expo.

Heating, Cooling & Heat Reclaim Coils

ASME Design & Manufacturing
Fluid & Synthetic Oil Coils
DURABLE, RELIABLE, PROVEN Housings & Custom Components

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www.process-heating.com OCTOBER 2017 11

 Thermal Fluid Heaters

The Importance of
EXPANSION AND
DRAIN STRUCTURE
in Hot Oil Systems
Preplanning during design can save time and money during planned or
unplanned shutdowns.

By the Applications ing temperature, accommodations must
Engineering Team, be made for that expansion. It also is
inevitable that some part of the system
Sigma Thermal
will require service in the future. At that
point in time, the system will need to be
with these systems daily and understand
their key terms intimately, process engi-
neers charged with thermal processing
operations may not be. As a refresher, the
most common components and concepts

T
he provisions made for thermal
expansion and draining of the
thermal oil are key factors to
consider for the successful in-
stallation of any thermal oil heating sys-
tem. Important system design principles
like this often are overlooked; instead, the
focus is placed on specific components like
pumps, valves or the heater itself.
Because most thermal fluid heating
systems are closed-loop systems, and be-
cause thermal oil expands with increas-
partially or fully drained, depending upon
the nature of the service required. A little
thought and preplanning can make drain-
ing a system relatively easy, potentially
saving time and money during planned or
unplanned shutdowns.
There are many ways to design expan-
sion and drain systems, and all have their
advantages and disadvantages. Despite the
differences, most designs incorporate stan-
dard parts and related theories. Though
thermal fluid heating manufacturers work
used in expansion and drain system de-
signs are defined (see sidebar on page 15).
Next, consider the design principles for
some system components and analyze how
they are employed during commissioning
and the everyday operation of a thermal
oil system.
Expansion Volume
Because the fluid within a closed-looped
system is heated during liquid phase, it will
expand. Your system must be designed to

12 OCTOBER 2017 Process Heating


accommodate the liquid expansion to avoid
the overflow of hot oil into the operating
facility or overpressurization of your system
devices and associated equipment damage.
First, let us look at how to calculate the
amount a fluid will expand from its cold-
fill volume to its max-operating level. Be-
cause the fluid volume is changing but the
fluid mass is not, this is a simple conserva-
tion of mass equation.
The mass of fluid in the system depends
upon the volume of liquid (when the system
is first filled) and the ambient temperature.
In this example, we will use Thermi-
nol 55 while filling at 60F. The equation
shows the density of Therminol 55 at 60F.
lb
cold := 54.6
ft3
Assume total system volume all of
the users, piping, cold-fill level in the ex-
pansion tank, etc. and calculate the total
system volume at initial fill (cold).
This multi-heater system is shown with expansion tanks, nitrogen blanket manifolds and double-leg drop piping structure.
Thermal Fluid Heaters
Vcold := 1000 gal =133.681 ft3 Vexp := Vhot Vcold = 281.69 gal
Next, calculate the density of Therminol Tank Dimensions
55 at 550F. Now that we know how much the fluid
will expand, we must select the right ex-
lb pansion tank size to accommodate the
hot := 42.6 3 expansion. Generally, you will need some
ft
excess volume (commonly 20 to 25 per-
cent) to account for the possibility of cal-
culation errors (impossible!) or in case the
m=Vcold *cold=Vhot *hot system has temperature excursions above
the anticipated operating temperature.
Keep in mind that having some volume of
Mass is conserved. Therefore, solve for vapor space (vapor-disengagement area)
the expanded volume: at the top of the tank is crucial for deaera-
tion and vapor removal during startup or
cold when new fluid is added. In addition, all
Vhot := Vcold . = 1281.7 gal systems should include a level switch to
hot maintain a minimum liquid level in the
expansion tank. Such factors will reduce
The difference in volume is the amount the available volume in the tank; there-
of fluid expansion that we must accom- fore, they must be accounted for in the
modate. final tank size selection.
www.process-heating.com OCTOBER 2017 13
 Thermal Fluid Heaters
For instance, continuing the previous
example (calculating fluid expansion),
we will presume that the next and largest
standard tank size is 400 gal. Also assume
the minimum fill in the tank (to satisfy the
level switch) is 35 gal (typically specified
by the manufacturer).
Vspare := 400 gal 281.69 gal 35 gal = 83.31 gal
As a percentage, this leaves you with
about 21 percent volume remaining in the
tank.
Selecting the Location
of the Tank
Now that we have sized the tank, we must
think about where we want to place it. Sev-
eral factors govern the location of the ex-
pansion tank. These factors are important
and should be thoroughly discussed when
laying out the system. Generally, many of
these factors are installation specific (e.g.,
location of available safe containment,
maintenance access). The safety of opera-
This single heater system has an elevated atmospheric expansion tank, double-leg
drop piping structure and drain tank with a fill-and-drain pump.
14 OCTOBER 2017 Process Heating
tors and plant personnel also must be well
thought out. Expansion tanks are occa-
sionally full of hot thermal oil making
them both burn and fire hazards.
The ideal height for the expansion tank
is above the highest liquid level in the sys-
tem. This can be system piping, the heater
or sometimes the thermal fluid space with-
in a user (for instance, the heat exchanger,
calendar roll or press platen). The bottom
of the tank should be several feet above the
highest point (5 is a good rule of thumb).
This provides several benefits, including:
Creating static head above the pump in-
let to prevent pump cavitation.
Aiding in degassing of the system.
What happens if the tank cannot be
placed at the highest point? Do not aban-
don all hope. While not ideal, there are
ways to accommodate this, including:
Using an inert-gas blanket system (usu-
ally nitrogen).
Using a bladder-style expansion tank
(only possible on lower temperature sys-
tems).
Sealing the tank with nitrogen in the
vapor space.
We will explore each option.
Inert-Gas Blanket System. If an inert
gas blanket system is used, either plant
nitrogen (if available) or bottled nitrogen
may be used to fill the vapor space in the
expansion tank to a relatively low pressure
(5 to 10 psig is typical). This will vary de-
pending upon the net positive suction head
(NSPH) requirements of the pump and
the vapor pressure of the fluid. The amount
of nitrogen used will depend on how of-
ten the system temperature is cycled. Re-
member, the change in temperature will
change the system volume. If the system
is cooled, the fluid will contract, and the
liquid level in the expansion tank will drop.
This change in level (and, thus, volume)
must be made up by adding more nitro-
gen. Conversely, if the system is heated, the
liquid level will rise and push some of the
nitrogen out.
Bladder-Style Expansion Tank. Using
a bladder-style expansion tank separates
the liquid in the tank from the vapor space.
The vapor space then is charged with air
to some pressure. As the system expands,
the air in the vapor space increases in pres-
sure. As the system cools, the pressure in
the vapor space will fall (but never below
the original charge pressure). Also, as pre-
viously mentioned, bladder tanks can only
be used at lower temperatures because they
typically are made from some type of rub-
ber compound. Commonly, they are found
in water-glycol systems. They also can be
used in thermal oil systems if the bladder
materials are compatible with the oil and
the operating temperature.
Sealing the Tank with Nitrogen in the
Vapor Space. Sealing the tank with nitro-
gen in the vapor space is similar to using
the bladder-style expansion tank, but no
barrier exists between the fluid and vapor
space. To keep the fluid from oxidizing, an
inert gas must be used.
Though all three methods can be used,

careful consideration must be used if ei-
ther of the last two options is chosen to
ensure the rise in liquid level does not in-
crease the pressure in the tank above its
design rating. A pressure safety valve is
critical to protect the tank if it is not open
to atmosphere.
Degassing the System
Each thermal fluid system, when initially
filled, will contain several undesirable con-
stituents. As the system is operated over
time, or when maintenance is performed,
new fluid can be added that can create
conditions similar to the initial fill. If not
removed, these gases can create flow stabil-
ity problems and pump cavitation that will
prevent the system from operating reliably.
The most common constituents are:
This electric thermal oil system package includes an integral expansion tank
and tower.
Air.
Water.
Low molecular weight components of
the thermal fluid (also known as low-
boilers).
These constituents must be removed for
trouble-free system operation. The ease
with which these gases can be removed is
heavily dependent upon the system piping
design and expansion tank elevation.
Generally speaking, piping should be
designed to minimize local high points,
and the expansion tank should be above
the highest point of the system. Piping also
should be designed to include high point
vent valves. If the tank is the highest point,
then removing these troublesome elements
from the system can be accomplished rela-
www.process-heating.com OCTOBER 2017
Thermal Fluid Heaters
Common Terms
for Thermal Fluid Heaters
The most common components and
concepts used in both expansion and
drain system designs are defined.
Expansion Tank. Vessel designed to
contain thermal expansion within a
closed loop thermal fluid system.
Drain Tank. Vessel designed to contain
all or part of a thermal fluid systems
volume.
Containment Area. An area designated
as a safe zone for vents or overflow
discharge from pressure safety valves
and/or vents and drains of a thermal
fluid system.
Inert Gas Blanket. A system that applies
inert gas pressure (typically nitrogen at
the expansion tank) to prevent oxidation
of thermal oil and/or to create system
pressure to overcome height restrictions
for an expansion tank.
Thermal Buffer. A vessel that
cools thermal oil before it enters an
atmospheric expansion tank to help
minimize oxidation of the oil.
Deaerator. A vessel created to
continually assist in the degassing of a
thermal fluid system.
Cold Seal Tank. Vessel constructed
to create a cold fluid seal between
ambient air and any hot fluid that
may be present in the expansion tank,
helping to minimize oxidation of the
thermal oil.
Heatup Line/Valve. The line
connected to the expansion tank, from
a low pressure part of the system, to
create flow through the expansion
vessel when the heatup valve is open
to assist in deaeration during thermal
oil cookout.
Double-Leg Drop. A piping structure,
consisting of a block and bypass valve,
that forces a high volume flow rate
through the expansion tank, to aid in
deaeration during thermal oil cookout.
15
 Thermal Fluid Heaters
This thermal oil heat exchanger secondary loop package offers a modular
expansion tank tower mounted above the pump skid.
tively easily through the disengagement
space in the expansion tank. Otherwise,
high point vent valves must be used, and
the system should be vented (burped) inter-
mittently until vapor is no longer present.
Depending upon the piping design and
expansion tank elevation, there are a few
methodologies that can be used to effec-
tively get the vapor to the highest point.
These include a double-leg drop or heatup
line piping arrangement connecting to the
expansion tank or a deaerator
A double-leg drop arrangement allows
all or a portion of the fluid to flow through
the tank during commissioning. A heatup
line piping arrangement achieves the same
purpose, but it does so with smaller piping
and by using pressure differential across
different parts of the system to drive flow
through the expansion tank. By forcing
circulation through the expansion tank
while the fluid is being circulated, the va-
por in the system can disengage from the
liquid level in the tank. As a result, it can
be vented from the top of the tank. This
can be done with the system open to at-
16 OCTOBER 2017 Process Heating
mosphere or using an inert gas blanket
with settings that allow it to sweep the
vapor from the expansion tank through
continuous purge.
A deaerator performs a similar function
as the double-leg drop arrangement, but it
is a part of the system-return piping. Also,
a deaerator is used continuously rather
than exclusively during commissioning.
While deaerators are effective for continu-
ous deaeration, it is worth noting that they
are not always as effective as forcing large
volumes of flow through an elevated ex-
pansion tank. Also, they do not necessarily
negate the need for a double-leg drop or
heatup line piping structure.
Simple centrifugal deaerators are com-
mon, but there are many types that can be
used effectively. Regardless of the vessel
design, the basic premise is to allow the
vapor and liquid to disengage and rise up
to the expansion tank instead of disengag-
ing within the expansion tank. The vapor
should flow up and out of the system, and
the liquid flow down and back to the suc-
tion side of the pump.
Preventing Fluid Degradation
If properly designed and maintained, ther-
mal fluid systems are easy to operate, and
the life of the fluid within the system can
be sustained for a long time. If the fluid
should degrade, it will diminish the perfor-
mance of your system. There are a couple of
reasons why fluid degradation could occur:
oxidation and contamination.
Oxidation. Thermal fluids, when ex-
posed to oxygen, especially at elevated
temperatures, will oxidize and break
down into lower molecular weight com-
ponents. They also can form acidic by-
products that can damage system com-
ponents.
Contamination. The most common
contaminant is water, but contamina-
tion can also be due to a leak on the pro-
cess side of the system (a heat exchanger
tube, reactor jacket, etc.).
Preventing oxidation is simple in con-
cept; either remove the heat or remove the
oxygen at the interface point in the expan-
sion tank. Removing the oxygen typically
is done with an inert gas blanket as pre-
viously described. If you do not have the
ability to inert the expansion tank, and it is
directly open to atmosphere, removing the
heat is the only solution.
As a rule, the expansion tank and the
piping leading to the tank should not be
insulated. This allows any hot fluid that ex-
pands into the tank to cool before it hits
the vapor-disengagement space at the top
of the tank. Most often, expansion piping
alone does not allow enough surface area
to cool the expanding fluid before it gets to
the tank. In those cases, the use of a ther-
mal buffer allows the fluid to cool by creat-
ing more surface area and residence time
than the expansion piping alone.
Preventing contamination can be tricky.
It is not always a dramatic event that is
noticeable. Impurities often creep into a
system over time, and they will not neces-
sarily create an increase in system volume
or an obvious change in performance. Be-
cause there are many potential sources of
contamination, and because it can be hard
to detect with observation alone, the best
defense is to have the fluid tested at least
 Thermal Fluid Heaters

yearly. Most fluid manufacturers offer this service at no charge.

Based on the results, the fluid manufacturer usually can pinpoint
the root cause of the contamination.

Drain Tank Sizing

Inevitably, at some point in the life of any thermal fluid system,
the system will need to be drained to perform maintenance or to
perform a repair. There is also a benefit to routing things like pres-
sure safety valve (PSV) discharge and emergency drain lines to a
location where the thermal oil is safely contained. Routing these
devices to small drums or inadequate containment vessels may
not be sufficient. Many smaller systems do not have a dedicated
drain tank, and this can be a problem in case an emergency repair
is needed or a safety relief event is triggered. It is highly recom-
mended to have the drain tank sized for the entire system volume
(e.g., smaller systems upward to 10,000 gallons) or adopt a design
that segments the system in such a way that sections can be isolated
and drained independently. This is common with larger systems.
Normally you want a 20 to 25 percent buffer with the drain tank
size. Depending upon your insurance carrier, the drain tank typi-
cally will be placed away from any building or main process areas.

What happens if the expansion

tank cannot be placed at the
highest point? Do not abandon
all hope. While not ideal, there are
ways to accommodate this, including
using an inert-gas blanket,
selecting a bladder-style tank or
sealing the tank with nitrogen in
the vapor space.

It is also noteworthy that relatively low cost reversible fill-and-

drain pumps are available. They will make filling and draining of
the system considerably easier. When designing the system pip-
ing, be sure to pay special attention to creating low point drains
and connecting that piping back to a central drain tank. A small
amount of investment in a drain tank, fill-and-drain pump and
well-planned drain piping can save hours or even days during com-
missioning and maintenance activities.

A manufacturer of thermal fluid heaters, Sigma Thermal is based in

Marietta, Ga. The company can be reached at 678-616-2820 or visit
www.sigmathermal.com.

www.process-heating.com OCTOBER 2017 17

 Heaters

With laminating, drying, pasteurizing, curing,

flashing, evaporating, sterilizing, sealing, shrinking
and recycling, it is not uncommon for automated
machines to utilize or add several types of heating
products throughout the packaging process.

Heaters Help Deliver

PACKAGING FOR
FOOD SAFETY
and Consumer Acceptance
Packaging innovations such as heat-sealed packages, tamper-resistant bottles and
shrink wrap are all a result of evolution in process heating technologies. Though
process heating is essential to many effective packaging solutions, too often, it is
an afterthought.

By Jeff Myatt, safety concerns, and increased scrutiny has in process heating, the speed at which the
Osram led advocates to demand sustainable, recy- machines are capable of printing, cutting,
clable and safer materials for consumers. seaming, filling and wrapping has im-

F
ood- and medicine-safety con-
cerns have led to many packag-
ing innovations over the years.
Perishable foods, dairy products
and pharmaceuticals have pushed packag-
ing inventors to increase shelf life, enhance
safety measures and create convenient stor-
age options for consumers. From the food
humans consume to pet food, concerns
over contaminants leaching into the food
chain have raised material risk awareness.
The race for convenience has raised several
In addition to the innovations derived for
convenience, improved printing and mark-
ing drive material choice. Branding largely
leads the innovation march because market-
ers use branding opportunities to set their
products apart from one another. Shapes,
colors and presentation all factor into pack-
aging designs and material selection.
Like other innovation-driven industries,
the packaging industry has tapped auto-
mation in its quest to develop new and
better materials. Thanks to advancements
proved handling and process times. Despite
process heatings crucial role in the packag-
ing industry, it seems to take a back seat in
many minds. Only rarely is it discussed for
what it is: a critical piece of equipment for
ensuring effective packaging.
Popularity of Plastic
Packaging Drives Innovation
Before delving into some of processes that
ensure packaging is safe, secure and adapt-
able, a look at the evolution of packaging

18 OCTOBER 2017 Process Heating

 Heaters

materials and the concerns around
them is necessary. No lesson on packag-
ing history would be complete without an
introduction to plastic packaging. Love it
or hate it, plastic has dominated the pack-
aging industry since its introduction in the
early 1900s. It is lightweight, malleable
and easy to manufacture. Today, plastic
resins and other derivative materials con-
tinue to play an integral role in packaging.
From tamperproof seals to shrink wrap-
ping and to multipack water bottles
all made with process heating plastic
packaging protects products until they are
put to use.
Fast foods popularity after World War
II created a packaging boom, produc-
ing numerous short-term and condiment
packaging innovations. The increased out-
put led to mountains of trash and spawned
recycling urgency.
Today, the plastics industry boasts an
improved environmental footprint. De-
spite the progress that has been made, and
the increased awareness of plastics impact,
it is still nearly impossible to drive down a
freeway or swim in an ocean without see-
ing the impact plastic resins have on our
planet. If not properly recycled, the prod-
uct will not degrade or breakdown within
our lifetime. That is why reinventing plas-
tics using biodegradable solutions and
packaging them with Earth-friendly pro-
cess heating solutions is a necessity for
the ecosystem and for the safety of our wa-
ter sources and food chain.
Despite the industrys recent innova-
tions, scrutiny over potential long-term
hazards and exposure to BPA-based plas-
tics still remains contestable.
Hesitations Around BPA
One such concern is Bisphenol A, which
is better known as BPA. BPA is an envi-
ronmental chemical building block that
is used primarily to make polycarbonate
plastic and epoxy resins. Polycarbonate
plastic is the most popular lightweight,
high performance plastic and is used in a
wide variety of common food and drink
packaging. Despite its tough, resilient and
heat-resistant nature, many countries have
banned the use of BPA with consumables
for fear of BPA leaching. Just recently, the
FDA banned its use for infant food pack-
aging and teething or oral products.
BPA is one of the most extensively
tested materials in use today, according to
experts with BiphenolA.org. (It has been
studied for more than 40 years.) The orga-
nization claims scientific evidence clearly

Thanks to advancements in process heating, the speed at which the machines are capable of printing, cutting, seaming, filling
and wrapping has dramatically improved handling and process times. Things like sealing, tamper-resistant bottles and shrink
wrap are all a result of evolution in process heating. Shown here is a threaded in-line heater.

www.process-heating.com OCTOBER 2017 19

 Heaters
supports that BPA is safe to use and that
there is no basis for human health con-
cerns from exposure. They go on to say
that levels of BPA leached into food are
extremely low, and that the amount is, on
average, five parts per billion under typical
conditions for packaging products. At that
level, people would have to consume 1,300
pounds of food and beverages every day for
an entire lifetime to exceed a safe level.
Despite these findings, most of the re-
search from this group of experts is dated.
Furthermore, there is evidence and re-
search to the contrary, showing cognitive
deficits, anxiety, obesity and cancer from
exposure to BPA. As the FDA continues
to be pressured by advocates, more research
is expected, and limitations to exposure are
advised for those concerned about the im-
pact and long-term ramifications. Moving
forward, bioplastic alternatives from
things like wheat, sugarcane and corn
are positioned to be a responsible choice
for the planet and safer to the consumers
who use it.
Food and medicine safety concerns have led to many packaging innovations over
the years. Perishable foods, dairy products and pharmaceuticals have pushed
packaging inventors to increase shelf life, enhance safety measures and create
convenient storage options for consumers.
20 OCTOBER 2017 Process Heating
Tylenol Tampering Curtails
Consumer Trust
Consumers are not only concerned about
materials safety. Tampering also has been a
serious issue, and one that led to significant
changes in the packaging industry. In the
early 80s, Tylenol found itself at the center
of a crisis: Bottles of the over-the-counter
pain reliever had been tampered with and
poisoned with cyanide. Several people
died as a result of the poisoning. Tylenol
ordered a mass recall of its product and ac-
tively participated with the media to avoid
additional deaths and reputation damage.
Tylenol insisted the poisonings were per-
petrated outside of the factory and investi-
gators agreed. Those responsible, who were
never caught, allegedly removed the Tyle-
nol from the retail shelves and tampered
with the contents.
Today, great measures are taken to alert
consumers of product tampering, and there
have been significant safety improvements.
Updates like foil seals, shrink-wrapped
tops and gelatin-covered tablets were in-
troduced shortly after the Tylenol tam-
pering case. By 1989, the measures were
standard practice, and published guidelines
were produced by the FDA.
Process Heating Makes Safer
Packaging Possible
What many do not realize is that pack-
aging changes like foil seals and shrink-
wrapped tops could not have been intro-
duced without process heating. Process
heating technology has remained a critical
element in keeping products safe and se-
cure as demands on heating components
have been pushed to the limits. It is not
hard to see why. What drives the need for
more process heating solutions? Constant
improvement to automation lines, research
and testing, and new processes are just a
few of the things forcing the process heat-
ing industry to expand their offerings.
With laminating, drying, pasteuriz-
ing, curing, flashing, evaporating, steriliz-
ing, sealing, shrinking and recycling, it is
not uncommon for automated machines
to utilize or add several types of heating
products throughout the packaging pro-
cess. In addition, continued demands are
placed on heating components to produce
higher temperatures at faster speeds. Pack-
aging manufacturers are constantly look-
ing for ways to improve process times, sup-
port new material initiatives, reach more
customers and improve quality. Process
heating technology helps them do this.
In addition to process heatings tradi-
tional electric air heater elements, infrared
heaters are just as important. The non-
contact, efficient use of power can radiate
wavelengths that rapidly heat surfaces,
focus energy where needed, and activate
adhesives used to seal in freshness. Combi-
nations of the technologies have been used
for years because they have the ability to
scale up and down as the industry changes.
Beyond the packaging industry, it is
known that UV light can damage and
even kill biologicals (think sunburns and
skin cancer). All UV wavelengths alter
cells and are capable of destroying biologi-
cal tissues. In the packaging industry, UV
disinfection systems are used throughout
food processing plants, pharmaceutical
facilities and hospital facilities. Because of
 Heaters

Packaging changes like foil seals and shrink-wrapped tops Jeff Myatt is product marketing manager
could not have been introduced without process heating. of process heating products in Osrams
Process heating technology has remained a critical element Professional and Industrial Applications
in keeping products safe and secure as demands on Division. The Wilmington, Mass.-based
heating components have been pushed to the limits. company can be reached at 978-570-3000 or
visit www.osram-americas.com.

their construction, UV lamps are usually

in a sealed environment with regenera-
tive circulating heated air. Duration of UV
exposure is the key to its effectiveness to
disinfect and sterilize packaging materials
and the automated machine parts. Steps
like UV disinfection systems play a major
role in keeping consumer packaging secure
and protected.
Thermal Fluids that
In conclusion, the packaging indus-
try has come a long way. Packaging helps go beyond precise
solve consumer problems, improve prod-
uct safety and answer a number of seri- temperature control
ous concerns. Without innovations in
process heating technology and the kind
of safe packaging that it provides, changes Working closely with equipment manufacturers and our customers, weve
to problematic packaging and materials gained an intimate and unrivaled understanding of real-world concerns for
would take far too long or may not even heat transfer fluids. Our full range of environmentally responsible thermal
be possible at all. Packaging manufactur- fluids and unique and innovative system cleaners make Duratherm a single
ers must ensure they are implementing
source for all aspects of heat transfer fluid applications.
solid process heating procedures and safe
packaging standards. If they do not, they
risk the safety of their consumers and the
health of planet Earth. Operating range -84C to 338C (-120F to 640F)
Non-toxic/non-hazardous
Complete engineering data
Additional Reading
For more information on the studies discussed in
this article, please see the following sources.
OEM system design collaboration
Online thermal fluid calculators
Plastics and Sustainability: A Valuation of En-
vironmental Benefits, Costs, and Opportunities
for Continuous Improvement, Trucost, 2016,
https://plastics.americanchemistry.com/study- 24/7 technical support
from-trucost-finds-plastics-reduce-environ-
mental-costs/.
Potential Exposure to Bisphenol A from Food-
Free fluid analysis
Fast response to all inquires
Contact Use of Polycarbonate Resins. Howe,
S.R. and Borodinsky, L. 1998. Food Addit. Con-
tam. 15(3):370-5. Abstract available at PubMed,
http://www.bisphenol-a.org.
Low circulating levels of bisphenol-A induce
cognitive deficits and loss of asymmetric spine
synapses in dorsolateral prefrontal cortex and
hippocampus of adult male monkeys. Els-
1 800 446 4910
worth, J. D., Jentsch, J. D., Groman, S. M., Roth,
R. H., Redmond, E. D. and Leranth, C. (2015), www.durathermfluids.com
J. Comp. Neurol., 523: 12481257. doi:10.1002/ 2016 Duratherm.
cne.23735.

www.process-heating.com OCTOBER 2017 21

 Portable Chillers
How
VARIABLE-
SPEED
PORTABLE
CHILLERS
Can Help
An alternative for process cooling applications, variable-speed compressors
coupled with advanced PLCs continuously monitor the heat load and adjust
the compressor speed for peak efficiency and temperature control.
By Tom Stone and
Steve Wojcieszek,
Thermal Care
A
packaged system housed in a
single cabinet with mounted
casters, a portable chiller
contains an integral tank and
pumping system and uses refrigeration to
cool a water circuit for industrial processes
that generate heat. The removal of this
heat allows for increased productivity and,
therefore, increased profits. Effective cool-
ing using portable chillers is the backbone
of process industry applications such as in-
jection molding.
Conventionally, a portable chiller uses a
compressor running at a continuous speed.
This type also is known as a fixed-speed
compressor. Regardless of the require-
ments placed on it by the process load, the
speed remains the same.
Fixed-speed chiller systems employ a
22 OCTOBER 2017 Process Heating
hot gas bypass design to maintain the
demand on the compressor. This design
avoids wide fluctuations in the coolant
temperature delivered to the process.
A hot gas bypass is an electronic valve
located on the high pressure refrigerant
line downstream of the compressor. The
chillers controller typically a micro-
processor reads the water temperature
returning from the process. The control-
ler actuates the valve as needed, allowing
a portion of hot refrigerant gas to be
reinserted or bypassed directly into
the low pressure refrigerant line upstream
of the evaporator. The evaporator is the
heat exchanger that transfers heat from
the process water to the refrigerant cir-
cuit. Introducing the hot, high pressure
refrigerant to the low pressure side creates
a false load on the system. This allows the
compressor to continue running at 100
percent speed and maintains a stable pro-
cess water temperature.
Some portable chillers use
components such as R410A
refrigerant, scroll compressors,
microchannel condensers,
low noise fans, stainless steel
brazed-plate evaporators and
modern controls to improve
performance and reliability.
For example, a hot gas bypass system,
limited to 75 percent of compressor
capacity on a 10-ton chiller, delivers
stable water temperature down to a 2.5-
ton heat load. As the heat load falls
below the 2.5-ton mark, the compres-
sor is forced to cycle on and off as its
last means of temperature control and,
ultimately freeze protection. With any
motor, rapid cycling is detrimental to
the life expectancy. This is known as
short cycling. An anti-short-cycle timer
is employed to protect the compressor
from premature failure.
A conventional hot gas bypass sys-
tem coupled with a widely varying pro-
cess heat load leads to rapid temperature
swings delivered to the process. Many
process cooling applications require stable
incoming cooling temperatures. Avoiding
fluctuations like this is crucial to consis-
tent output from the process and elimi-
nating scrap.
 Portable Chillers

An Alternative to
Fixed-Speed Chillers with
Hot Gas Bypass
Variable-speed chillers offer an alternative
for process cooling applications. They use
variable-speed compressors coupled with
advanced PLCs. The controller continu-
ously monitors the heat load and adjusts
the compressor speed for peak efficien-
cy and temperature control. The speed
adjustment eliminates the need for hot
gas bypass. These chillers ensure the work
done closely follows the energy required,
effectively eliminating energy waste.
Studies by one manufacturer have shown
that a 20 percent reduction in motor speed
can lead to a 51 percent energy savings.
With the variable-speed chiller design,
incoming utility power is connected to
an inverter control drive using frequency
modulation to adjust compressor motor
power output. The inverter control drive
speeds up or slows down the compressor,
matching system load demand accurately.
The sophisticated electronics incorporated
in the inverter control drive provide addi-
tional levels of compressor protection
that surpass the levels of protection found
in fixed-speed systems. Active protec-
tion algorithms improve reliability and
safeguard the compressor and inverter
control. Key features are locked rotor pro-
tection, phase protection and correction,
maximum operating current detection,
discharge line temperature protection and
anti-short-cycling control.
Energy savings are one of the most
prominent benefits of chillers designed
with variable-speed compressors.
Variable-speed technology offers ben-
efits beyond energy savings, however.
One of the most important is soft-start
control, which provides two ancillary
benefits: First, it effectively eliminates
peak demand penalty costs, and second,
it reduces mechanical stress on all system
components. The life expectancy of all
system components is extended.

10-Ton Air-Cooled Variable-Speed Compressor Option Payback

(Years based on $0.10/kWHr power cost)
Process Load as Percent of Available Chiller Capacity
Hours/Year
50% 55% 60% 65% 70% 75% 80% 85% 90%
Based on 50 Weeks/Year
4,000 hours/year
1.1 1.2 1.3 1.4 1.6 1.9 2.4 3.2 5.1
(16 hours/day, 5 days/week)
6,000 hours/year
0.7 0.8 0.9 0.9 1.0 1.2 1.6 2.1 3.4
(24 hours/day, 5 days/week)
8,400 hours/year
0.5 0.6 0.6 0.7 0.7 0.9 1.1 1.5 2.4
(24 hours/day, 7 days/week)

20-Ton Air-Cooled Variable-Speed Compressor Option Payback

(Years based on $0.10/kWHr power cost)
Process Load as Percent of Available Chiller Capacity
Hours/Year
50% 55% 60% 65% 70% 75% 80% 85% 90%
Based on 50 Weeks/Year
4,000 hours/year
1.4 1.4 1.4 1.4 1.5 1.8 2.2 3.3 6.5
(16 hours/day, 5 days/week)
6,000 hours/year
0.9 0.9 0.9 0.9 1 1.2 1.5 2.2 4.4
(24 hours/day, 5 days/week)
8,400 hours/year
0.7 0.7 0.7 0.7 0.7 0.8 1.1 1.6 3.1
(24 hours/day, 7 days/week)

www.process-heating.com OCTOBER 2017 23

 Portable Chillers

10-Ton Chiller Energy Use 20-Ton Chiller Energy Use

100% 100%

90%
90%

80%
80%
Power Use (% of Full Load Power)

Power Use (% of Full Load Power)

70%

Energy Savings 70%

60%

60%
50%

40% 50%

30% 40% Energy Savings

20%
30% 40% 50% 60% 70% 80% 90% 30%
30% 40% 50% 60% 70% 80% 90%
Load Percentage (% of Full Capacity)
Load Percentage (% of Full Capacity)

Fixed-Speed Compressor (Hot Gas Bypass Capacity Control)

Fixed-Speed Compressor (Hot Gas Bypass Capacity Control)
Variable-Speed Compressor (Variable Speec Capacity Control)
Variable-Speed Compressors (Variable Speed Capacity Control)

FIGURE 1. This energy comparison chart shows the FIGURE 2. The energy use of a 20-ton chiller
difference in energy use between a 10-ton variable- (which used two 10-ton variable-speed compressors)
speed compressor and a fixed-speed compressor. is shown vs. a 20-ton fixed-speed compressor.

What Kind of Energy Savings In a second example, compare the per- fixed-speed compressor to generate energy
Can I Expect? formance of a fixed-speed vs. variable- savings. It efficiently handling loads from
Compared to a typical chiller with a fixed- speed compressor on a 20-ton chiller 3 to 20 tons, and it delivers energy savings,
speed compressor, a chiller with a variable- (table 2). In this case, a portable chiller especially in the 3 to 8 ton range and the
speed compressor can provides power sav- with two 10-hp compressors generates 13 to 16 ton range.
ings at partial loads. For instance, compare savings over a wider range. This spe- Note that the energy savings are not as
the performance of a fixed-speed vs. vari- cific chiller design combines a 10-ton significant in the middle-load range where
able-speed compressor on a 10-ton chiller variable-speed compressor with a 10-ton either compressor fixed or variable
(figure 1). At a 30 percent load, for example,
the variable-speed compressor consumes 24
percent of full-load power. The fixed-speed Effective cooling using portable chillers is
chiller consumes 85 percent of full-load
power. Using a variable-speed compressor
the backbone of process industry applications such as
at this load would provide energy savings injection molding.
of more than 50 percent (table 1).

24 OCTOBER 2017 Process Heating

 Portable Chillers

would be running near its full capacity of

10 tons. The curve for the 20-ton fixed
4 Questions to Consider Before
speed chiller is a bit different too (figure
2). It has two 10-ton compressors so that
Purchasing a Variable-Speed Chiller
it can run on just one (half power, more
or less) until the second compressor needs
1. What is my load profile? Does my heat load vary widely?
to kick in. Still, it is clear that there are
You should consider if your heat load spends a lot of time operating well
significant energy savings to be realized.
below the chillers available capacity.
In conclusion, the energy savings gener-
ated by variable-speed compressors enable
2. Will I require flexibility to move the chiller among various different
rapid payback on an investment, particu-
applications? If you have multiple processes that run intermittently with
larly under low and partial-load conditions.
different heat loads, a single variable-speed chiller may be the best solution
In the end, one must weigh the ben-
rather than purchasing multiple individual chillers of different sizes.
efits of employing variable-speed technol-
ogy. Key benefits that support the switch
3. Does standardizing to one chiller size make sense?
include stabilizing the process, preserving
If you can cover a variety of heat loads with one style chiller, you can benefit
the equipment investment and saving on
from commonality of parts.
electrical costs.
4. Are energy savings or green initiatives important to my company?
Tom Stone is the Eastern U.S. regional
In some instances the electrical costs alone justifies the decision. Other
manager and Steve Wojcieszek is director of
times, a company is working toward a more environmentally friendly culture.
industrial sales with Thermal Care. The Niles,
This is reinforced with the energy savings from the variable-speed chiller.
Ill.-based company can be reached at 847-
966-2260 or visit www.thermalcare.com.

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www.process-heating.com OCTOBER 2017 25

 Industrial Gases/Combustion

Improved NOx
LIMITATION STANDARD
to Reflect Combustion Efficiency
In many locations throughout North America, nitrogen oxide (NOx) emissions
of gas-heated furnaces are limited by law or code. This is typically the case in
urban areas or in places where special topographical characteristics intensify the
negative local and regional effects of NOx emissions.

By Martin Schoenfelder, showing how a one-dimensional emis-
sions-limitation standard can lead to ad-
Steven Mickey and
verse effects, preventing a well-intended
Joachim G. Wuenning, initiative from achieving its goals or even
WS Thermal Process Technology Inc. leading to the exact opposite. It further
outlines an approach for a very simple cor-
even if clean fuels such as hydrogen or
natural gas are being used. The main source
of NOx in gas-heated industrial furnaces
is called thermal NO. There are two other
modes of formation: prompt NO and fuel-
bound NO. These are, however, both negli-

W
hile the approach of
limiting hazardous
emissions is for the
benefit of the environ-
ment and society, the method used to
define the limitation can significantly
alter its outcome (e.g., if it does not ac-
count for the full extent of influencing
factors). In particular, this is the case for
the combustion efficiency in gas-heated
industrial furnaces.
This article presents a simple example
rection of the current one-dimensional
formula in order to properly reflect com-
bustion efficiency and, therefore, actually
achieve its intended goals.
NOx Formation in Gas-Heated
Industrial Furnaces
Nitrogen oxides are highly undesirable
emissions because they can be directly
harmful to our health and contribute to
ozone formation and acid rain.[1] NOx
can be generated in combustion processes,
gible in industrial furnaces.
The formation of thermal NO is de-
fined by the extended Zeldovich Mecha-
nism.[5,6]
N2 + O NO + N
N + O2 NO + O
N + OH NO + H
As implied by the name thermal NO,
the formation is temperature-driven and
can be described with an exponential
function. Peak temperatures, therefore,

26 OCTOBER 2017 Process Heating


Reacting
fuel
and air
Flame Flame
stabilization fronts
Air
Fuel
Flame supervision and ignition
FIGURE 1. Illustration of FLOX combustion
technology and effect on temperature profile
(courtesy of WS)
contribute greatly to NOx emissions. The
peak temperature in a combustion pro-
cess is typically found in the reaction zone
(conventionally this is the flame). Tradi-
tionally, this has led to a trade-off between
burner efficiency and NOx emissions, be-
cause preheating combustion air (being the
most effective efficiency technology) also
increases the flame temperature and, thus,
leads to higher NOx emissions.
Lowering peak temperatures while still
maintaining complete combustion is the
goal of NOx-reduction techniques, which
has been a main focus in combustion re-
search over the last several decades. The
most common methods currently used in
industrial furnaces are air/gas staging, flue-
gas recirculation and flameless-combus-
tion techniques such as FLOX (figure 1).
Example
A company is planning to build a new forge
furnace in the Los Angeles, Calif., area. Per
design, the furnace needs to be operated up
to 2282F (1250C) and requires a net heat
input of 10 MMBTU/hour (3,000 kW
LHV) for the intended application. The
furnace is going to be operated 6,000 hours
per year with an average load factor of 75
percent. Since electricity is very expensive
and also not desirable for heating industri-
al furnaces for environmental reasons, the
companys preferred technology is natural
Industrial Gases/Combustion
Temperature, F
Air 32 482 932 1382 1832 2282 2732
100 0
Fuel
= 1
75 = 0.8
Waste gas losses, %
25
Regenerative burner = 0.6
Efficiency, %
Recuperative burner = 0.4
50 50
Temperature Strong Plug in or central heat exchanger
supervision recirculation = 0.2
25 = 0 75
air preheat temperature
Relative air preheat
exhaust temperature
0 100
0 250 500 750 1000 1250 1500
Mixing of air and fuel with exhaust prior to
reaction (no flame front) Exhaust temperature, C (prior to heat exchanger)
FIGURE 2. Efficiencies of different types of gas-
burner technology (courtesy of WS)
gas heating. reduction techniques such as FLOX com-
Due to the location of the furnace, the bustion, the regenerative system can still
South Coast Air Quality Management achieve 0.08 pounds/MMBTU (70 ppm)
District (SCAQMD) has set a strict limit at 3 percent O2. Based on the limits de-
of 0.06 pound/MMBTU (50 ppm) NOx fined by the SCAQMD, however, the
at 3 percent O2 for the combustion pro- company is being forced to use the inef-
cess at the highest furnace temperature. ficient cold-air burner system since the
This limit is based on a one-dimensional highly efficient regenerative burners lead
approach and, as such, does not consider to a slightly higher NOx concentration
adjustments for high-efficiency technolo- than the specified limit of 0.06 pounds/
gy. The limit is also not defined on an abso- MMBTU (50 ppm) at 3 percent O2.
lute scale such as pounds per year, but it is The one-dimensional standard defined
given as a concentration in the exhaust gas. by the authorities, therefore, prevents the
This implies that all available technologies use of the best-available technology since
emit the same total volume of exhaust gas- the limitation of a concentration (pounds/
es. This assumption is false, however, due MMBTU or parts per million pollutant
to different combustion efficiencies of the in exhaust at a specified oxygen content)
various available combustion technologies. does not consider the total amount of
In this example, the high furnace tem- exhaust gas produced by each alternative
perature and the operating time per year combustion setup. The reference cold-air
make efficiency measures highly desirable. burner system only achieves an efficiency
Compared to a cold-air burner system (i.e., of approximately 37 percent LHV at the
no heat recovery), a modern regenerative- specified furnace temperature. Hence, an
burner system will achieve fuel savings on equivalent of roughly two-thirds of the
the order of 53 percent. While a cold-air natural gas combusted is wasted through
burner system will achieve the required the stack of the furnace. At the same time,
NOx concentration of 0.06 pounds/ the alternative regenerative-burner solu-
MMBTU (50 ppm) at 3 percent O2, the tion achieves a combustion efficiency of 78
high air preheat of a regenerative-burner percent LHV and a significantly decreased
system would lead to an increase in its spe- use of natural gas along with proportion-
cific NOx emissions (i.e., concentration in ally less exhaust gases (figure 2).
the exhaust). The resulting annual energy savings
Due to the use of appropriate NOx- compared to the cold-air burner system
www.process-heating.com OCTOBER 2017 27
 Industrial Gases/Combustion

Efficiency ratio/correction factor NOx emissions/limits

NOx emissions/limits, ppm @ 3% O2

100 2.50 120 0.16
90 110

NOx emission/limits, lb./

Correction factor [-]
80 Regenerative burner 2.00 100 0.13
for efficiency
Efficiency LHV, %

70 90 it adjusted
Correction factor 80 New NOx lim 0.10
1.50

MMBTU
60 70 Correction factor
50 60 0.07
40 1.00 50
30 Cold air burner 40 0.05
30 Regenerative burner
20 0.05 20 0.03
10 10
0 0.00 0 0.00
1500 1600 1700 1800 1900 2000 2100 2200 2300 1500 1600 1700 1800 1900 2000 2100 2200 2300
Furnace temperature, F Furnace temperature, F

Annual natural gas consumption Annual NOx emissions

40.00 4000 8800
Energy use, GWh natural gas

Regenerative burners Regenerative burners

NOx emissions per year, kg

NOx emission per year, lb

35.00 Cold-air burners 3500 Cold-air burners
30.00 Example furnace 3000 Example furnace 6600
25.00 2500
20.00 2000 4400
15.00 1500
10.00 1000 2200
5.00 500
0.00 0 0
1562 1652 1742 1832 1922 2012 2102 2192 2282 1562 1652 1742 1832 1922 2012 2102 2192 2282
Furnace temperature, F Furnace temperature, F

FIGURE 3. Cold-air burner vs. regenerative burner illustration of efficiency ratio, correction factor, traditional one-
dimensional NOx limit, NOx limit corrected for efficiency, energy use and absolute NOx emissions per year. Data for
exemplary furnace application as defined in the article is highlighted in green.

equates to 19 GWh, which equals the an- is currently defined favors the inefficient with an efficiency factor.
nual natural gas use of 851 average U.S. and higher-emission technology rather While option 1 seems to be straight-
households.[4] Even though the specific than a far more advantageous combus- forward at first, it can be difficult to ver-
NOx emissions of the regenerative-burner tion technology using less energy with ify compliance in real-world applications.
system are slightly higher than the refer- significantly lower overall emissions. The There is typically no emissions-monitoring
ence system, the absolute amount of NOx next section introduces a simple correc- device permanently installed to prove the
emitted is, in fact, significantly lower. tion method to account for the differenc- true absolute amounts of a pollutant emit-
The inefficient cold-air burner system es in efficiency. This method can be used ted per year. It would be possible, however,
emits 8,172 pounds (3,707 kg) of NOx to correct the emissions limit in order to use extrapolated values based on actual
per year, whereas the high-efficiency re- to easily equate two or more alternative measurements to prove compliance with
generative system only emits 5,419 pounds technologies. the limitation defined as an absolute value.
(2,458 kg). This equates to 33 percent low- Option 2 could be used in a very similar
er actual NOx emissions in the same time Improved Formula for way to todays standard approach. Current-
span (values derived from energy-based Emissions-Limit Calculation ly, the limitation of the concentration of a
emission factors for natural gas H).[2] In general, there are two possible methods pollutant in the exhaust is spot-checked
At the same time, a CO2 reduction to better define the emissions limitation over the course of a typical operation cycle.
of approximately 4,244 (3,850 metric) in order to make sure its actual goal will In the case of NOx emissions, an exhaust-
tons per year can be achieved due to the be achieved. gas analyzer probe is inserted into the ex-
increased fuel efficiency (based on CO2- haust system and several NOx readings are
emission factor 0.126 pounds/ft (2.02 kg/ 1. The overall absolute emissions of a pol- taken over a certain period of time. These
m) for natural gas H). For just one furnace, lutant can be limited. For example, the values are then averaged in order to com-
this difference is equivalent to removing limit could be given in pounds per year. pare them to the limit previously set for
820 passenger cars from the road.[3] 2. The limitation of an emissions concen- the audited furnace.
To summarize, the way the standard tration in flue gases can be corrected At the same time, exhaust-gas analyz-

28 OCTOBER 2017 Process Heating


ers typically also determine the efficiency
of a combustion system based on the
CO2 content and the temperature of the
exhaust. These efficiency readings or the
published/guaranteed efficiency from the
manufacturer can then be used to adjust
the emissions limitation for increased ef-
ficiency (or vice versa, penalize the ineffi-
cient technology with the same factor).
Assume that the reference system (ref )
is defined as the most efficient combustion
technology that still achieves the emissions
concentration limit EB as defined by the
authorities. If the reference technology is
able to achieve lower specific emissions,
EB should be set according to this lower
value. Furthermore, assume that there is
a more fuel-efficient technology available
(eff ) that does not meet the limitation for
specific emissions.
The corrected emissions concentration
limit EN shall serve as the new limit for
the high-efficiency technology because
it represents the value at which the total
absolute emissions of the more efficient
system are equal to those emitted by the
less efficient system. If the high-efficiency
alternative stays below this new emissions
limit EN, it is the environmentally favor-
able solution, because not only is the total
amount of pollutant emitted lower than for
the reference system but also the total fuel
consumption.
For the example defined in the previous
section, the corrected specific emissions
limit EN for NOx computes to:
The regenerative-burner system emit-
ting 0.08 pounds/MMBTU (70 ppm) at 3
percent O2 stays well below the corrected
limit EN of approximately 0.14 pounds/
MMBTU (105 ppm) at 3 percent O2, thus
saving 33 percent NOx emissions per year
Industrial Gases/Combustion
compared to the option that would have
had to be selected previously.
Figure 3 illustrates a broader compari-
son of cold-air and regenerative-burner
systems over a range of operating tem-
peratures. The graphs show that the more
efficient combustion system consistently
offers lower overall NOx emissions and
also leads to significant energy savings.
In addition, the energy-savings effect in-
creases with the operating temperature,
making the overall environmental benefits
especially important for high-temperature
applications.
Lowering peak
temperatures while still
maintaining complete
combustion is the goal
of NOx-reduction
techniques.
Conclusions
This article shows that the method cur-
rently used to define the limitation of pol-
lutant concentration in the exhaust of a
combustion system often does not achieve
its intended goal. Without proper quanti-
fication and integration of the process in-
puts (fuel), the standard method can even
act counterproductively to its intentions.
An undifferentiated limitation of
volume-based pollutant concentra-
tion (NOx) is only possible if all avail-
able technologies use the exact same
amount of fuel to heat a furnace. Since
this is rarely the case, we propose using
an emissions limit corrected for com-
bustion efficiency. Its compliance can be
checked just as easily as the current, typi-
cally undifferentiated concentration limit
since exhaust-gas analyzers not only re-
veal emission concentration but also the
efficiency of a combustion system. As an
alternative, authorities could also easily
define classes of combustion equipment
based on existing literature showing typi-
www.process-heating.com OCTOBER 2017
cal combustion efficiencies for different
available technologies.[2,7]
The example discussed represents a
typical furnace application. Due to the
disincentive set by the current approach
for defining the emissions limitation, less
efficient technology has to be selected. For
only one exemplary furnace, this leads to
19 GWh of additional energy use, 4,244
(3,850 metric) tons of additional CO2
emissions and 33 percent higher NOx
emissions than what could be achieved
with a more sophisticated combustion
system. This equates to potential savings
equivalent to the average annual natural
gas use of 851 U.S. households and NOx
reductions equivalent to removing 820
passenger cars from the road.
Extrapolated to hundreds of furnaces,
the effects quickly become highly relevant
to the public and society. A simple correc-
tion to the standards set by the authorities
will therefore lead to significant positive
effects for both the environment and the
economy.
Contact Dr. Martin Schnfelder, VP technical
sales; WS Thermal Process Technology Inc.,
8301 West Erie Avenue, Lorain, OH 44053;
tel: 440-385-6829; fax: 440-960-5454; e-mail:
wsinc@flox.com; web: www.flox.com
References
1. United States Environmental Protection
Agency (EPA), Office of Air Quality Plan-
ning and Standards: NOx How nitrogen
oxides affect the way we live and breathe,
Triangle Park, NC, 1998
2. J. G. Wnning, A. Milani: Handbook of
Burner Technology for Industrial Furnaces,
2nd Edition, Vulkan Verlag, Essen, 2015
3. United States Environmental Protection
Agency (EPA), Office of Transportation
and Air Quality: Greenhouse Gas Emis-
sions from a Typical Passenger Vehicle,
Ann Arbor, Michigan, 2014
4. U.S. Energy Information Administration:
Residential Energy Consumption Survey,
2009
5. Y. B. Zeldovich; The Oxidation of Nitrogen
in Combustion Explosions, Acta Physico-
chimica 21: 577628, U.S.S.R., 1946
6. G. A. Lavoie, J. B. Heywood, J. C. Keck;
Experimental and Theoretical Study of Ni-
tric Oxide Formation in Internal Combus-
tion Engines, Combust. Sci. Tech. 1 (4):
313326, 1970
7. R. J. Reed; North American combustion
handbook. North American Mfg. Co., 2014
29
 Temperature Sensors
TEMPERATURE
MEASUREMENT
FLEXIBILITY
Helps Quality and Validation
Understanding different sensor types helps create better temperature profiles.
By Stew Thompson,
CAS Dataloggers Inc.
O
ven temperature data is criti-
cal to the entire process, in-
cluding preheating, curing
and drying. Using different
types of temperature sensors, you can find
out if your oven interiors are uniform in
temperature or if there are uneven zones
impacting consistency.
With universal inputs, all the sensors are
recording data on the same device using
the same software to keep it simple and
to store the data to internal memory. It is
all with a goal of increasing profitability,
product coverage and optimizing the oven
heat treatment process.
30 OCTOBER 2017 Process Heating
Why Use Different
Sensor Types?
Available in several designs, temperature
sensors use different methods to record
data at varying degrees of accuracy. This
means that all temperature data is not
equal. Each type has advantages and dis-
advantages for particular applications.
Flexibility. Thermocouples are the most
typically used sensors available, due in part
to their wide operating range (typical accu-
racy of 1 to 2F). Consider thermocouples
when you want a low cost device that offers
ease of use. A thermocouple uses two metal
alloy wires fused together to produce an
output voltage related to the temperature
in the oven. A datalogger measures this
voltage and applies an equation to con-
vert the voltage to a temperature reading.
Because of the low voltages involved with
thermocouple measurements, signal noise
is often an issue, particularly in industrial
environments. If you need higher accuracy,
wires with reduced errors also are available.
Cost. Semiconductor devices are an-
other low cost choice. They incorporate
a solid-state device to generate a voltage
or current output proportional to tem-
perature. Much like thermocouples, they
have a limited operating range and accu-
racy. Consider using semiconductors when
budget is a factor and you have a specific
temperature range in mind.
Stability. Resistance temperature de-
tectors (RTDs) are sensors which have a
resistance that increases linearly with the

temperature within your oven. The most
common RTD consists of a fine platinum
wire wound around a cylinder. To measure
temperature, the datalogger will source
a known current through the RTD and
measure the resulting voltage, from which
it can calculate the resistance. Finally, us-
ing the slope of the resistance versus tem-
perature curve and the 0C resistance, the
datalogger can calculate the surrounding
temperature. RTDs typically are more sta-
ble and accurate than thermocouples, but
they have a more limited operating range.
Similar to RTDs, thermistors provide a
change in resistance that is related to tem-
perature. However, thermistors resistance
change is highly nonlinear. This means that
they offer higher accuracy than thermo-
This universal analog input datalogger offers a USB port and drive.
couples (down to an accuracy of 0.01C)
but only over a limited temperature range
(typically -40 to 302F [-40 to 150C]).
Each family of thermistors has a specific
resistance versus temperature characteristic
that the oven datalogger must be able to
accommodate.
Consider RTD/thermistor sensors
when price is not a factor, and you need
high-precision measurements for a narrow
temperature window.
Temperature Measurement
for Process Optimization
While many logger models are designed
to connect to specific sensor types (for ex-
ample, Type K thermocouples), universal
loggers are able to record data from many
www.process-heating.com OCTOBER 2017
Temperature Sensors
different types. This includes thermistors,
RTDs and air temperature sensors.
For thermocouple applications, some
loggers also utilize a cold junction reference
to compensate for any offset voltage that
occurs at the connections between the ther-
mocouple wires and the logger. Addition-
ally, an analog-to-digital converter (ADC)
helps to ensure precision measurements.
Using a temperature datalogger
equipped with universal analog inputs, you
can log data from several different types of
temperature sensors. This is especially use-
ful if you do not know which sensor types
you need, or if you want to experiment
with different temperature sensor types.
For example, maybe you want to run ther-
mocouples to the logger, but your readings
31
 Temperature Sensors

keep getting signal interference. You also

can connect RTDs.
Adding Sensor Power. In the setup sec-
tion of many logger software applications,
you can select a sensor power timer for the
temperature input channel you want. For
example, you can choose to have the con-
nected temperature sensors take a minute
or more to power up, helping to ensure that
they take a stable reading. Many software
packages also will show you sensor power
wiring diagrams for the loggers blocks.
When all this is completed, you can send
this setup to the datalogger so it is saved
for future use.
Setting up a Temperature Channel.
To set up a temperature channel, fol-
low these steps: run the logger software,
go to the setup section or tab, select the
first temperature channel, select your sen-
sor type (for instance, thermocouple Type
K), and input the temperature range you
want to monitor. You can also add scal-
Temperature dataloggers can be enclosed within stainless steel barrier. ing, choose the temperature scale (F/C)
and other options. Diagrams show where

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32 OCTOBER 2017 Process Heating

 Temperature Sensors

to connect into the block of the logger. To

simplify multichannel applications, you New Thermal Barrier Temperature Performance
also can enter names for different sensors
for easy reference. 400
New Barrier with Phase Change Heat Sink
350 New Barrier without Heat Sink
Monitoring Air Temperature
inside the Oven 300

Time (mins)
You may think that the interior of your oven
is a relatively stable environment, but inside 250
there are air currents and flows that often
200
cause product defects due the unpredictable
temperature. To help ensure a quality prod- 150
uct and process repeatability, you can use
100
specialized sensors to monitor air tempera-
ture and airflow in oven interiors simulta- 50
neously with temperature monitoring.
0
100 150 200 250 300
Oven Temperature (C)

A thermal barrier protects the datalogger as it passes through the oven.

Temperature dataloggers can work
with different sensor types.
The universal inputs on a datalogger can
connect with air temperature and airflow
sensors to give you the necessary multival-
ue data. Along with standard temperature
monitoring, this allows you to create an ac-
curate temperature profile. If you need to
view data in real time, fast-response probes
are available in clip-on, magnetic and com-
bination types to capture both air tempera-
ture and surface measurements.
Typically, a temperature recorders ana-
log input channels can accept different
types of thermocouple probes (for exam-
ple, Type T and Type K), capturing data
at a high sample rate (for example, eight
times each second). This creates the high
level of detail needed to generate a full
temperature profile for surface coating and
through process applications.
Naturally, temperature recorders need
thermal protection as they collect data
alongside your parts or products during
a run or sit within walk-in ovens. When
housed within a stainless steel thermal bar-
rier for heat absorption, the oven logger is
safe to record for the duration of the spe-
cific time period listed for the enclosure.
In this way, you can derive temperature
profiles for different applications including
curing, baking and more.
As the datalogger passes through the
oven, it samples the interior temperature
via the connected external temperature
sensors trailing out of slots in the enclo-
sure. The oven datalogger then stores and
timestamps the temperature data onto
internal memory for data download and
analysis via USB interface with PC.
Document Product Quality
and Validate Your Process
With the data collected over several runs,
you should be able to optimize your pro-
cess efficiency all with the goal of in-
creasing repeatability, product quality and
profitability. This can take the form of
minimizing curing times, ensuring more
even part coverage and other benefits.
Equipped with this temperature data,
you can use datalogger analysis software to
display stored data and get the inside view
on the heat treatment process. For exam-
ple, you can begin fine-tuning the process
parameters to achieve greater uniformity.
Presented in chart or graph format, the
time-stamped temperature data also serves
as a QA report for vendors and customers.
It can help prove that products have passed
through the process at the proper tempera-
ture for the proper duration.
Many oven loggers also offer tempera-
ture profile software packages designed
exclusively for the paint and finishing
industry. These programs enable users to
store preprogrammed cure data, to display
calculated cure percentages and other de-
sired features.
By using different types of temperature
sensors to record the temperature data of an
ovens interior, it is possible to equip yourself
with the high level of data needed to create
a detailed temperature profile. Whether
you are curing parts or replicating a batch
of perfectly roasted potatoes, temperature
profiling can serve as a guide needed to sta-
bilize and optimize the process.
Stew Thompson is a technical writer with
CAS DataLoggers Inc. The Chesterland, Ohio-
based company can be reached at 440-729-
2570 or visit www.dataloggerinc.com.

www.process-heating.com OCTOBER 2017 33

Equipment Overview
When selecting the type of heat exchanger to use, construc-
tion materials, heat transfer medium, flow arrangement and heat
transfer method are all factors to consider making the selec-
tion process a difficult job. But, Process Heating has something
to help you out: Our Equipment Overview on Heat Exchangers
will allow you find a few potential suppliers that can provide just
what you need.
Heat Exchangers
Our Equipment Overview on Heat Exchangers in print
and online at www.process-heating.com/directories offers
a side-by-side comparison of industrial heat exchanger manu-
facturers to show you which companies manufacture the types
you want. Cross-check multiple headings by skimming down
specific columns to find those manufacturers that have experi-
ence with the type of equipment you want. Weve even identified

CONSTRUCTION MATERIALS OF CONSTRUCTION FLOW ARRANGEMENT

You also can conduct your
supplier search online!

Tubular, Shell-and-Tube, Plate Baffle

Multi-Pass, Parallel Plate Multi-Pass

Tubular, Shell-and-Tube, Rod Baffle

Multi-Pass, Parallel Counterflow

Multi-Pass, Cross Parallel Flow
Multi-Pass, Cross Counterflow
Extended Surface, Plate-Fin
Extended Surface, Tube-Fin
www.process-heating.com/

Multi-Pass, Divided Flow

buyersguide

Tubular, Double-Pipe

Tubular, Spiral Tube

Fluoropolymers
Plate, Gasketed

Stainless Steel
Plate, Lamella

Plate, Welded
Plate, Brazed

Exotic Metals
Carbon Steel
Plate, Spiral

Aluminum

Titanium
Graphite
Ceramic
Companies

Copper

Nickel
Other

Other
Brass

Glass
Advanced Coil Technology LLC
www.advancedcoiltechnology.com
Process Technology
www.processtechnology.com
Aaron Equipment Co.
ACS Group, Application Engineering
Advanced Heat Recovery, Aqua Innovations Inc.
Adwest Technologies Inc., Ceco Environmental
AGC Heat Transfer Inc.
Alfa Laval Inc.
Allegheny Bradford Corp.
American Industrial Heat Transfer
Ametek Chemical Products
Ametek Fluoropolymer Products
Anguil Environmental Systems Inc.
API Heat Transfer
APV, An SPX Brand
Baelz North America
Bell & Gossett
Cast Aluminum Solutions, Cast-X Circulation Heater
CCI Thermal Technologies Inc.
Chemineer, a brand of NOV
Chester-Jensen
Chromalox
Colmac Coil Mfg. Inc.
DDI Heat Exchangers Inc.
DECA Srl
Delta Tee International
Diversified Heat Transfer
DME Co.
Doucette Industries Inc.
DRS Marlo Coil, Leondardo DRS
Enecon Corp.
Enerquip LLC
Epcon Industrial Systems LP
Exergy LLC
Feldmeier Equipment Inc.
Fin Tube Products Inc.
Fluorotherm Polymers Inc.
GEA PHE Systems North America
GF Piping Systems
Gooch Thermal Systems Inc.
Manufacturers listed in this Equipment Overview responded to a special mailing by Process Heating and do not necessarily represent the entire industrial heat exchanger market.
To be included in future listings, contact Linda Becker or email BeckerL@bnpmedia.com.

34 OCTOBER 2017 Process Heating

those companies that offer aftermarket parts for their equipment.
Visit www.process-heating.com/directories and select the
Equipment Overview on Heat Exchangers to use our RFP
Builder and request information via a single form. On any page
in the Equipment Overview, click the plus sign next to those
suppliers you wish to add to your distribution list. Once you've
selected the companies you are interested, click on the Submit An
Info Request button to create a prepopulated form. Fill in your
contact information and send it. If you realize you want to add
more companies, just click on the Add Suppliers button in the
contact form. All responses from suppliers will be sent directly to
you or the contacts you designate.
If you need more information than what we have specified here
and on our website, www.process-heating.com/buyersguide.

MEDIUM PROCESSED METHOD OF HEAT TRANSFER MANUFACTURING PROCESS INDUSTRIES SERVED

parts/supplies for our heat exchangers.

Ethanol/Biodiesel Fuels/Oil & Gas

We manufacture aftermarket
Evaporation/Condensation

Chemicals/Petrochemicals
Single Pass, Parallel Flow
Single Pass, Counterflow

Pulp/Paper/Converting
Single Pass, Crossflow

Plastics/Rubber/Vinyl
Multi-Pass, Split Flow

Packaging/Printing
Heat Transfer Fluid

Fibrous Effluent
Steam to Liquid

Pharmaceutical
Liquid to Liquid

Vapor Recovery
Feed Preheater

Pasteurization
Heat Recovery

Reactor Slurry
Heat Transfer
Interchanger
Gas to Liquid

Steam to Air
Air to Liquid
Refrigerant

Distillation

Electronics
Gas to Air

Finishing
Air to Air

Reboiler
Cooling
Steam
Water
Glycol

Other

Other

Other

Food
Gas
Air

Oil

*
*
Yes
Yes
Yes
Yes
Yes
Yes
*
*
Yes
Yes
Yes
Yes
*
Yes
*
Yes
Yes
Yes
Yes

Yes

Yes

*

*

Yes
*
Yes
Yes
*
Yes
Yes
*
Yes
Yes
Yes
Yes
*
*
Companies with in front of their name have an advertisement in this issue.

www.process-heating.com OCTOBER 2017 35

Equipment Overview Heat Exchangers
CONSTRUCTION MATERIALS OF CONSTRUCTION FLOW ARRANGEMENT
You also can conduct your
supplier search online!

Tubular, Shell-and-Tube, Plate Baffle

Multi-Pass, Parallel Plate Multi-Pass

Tubular, Shell-and-Tube, Rod Baffle

Multi-Pass, Parallel Counterflow

Multi-Pass, Cross Parallel Flow
Multi-Pass, Cross Counterflow
Extended Surface, Plate-Fin
Extended Surface, Tube-Fin
www.process-heating.com/

Multi-Pass, Divided Flow

buyersguide

Tubular, Double-Pipe

Tubular, Spiral Tube

Fluoropolymers
Plate, Gasketed

Stainless Steel
Plate, Lamella

Plate, Welded
Plate, Brazed

Exotic Metals
Carbon Steel
Plate, Spiral

Aluminum

Titanium
Graphite
Ceramic
Companies

Copper

Nickel
Other

Other
Brass

Glass
Graham Corp.
Greenwood Engineering Inc.
Harbridge Systems
Heat and Control Inc.
Heat Transfer Systems Inc.
Heatec
Heresite Protective Coatings LLC
Honeywell Thermal Solutions, Exothermics
Hydro-Thermal Corp.
Industrial Heat Transfer
Isotherm Inc.
JLS International
Koch Heat Transfer Co.
Komline-Sanderson
Litre Service Inc.
Luvata Grenada LLC
Lytron Inc.
Madden Manufacturing
Manning & Lewis Engineering Co.
Mascoat
Metso Minerals Industries Inc., Pyro Processing
MicroThermics Inc.
Mokon
Multitherm
Munters Corp.
Opti-Temp Inc.
Parker Boiler Co.
Paul Mueller Co.
Pick Heaters Inc.
Plate Concepts Inc.
Polaris Heat Exchangers LLC
PolyScience
Premier Furnace Specialists/BeaverMatic Inc.
ProSonix LLC
R.P. Adams, Subsidiary of Service Filtration Corp.
RAS Process Equipment
Robson Industries Inc.
Rubicon Industries
Sentry Equipment Corp.
Smithco Engineering
Standard Exchange
Sterling Products Inc.
Super Radiator Coils
Swep North America Inc.
Tek-Temp Instruments Inc.
Terlet USA
Thermal Transfer Systems Inc.
ThermTech Inc.
Thomas C. Wilson LLC
Tranter Inc.
Trent Inc.
Vilter Manufacturing LLC
Watlow
Waukesha Cherry-Burrell, An SPX Brand
WCR Inc.
Webco Industries Inc.
Xchanger Inc.

36 OCTOBER 2017 Process Heating

 MEDIUM PROCESSED METHOD OF HEAT TRANSFER MANUFACTURING PROCESS INDUSTRIES SERVED

parts/supplies for our heat exchangers.

Ethanol/Biodiesel Fuels/Oil & Gas

We manufacture aftermarket
Evaporation/Condensation

Chemicals/Petrochemicals
Single Pass, Parallel Flow
Single Pass, Counterflow

Pulp/Paper/Converting
Single Pass, Crossflow

Plastics/Rubber/Vinyl
Multi-Pass, Split Flow

Packaging/Printing
Heat Transfer Fluid

Fibrous Effluent
Steam to Liquid

Pharmaceutical
Liquid to Liquid

Vapor Recovery
Feed Preheater

Pasteurization
Heat Recovery

Reactor Slurry
Heat Transfer
Interchanger
Gas to Liquid

Steam to Air
Air to Liquid
Refrigerant

Distillation

Electronics
Gas to Air

Finishing
Air to Air

Reboiler
Cooling
Steam
Water
Glycol

Other

Other

Other

Food
Gas
Air

Oil

Yes
*
Yes
Yes
Yes
*
Yes
Yes
*
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
*
Yes
Yes
Yes
*
Yes
Yes
Yes
*
*
Yes
Yes
Yes
*
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
*
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
*
*
Yes
Yes
*
Yes

www.process-heating.com OCTOBER 2017 37

Product Highlights

Wondering where to find products beneficial to your process? This department provides a number of new products each month and allows you to easily request
more information. Simply call those companies in which you are interested, or visit those companies websites.

BriskHeat Grieve Corp.

Heating Mantles for Laboratory Use Oven Dries Water from Piston Rings
Metal-housed heating man- on Racks
tle are suited for laboratory A 500F (260C),
settings including research top-loading oven,
and development laborato- No. 844 is used for
ries that employ round-bot- drying water from
tom flasks for heating liq- racks of piston rings
uids. Model HM is made to at the customers
fit precisely around boiling facility. Work-
and distillation-style round- space dimensions
bottom flasks to provide measure 48 x 48 x
consistent, easy-to-control 36", and 40 KW are
heat. The metal-housed installed in Incoloy-
heating mantles fit flasks sheathed tubular
with capacities between 50 heating elements. A 4200-cfm, 3-hp recirculating blower
and 6,000 ml and provide provides horizontal airflow to the workload. This oven has 4"
high temperature capabilities up to 842F (450C). They are insulated walls, an aluminized steel exterior and Type 304, 2B
offered in tabletop designs and are available with built-in finish stainless steel interior with continuously back welded
controllers. The plastic-coated, chemically resistant metal seams. Additional features include an air-operated rear slid-
housing is thermally insulated for safe touch. ing door, reinforced 0.25" steel plate top and wear bars at
888-501-7491 sides of workspace. The floor of the workspace is reinforced
www.briskheat.com for 1000 lb loading at removable subway grate.
847-546-8225
Buhler Aeroglide www.grievecorp.com
Real-Time Data Monitoring For Optimum
Dryer Performance Thermcraft
AeroPro Moisture Control Box Chamber Furnaces
gives dryer operators Box-type chamber furnaces are suited for use in nearly all
access to full-time, types of thermal processing and heat treating applications. A
real-time monitoring pair of twin box furnaces will be used to process turbine parts
with hardware, software for a manufacturer of power generation turbines. Each of the
and ongoing process furnaces is equipped with multiple heavy-duty cast-plate
expertise, combined heaters with heavy-gauge wire-wound elements totaling 130
with technical support, KW of power. The vertical lift doors are opened and closed
to ensure efficient dryer using dual synchronized pneumatic cylinders. Temperature
operations. The moisture controls include a single-zone controller with integrated
control device reduces time-based moisture deviation with digital chart recorder/data acquisition and an independent
a control algorithm that improves dryer yield. It also reduces overtem-
dryer energy consumption, according to the manufacturer. perature
Microwave sensor technology, coupled with algorithms, controller,
deliver a closed-loop system for automated dryer control. In both read-
operation, discharged product passes through an analysis ing Type
chute, where approximately 20 percent is diverted to a sens- K thermo-
ing chamber that slows the product flow for analysis. The couples.
microwave sensor gathers moisture data and sends it directly Power is
to the moisture control systems control panel. Automation controlled
then makes necessary dryer adjustments that can instantly by zero-cross SCR power controllers in a three-phase configu-
produce product consistent to the target moisture content. ration and monitored by one ammeter per phase.
919-851-2000 336-784-4800
www.buhlergroup.com/drying www.thermcraftinc.com

38 OCTOBER 2017 Process Heating

 Learn from two high-prole Keynotes and over
a dozen subject matter experts about industry

QUALITY trends and new technologies that may solve the

challenges facing your business.
Education

Interact with thousands of experienced and

skilled quality engineers, manufactures and
production managers over 3 days to discuss
challenges, share experiences and build QUALITY
important relationships.
Networking

Explore a resource-rich exhibit hall and take away

actionable ideas on the latest test, measurement &
inspection equipment services and software that can
QUALITY improve quality in your manufacturing planning.
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Register for FREE Today! Quali tyS how.co m
Only Qu ali ty
October 24 26, 2017
Donald E Stephens Convention Center
Rosemont, IL

Platinum SIlver Bronze Collaborative

Sponsor Sponsor Sponsor Partners
Product Highlights

Xchanger Inc. Carlo Gavazzi Inc.

Heat Exchangers with Bolt-On Transitions Self-Learning 40-hp Soft Starters with
Heat exchangers Integrated Overload Protection
are available with A soft-starter for
optional bolt-on three-phase induc-
transitions that tion AC motors, the
ease access to the RSGD needs only
core and improve three settings. The
exchanger body self-learning algo-
strength. In most rithm adjusts the soft
applications, the starter parameters
simple bolted to work with varying
flange can significantly reduce labor costs and downtime for load conditions. It is
inspection and cleaning. The C-Series unit shown, designed active at every start
for 15 psig, can be used for heating pneumatic conveying air to ensure that the motor always starts with the optimal set-
to reduce or prevent product cooling during transport. They tings. New current-balancing algorithm keeps the current un-
can also be used to control humidity levels by combining a balance to less than 15 percent. The line includes an option
cooling core and reheating core in the same unit. for Class 10 electronic overload. Phase-sequence protection
952-933-2559 can be enabled and disabled through the use of an inte-
www.xchanger.com grated pushbutton. Torque controlled ramp-down provides
smooth deceleration of motors. Features include operational
Frigel current 12 to 45 A; up to 40 hp rating; and operational volt-
Central Cooling System, Process Pump age capacity of 220 to 600 VAC.
Sets with Variable-Frequency Drives 847-465-6100
www.gavazzionline.com

Conair Group
Adiabatic Cooling Towers
Cut Power, Water Consumption
EarthSmart ESTW Series eliminate the constant water
consumption and treatment requirements of conventional
evaporative towers, utilizing closed-loop cooling that isolates
process water from contamination. The adiabatic cooling
towers cycling it, through finned heat exchangers, where
ambient air absorbs process heat and cools it for recirculation.
During periods where ambient air is warmest and maximum
cooling capacity is needed, the adiabatic towers use top-
mounted fans to draw warm air through wetted adiabatic
panels located in front of the finned heat coils. The towers
controls automatically manage the adiabatic process, vary-
Designed to be used with the companys central cooling ing water volume and fan speed to reduce the temperature
systems, Aquagel GPV pump sets help ensure the pumps of the ambient air passing through the heat exchangers.
operate at peak efficiency with lowest possible energy The line includes eleven
consumption. The pump sets with variable-frequency drives models capable of
(VFDs) allow users the ability to gain precise control of the handling nominal
units. The pump sets are part of the companys line of pump- process coolant
ing, reservoir and filtration systems for its Ecodry or Heavygel flow rates of 45 to
central cooling systems. With the addition of the companys 510 gal/min (170 to
3PR control console, users can monitor all data in real time for 1,930 l/min), with
the pump stations. Users can access full operating schematics cooling capacities
that monitor pump performance such as pressures, flow rates ranging from 17
and VFD capacity. tons to 195 tons.
847-540-0160 724-584-5500
www.frigel.com www.conairgroup.com

40 OCTOBER 2017 Process Heating

 FABTECH 2017

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Product Highlights

GF Piping Systems Advanced Thermal Solutions (ATS)

Solid-State Electric Actuator Heat Sinks Provide Cooling for Systems
with Adequate Airflow
A high aspect ratio
design allows the Pin
Fin heat sinks to provide
low thermal resis-
tance from base
to fins in systems
where the airflow
measures more
than 200 linear feet
per minute. The cross-
Model EA15 is suited for smaller diameter, open/close ball cut design also allows the heat sinks
valve applications in chemical processing, refrigeration and to be effective in systems where the airflow
water treatment. As a part of the companys EA25-250 actua- is ambiguous. The high efficiency platform products, made
tor series, the device incorporates standard features such from extruded aluminum, are available in component sizes
as open/close limit switches; a seven-segment error code from 0.39 x 0.39" (10 x 10 mm) to 2.36 x 2.36" (60 x 60 mm).
display; adjustable internal heating element; and a chemi- Heat sink heights range to 1" nominal (25 mm). At higher
cally resistant polypropylene housing. Designed to operate airflows, the heat sinks can provide thermal resistance as low
quarter-turn valves, the actuator delivers a nominal torque of as 4.5F/W (2.5C/W). They can be attached with standard
10 Nm and a peak torque of 20 Nm. thermal tape or the companys clip kit.
800-854-4090 781-769-2800
www.gfps.com www.qats.com

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42 OCTOBER 2017 Process Heating

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FREE Subscription, go to
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When you have assurance, you have confidence
youre getting what you paid for. By advertising in a
BPA-audited publication, you know the circulation
is verified by an independent third-party who makes
sure you dont get short-changed.

44 OCTOBER 2017 Process Heating

PH Classifieds Display Classified Rates:
1X $125 3X $120 6X $115 12X $105
Send advertising copy to:
Process Heating/Attn. Becky McClelland
Phone: 412-306-4355 Fax: 248-502-1076
E-mail: becky@bnpmedia.com

Equipment for Sale

HEAT EXCHANGERS
For $30 Liquid Cooled

we will
SEE YOUR AD HERE
post & link Air Cooled

your print ad on FOR GASES & LIQUIDS!
Talk Directly with Design Engineers!
www.process-heating.com Blower Cooling Vent Condensing

(952) 933-2559 info@xchanger.com

ADVERTISING INDEX
11 Advanced Coil Technology 507-451-0130 www.advancedcoiltechnology.com

10 ARI Valve 770-933-8845 www.arivalve.com

43 Chem Show www.chemshow.com

7 & 21 Duratherm 800-446-4910 www.durathermfluids.com

41 FABTECH www.fabtechexpo.com

48 Heatec, Inc. 423-821-5200 www.heatec.com

2 Industrial Combustion 608-329-3131 www.ind-comb.com

17 Process Technology 440-974-1300 www.processtechnology.com

10 & 32 Protection Controls 847-674-7676 www.protectioncontrolsinc.com

39 Quality Show www.qualityshow.com

9 Sigma Thermal 866-923-6121 www.sigmathermal.com

5 Themal Product Solutions 570-538-7200 www.thermalproductsolutions.com

47 Wisconsin Oven 262-642-3938 www.wisoven.com

www.process-heating.com OCTOBER 2017 45

Places Faces
London-based Lloyds Register issued
its first certification of a part produced
through additive manufacturing for
the oil-and-gas industry. The part, a
titanium gateway manifold for pipelines,
was designed by Surrey, England-
based Safer Plug Co. (SPC) and
built by the additive manufacturing
production company 3T RPD using
powder bed fusion. The entire process
was overseen and certified by Lloyds
Register using its framework, which
guides manufacturers on additive-
manufacturing processes to certify
components. The manifold will be
included in an assembly for a suite of
pipeline isolation tools.
Patrick McKenna was promoted to
president and CEO for Ipsen USA,
Cherry Valley, Ill. Also, Pete Kerbel
was promoted to vice president of
sales at Ipsen USA.
Ava Drayton was
named vice president,
food and beverage, for
Charlotte-based SPX
Flow Inc. Drayton will
be responsible for driv-
Drayton ing market share in the
Americas. At the same time, SPX Flow
named Pierre Sbabo as the vice presi-
dent of its food and beverage business
in EMEA. SPX Flow manufactures
engineered flow components, process
equipment and turnkey systems.
Metso strengthened its presence
in India with the signing of four
nonexclusive distribution agreements
for its valve products. The agreements
with Fluidline Systems, General
Energy Management Systems Ltd.
(GEMSL), SB Enterprise and Proflo
46 OCTOBER 2017 Process Heating
Systems expand the coverage of
Metso's Neles and Jamesbury valve
and positioner product families in
India. The distribution network also will
provide support in services.
Nationwide Boiler Inc., Fremont,
Calif., represents Webster
Combustion Technology LLC,
Winfield, Kan., in central and northern
California following an agreement
between the two companies.
Webster manufactures industrial and
commercial boiler burners. Nationwide
is involved in boiler system sales,
rentals, leasing, turnkey installations,
operations and repair.
GF Piping Systems Irvine, Calif.-
based facility was recognized with
the Pacific Southwest Regional
Outstanding Building of the Year award
in the industrial office building catego-
ry. The campus includes warehouse
and manufacturing space as well as
offices for engineering, technical sup-
port and training, and a showroom for
the company's piping solutions.
After more than
15 years with BJM
Pumps, Old Saybrook,
Conn., Jay Gallagher,
who served as Atlantic
regional sales man-
Gallagher ager, retired. Steve
Mosley, who has served as BJMs
application engineer for five years,
will succeed Gallagher as the Atlantic
regional sales manager.
SUBSCRIPTIONS
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PUBLISHING STAFF
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412-306-4360 reed@process-heating.com
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412-306-4350 bill@process-heating.com
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