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Circulation

Circulation Heaters
Overview

In-Line or Recirculating

Water, Solutions, Oils, Steam


and Gas Heating

High Efficiency

Circulation
Packaged Heater, Vessel and
Control

ASME Certification

Custom Designs

Circulation heaters are packaged units


designed to heat a flowing medium using in-
line or side-arm piping configurations.
Complete units consist of built-in heating
elements, a heating chamber, thermostat and/
or sensors (stock units), insulation, insulation Applications Application Engineering
jacket, mounting brackets and inlet and outlet
connections. Typical applications include heating water, oils, The Chromalox sales and service organization
heat transfer fluids, mild and corrosive fluids, has the technical capabilities and equipment to
Circulation heaters offer high efficiency since gases and steam. Heaters can be mounted on satisfy virtually any circulation heating
all heat is generated within the solution. Fluids the side of tanks, inserted into closed-loop application and to assist you in calculating
are directed past the heating elements giving systems or installed in-line for process requirements for the more common heating
fast response and even heat distribution. heating. processes.
A wide selection of kilowatt ratings, materials, Water Heating Washrooms, dish washing The Chromalox organization is the most
vessel sizes, terminal enclosures, control and rinsing, process water heating, jacketed experienced and diversified manufacturer in
features and mounting methods are available kettles, hot water storage tanks and hydronic the electric heating business. Whatever your
for all types of heating requirements. heating systems. heating requirements, you can depend on the
technical know-how of your Chromalox field
SCR and Contactor Control Panels available Freeze Protection Water cooled engines, representatives. Backed by the highly skilled
for integral or remote mounting. Consult stand pipe water tanks for fire protection, oil engineers and modern manufacturing
Controls section for details. sump heaters. facilities, Chromalox field sales engineers can
Heat Transfer Oil Heating Process kettles, help determine your requirements and provide
molding dies and platens, mixing and blending you with high quality equipment, properly
mills, closed-loop heat transfer systems for selected, sized and applied.
asphalt and heat sensitive materials.
Section Outline
Fuel Oil Heating Preheating to pumping Section Page
viscosity, preheating for delivery to burners.
Features C-4
Steam, Air and Gas Heating Steam Terminal Enclosures C-5
superheating, air preheating for process Control Options C-6
More Information equipment. Clean Water Series C-7
Oil Series C-16
is Available Online Special Features Steam, Air & Gas Series C-27
on Tank Heating. Solution Water & Hi-Temperature C-34
Gas Series
Consult your Local Chromalox Sales office for
Bookmark Your Browser to Custom Engineering C-42
more detailed information on many special
www.chromalox.com features, larger kilowatt heaters and skid
and Select Manuals. mounted circulation heater systems.

www.chromalox.com 1-800-443-2640 C-1


Circulation

Circulation Heaters
Selection Guidelines
Selecting a Circulation Heater Application Factors Corrosion Policy
Selecting the proper circulation heater Heater selection is influenced by the following Chromalox will not warrant any electric heater
component requires critical engineering parameters. against failure by sheath corrosion if such
judgement and careful evaluation of the 1 The heated medium, viscosity, specific failure is the result of operating conditions
application. After determining the heat heat, density and corrosive properties. beyond the control of the heater manufacturer.
requirement for a specific heat application, the It is the responsibility of the purchaser to
proper selection of the flange and vessel 2 The presence of contaminants in the make the ultimate choice of sheath material
material, heating element sheath material, and medium. based on his knowledge of the chemical
correct watt density is critical to achieve long 3 The corrosion resistant properties of the composition of the corrosive solution,
heater life. The ultimate selection of equipment heater sheath material. character of materials entering the solution,
is determined by the knowledge of the process and controls by which he maintains the
and engineering acumen of the designer or 4 The sheath watt density of the heating process.
elements the watts per square inch, and
plant engineer. Consult the Technical section
the flow rate of the heated medium.
of this catalog for circulation heater calcula-
tions and guidelines. 5 The vessel design and material pressure
and temperature of the fluid being heated.

Circulation Heaters Selection Guidelines


1 2 3 4 5

Solution or Alkaline or Acid Content Sheath Watt Density Vessel


Application Heater Type (Est. % by Volume) Material (W/In2) Material
Water Clean Water pH6 to pH8 (Neutral) Copper 45 - 100 Galvanized Steel
Mild Solutions Process Water and Very Weak Solutions pH5 to pH9 (2 - 3%) INCOLOY 45 - 86 Stainless Steel
Weak Solutions 5 - 6% INCOLOY 45 - 75 Stainless Steel
Demineralized, De-ionized or Pure Water INCOLOY 45 - 75 Stainless Steel
Corrosive & Mildly Corrosive Solutions 5 -15% INCOLOY 20 - 25 Stainless Steel
High Viscous More Severe Corrosive Solutions 10 - 25% INCOLOY 20 - 25 Stainless Steel
Solutions Severely Corrosive Solutions 30 - 60% INCOLOY 10 - 20 Stainless Steel
Oil Low Viscosity Oils Steel 20 - 25 Steel
Medium Viscosity Oils Steel 10 - 20 Steel
High Viscosity Oils (Fuel Oil) Steel 5 - 15 Steel
Air, Gases Medium Temperatures to 750F INCOLOY 20 - 25 Steel
& Steam High Temperatures to 1400F INCOLOY 10 - 20 Stainless Steel

Typical Applications
Inline Heating Where demands for heated Side Arm Requirements of large storage Closed-Loop Fuel Oil Heating Require-
water or oil are nearly constant, circulation tanks can be satisfied by using a number of ments may be provided by a number of
heaters may be installed directly in the fluid circulation heaters, providing flexibility in circulation units individually adjustable to
line, eliminating the need for storage tanks and temperature control and reducing power temperature and fluid flow, reducing electrical
their related heat losses. demand. demand on your utility bill.

Pressure Relief Valve Return Line to Tank


Shut Off Valve
Pressure Relief Valves Storage Tank
Outlet to
Application Outlet

To Fuel
From Fuel Oil Burner
Oil Tank
Sump
Inlet from
Storage Supply
Strainer
Strainer Thermostat Drain Pump
and Pump Bulbs
(when used) Drain

C-2 1-800-443-2640 www.chromalox.com


Circulation

Circulation Heaters
Selection Guidelines (cont.)
Circulation Heaters Selection Guidelines
Heater/Vessel kW
Application Material Rating Feature Model Page
Clean Water Copper/Galv. 3-5 Oval Flange NWHA C-8
Steel 3 - 18 Screw Plug NWHMT C-9
6 - 500 Flanged NWH C-10
Copper/Steel 1.5 - 3 Booster NWHJR C-12
or Brass
Clean Water INCOLOY/ 0.5 - 40 Field Adjustable NWHSRG C-13
& Oil Cast Iron NWHORG C-14

Circulation
or Galvanized
Pure Water & Stainless/ 3 - 18 Screw Plug NWHMTSS C-35
Mildly Corrosive Stainless
Corrosive & INCOLOY/ 6 - 200 Flanged NWHIS C-36
High Viscous Stainless 2 - 30 Reduced Watt Density NWHOIS C-37
Solutions INCOLOY/ 1.5 - 3 Non-Metallic Body CVCHS C-15
CPVC
Oil Steel/Steel 1.5 - 2.5 Oval Flange NWHOA C-17
Light 3-9 Screw Plug NWHMTO C-18
Medium 1-9 Reduced Watt Density NWHMTOR C-19
3 - 120 Flanged NWHO C-20
30 - 120 Baffled NWHOB C-22
Heavy 3 - 120 Reduced Watt Density NWHOR C-23
20 - 70 Baffled NWHORB C-25
Fuel Oil 30 - 40 Suction, Pump Mount SHO C-26
& Asphalt
Steam, Air & Gas INCOLOY/ 1 - 1.5 Oval Flange GCHAI C-28
Med. Temp Steel 1-9 Screw Plug GCHMTI C-29
1-9 Reduced Watt Density GCHMTIR C-30
3 - 350 Flanged GCHI C-31

High Temp INCOLOY / 2 - 200 Flanged GCHIS C-38
Stainless 30 - 50 Baffled GCHISB C-38
0.5 - 3.0 Low Flow GCHCIS C-40
Pre-engineered Packages Wired & Skid Mounted C-41
ASME & Custom Engineering Specifications (SDS) C-42

Codes & Standards Pressure Ratings 150, 300, 400, 600, 900,
1,500 and 2,500 Lb. Class.
ASME Certification to Sections I, IV and VIII,
Materials 304, 316, 321, 347 Stainless
Division 1 Chromalox is the leader in
Steel, INCONEL and more.
providing ASME (American Society of
Mechanical Engineers) certification for Thermocouples can be provided on element
pressure vessel applications. sheath for overtemperature protection and/or
mounted in the outlet nozzle for process
Underwriters Laboratories UL Listing
control.
available for many circulation heaters. Consult
your Local Chromalox Sales office. Inlet and Outlet Nozzles Available with
Canadian Standards Association CSA flanged or threaded connections, smaller or
certification available including NRTL/C. larger pipe sizes and different orientations.

National Electrical Code (NEC) All Baffles mounted on element bundle inside
Chromalox circulation heaters are built to allow chamber to increase fluid or gas velocity.
NEC installation requirements. Terminal Standoffs in 4, 6 and 8" allow the
terminal enclosure housing and the field
Special Features wiring connection to operate at lower
temperatures in high temperature heaters.
More Information Kilowatt Ratings Large kilowatt circulation Standoffs are frequently used in heat transfer
is Available Online heaters (500 kW and above) are available as and gas heating applications.
single chambers or with multiple chambers in
on Tank Heating. series. Skid mounting and integral control Mounting Saddles for horizontally mounted
panels are also available. circulation heaters.
Bookmark Your Browser to
www.chromalox.com Vessel Construction Chamber size available Weatherproof Insulation Jacket for outdoor
in 10, 12, 14, 16, 18" and above for larger unprotected installations.
and Select Manuals. kilowatt capacities.

www.chromalox.com 1-800-443-2640 C-3


Circulation

Circulation Heaters
Features Basic Construction

Terminal Enclosure

Kilowatt Ratings from 0.5 kW


(500 W) to Over 500 kW (500,000 W)
To Power Supply
Voltage Ratings to 600V Pipe Outlet (Std.)

Pressure Ratings from


150 - 2,500 psig Thermostat (type AR)
Insulation
Temperatures to 1500F (815C)
Pipe Chambers 1 - 18" NPS (or
Larger)
Quality Heating Elements in
Screw Plugs or Flanges for Ease
of Installation
Mounting Lugs Outer Jacket
Sheath Materials include Copper,
Steel, Stainless, INCOLOY and
INCONEL to Suit Most Operating or
Corrosive Environments
Vessel Materials include Carbon
Steel, 304 or 316 Stainless Steel,
Non Ferrous Alloys and High
Temperature Plastics
Heating Chamber
Terminal Enclosures for General
Purpose, Moisture Resistant and Heavy Duty Heating Elements
Pipe Inlet (Std.)
Explosion Resistant Applications
Thermocouples and RTD Sensors
for Process and Overtemperature
Control
Sediment
Wide Range of Mechanical and Drain Plug
Solid State Electronic Controls
including Temperature Controllers
Contactor or SCR Power Panels for Basic Construction
Close Temperature Control (see or threaded end to receive heater assembly
Controls section) and are closed at the opposite end. Larger
Terminal Enclosures E1 General Purpose, units have drain connections to allow sludge
Vertical or Horizontal Mounting sheet metal, painted with red enamel, E2 removal. Inlet and outlet nozzles are provided
with Mounting Lugs or Saddle Moisture Resistant/Explosion Resistant, E3 for circulation of fluid or gas through heater
Supports Explosion Resistant, E4 Moisture Resistant. chamber. Chamber material available in Steel,
Available with High Temperature Controls Stock and assembly stock NWH, Galvanized Steel or Stainless Steel depending
Standoffs and Internal Element NWHO and GCH circulation heaters, models -A, on the application.
Baffles -MT, -3 and -6, are provided with a thermostat Heating Elements Flange or screw plug
mounted on the heater. mounted tubular type heating elements
Custom Designed Skid Mounting,
Multiple Chambers and Integral Mounting Small units supported by inlet offered in Stainless Steel, Copper, Steel or
Control Panels and outlet piping; larger units provided with INCOLOY sheath to suit corrosive resistance
mounting lugs for support. requirements.
ASME Certification Section I, IV
or VIII, Division 1 Wiring Connections All Chromalox
Outer Jacket Constructed of heavy gauge
painted steel sleeving which contains high circulation heaters are provided with internal
UL, CSA and Other Third Party
temperature thermal insulation to reduce heat wiring and power connections that are sized in
Approval, Listing or Certification
Available on Many Models losses from heating chamber. accordance with wiring tables in the National
Electrical Code. For safe operation of the
Heating Chamber Pipe chambers (150 Lb heaters, all external wiring should also be in
welded construction, standard) have a flanged accordance with NEC, state and local codes.

C-4 1-800-443-2640 www.chromalox.com


Circulation

Circulation Heaters
Terminal E4 Moisture Resistant Enclosure Suitable
for outdoor or wet locations. The terminal
Typical Terminal Enclosures

Enclosures covers are provided with water-tight gaskets


to seal the electrical terminals and connections
B

from the environment.


A
Special Requirements for Electric
E1 General Purpose
Heaters & Terminal Enclosures in
E2 Moisture Resistant/Explosion Hazardous Locations:
General Purpose, Type E1
Resistant
Wiring The proper use of Type E2 and E3 B
E3 Explosion Resistant terminal enclosures on electric heaters located
in hazardous areas requires that all electrical

Circulation
wiring comply with National Electrical Code
E4 Moisture Resistant A
(NEC) requirements for hazardous locations.
Conduit Openings Matched Maximum Temperatures Safe operation in
to the Number of Circuits a hazardous location requires the maximum
operating temperatures of all exposed Explosion Resistant, Type E2/3
for Series 3 heaters
surfaces of the heater including temperatures
on the outside of the vessel, piping, flanges, B
Applications screw plugs, enclosures and other heat
conducting parts be limited. The maximum
The versatility of electric heaters permits
surface temperature permitted in any
them to be used in almost any conceivable A
hazardous location is determined by the
location indoors or outdoors, exposed to the
flammable liquids, vapors or gases present.
weather. Chromalox provides a variety of
The end user or purchaser of the electric
electrical terminal enclosures to match the
heating equipment is responsible for deter- Explosion Resistant, Type E2/3
unique requirements of virtually any for Series 6 heaters
mining the proper classification of an area and
environment.
for providing Chromalox with hazardous area B
Features specifications and requirements for proper
equipment design. (NEC Articles 500 and 501
E1 General Purpose Enclosure Suitable provide guidelines for evaluating and
A
for most indoor or protected commercial and classifying hazardous locations.)
industrial applications.
Safety Devices Approved pressure and/or
E2 Combination Moisture Resistant and temperature limiting controls must be used on
electric heaters and heating elements to Explosion Resistant, Type E2/3
Explosion Resistant and E3 Explosion for Series 8 and larger
Resistant Enclosures Type E2 and E3 ensure safe operation in the event of system
malfunctions. B
explosion resistant terminal enclosures are
intended for use in hazardous locations
Note 1 Class I Group B locations include
including:
Hydrogen gas. These areas require additional A
Class I Groups C & D, Div. 1 & 2 conduit seals and thread engagement. Contact
your Local Chromalox Sales office for heaters
Class I Group B1, Div. 1 & 2 and terminal enclosures suitable for Class I
Group B hazardous locations. Moisture Resistant, Type E4
Class II Groups E, F & G, Div. 1 & 2
typical for all heaters except Series 3
Class III, Div. 1 & 2.
Type E2 terminal enclosures are provided Terminal Enclosure Dimensions (Inches)
with gaskets and are suitable for outdoor or Dimensions (In.)
wet locations as well as hazardous areas. No. E1 General Purpose E2/3 Moist./Explos. Resistant E4 Moisture Resistant
Series Elements A B A B A B
3 3 4 3-1/2 4-1/4 5-3/8 4-1/4 5-3/8
6 6 6-11/16 3-1/2 5-3/4 6-15/16 3-9/16 6-3/4
18 18 9-13/16 5-3/8 9-1/2 10 10 5-11/16
27 27 11-3/16 6-9/16 10-1/2 9-1/8 12 5-11/16
36 36 13-3/16 6-9/16 12 9-1/8 12 6-5/16
45 45 15-3/16 6-9/16 14 9-1/8 14 6-5/16
72 72 17-3/16 6-9/16 18 10-1/8 18 7
108 108 19-3/16 7-7/8 20 10-1/8 20 7

www.chromalox.com 1-800-443-2640 C-5


Circulation

Circulation Heaters
Mechanical & Elec- Control Panels Integral or remote mounted
control panels with electronic controls and
Magnetic Contactors Heaters utilizing two
or more circuits or with amperage draw that
tronic Control Options solid state (SCR) or contactor power control-
lers can be provided using virtually any
exceeds the thermostat rating will require a
contactor(s). Contactors are ordered sepa-
combination of control devices. Consult the rately and mounted remote to the heater.
Controls Section for details. Consult the Controls Section for details.
Wide Range of Mechanical and
Overtemperature Protection Electronic Process Control Thermocouples
Electronic Control Options
De-energizing the heating elements when Thermal sensors can be mounted in a tee
sheath temperatures exceed recommended on the heater outlet nozzle. Electronic
NEMA 1, 4, 7 and 12 Enclosures limits can prevent element damage and extend controller is remote mounted. Option also
the life of the heater. A thermal sensor can be available with process controller mounted on
Process Controllers - Integral or attached to the element sheath for overheat the heater insulation jacket.
Remote with the Sensor in the protection. Properly connected to a solid state
Heater Thermowell (AR Control) high limit controller, the sensor will turn the
or in the Heater Outlet heater off in the event of a low-flow or no-flow
condition. Type J thermocouples are recom- T/C
High Limit Controllers - Integral mended for liquid and type K for gas applica-
or Remote, Sensor in the Heater tions. Outlet
Thermowell (AR Control) or
Welded to Element Sheath Remote Mounted Electronic Control
Tee
Optional Controller Location
Type J or K Thermocouples
Element
(Std.) RTDs and Other Type
Thermocouples Available Ordering Information To order circulation
heaters with electronic controls, specify
Mechanical and Electronic model, volts, kW and provide the following
Controls can be Combined information.
Expansion Loop
Magnetic Contactors for Multiple Electronic Control Check List
Circuits and High Amperages Overtemperature thermocouple: Yes No
1/8" Dia.
High temperature limit controller: Yes No
Stn. Stl. Sheath
Controller Model No.
Applications 2
Mounting: Integral Remote
Mechanical and Electronic Controls & Sensor
Process control thermocouple: Yes No
Thermal Sensors can be provided for all
circulation heaters for overtemperature Type:
protection for the heater and fluid medium Location:
and/or for process control. High Limit Controls Electronic high limit
controls can be mounted on the heater Process controller: Yes No
Control Selection Guidelines chamber with an overheat thermocouple Controller Model No.
welded to heating element sheath inside the
AR Controls Type AR bulb and capillary chamber. This arrangement provides protec- Mounting: Integral Remote
controls are standard on many stock heaters tion by shutting down the heater at a predeter-
with temperature ranges as indicated in the mined element sheath temperature. Option Assembly Stock Delivery Where heaters
product descriptions. These rugged non- also available with thermocouple only, welded are listed as Stock (S) or Assembly Stock (AS),
indicating controls are suitable for most or clamped to heater element sheath as shown electronic control options are available as
applications. Optional temperature ranges are above. assembly stock delivery. When heaters are
available. Consult the Controls Section for
listed with a standard mechanical Type AR
details.
thermostat, the thermostat will be provided on
Electronic Controls Electronic process the heater unless otherwise stated.
controls provide greater control accuracy and Note Circulation heaters with a screw plug
operating system flexibility than is available header - Series NWHSSMT, NWHMT,
with mechanical controls. Consult the NWHMTO and GCHMT are not available as
Controls Section for details. assembly stock with a thermocouple welded to
High Limit the element sheath.
Controller Outlet

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