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HOT WATER/WATER-GLYCOL SYSTEMS: SAFE BY DESIGN 

An Improperly designed water/water-glycol heat transfer system can present a safety hazard for personnel. The existence of these hazards has resulted in the development of a wide range of codes and standards covering the design and Installation of water-water/glycol systems. These codes and standards are now requirements for most local building codes, Insurance companies and thermal fluid manufacturers.  

SAFETY Is at the core of HEAT's design philosophy. There Is no compromise on the safety and well-being of our customers nor should our customers be exposed to additional liability that comes with installing a water-water/glycol system that does not meet the requirements of the fluid manufacturer or Insurance company.  

HEAT encourages our customers to check with their local codes, Insurance providers, and obtain design guides that most fluid suppliers have available. Most likely the following codes and standards will apply to the design and Installation of new water-water/glycol systems: 

  • ASME - Boiler & Pressure Vessel Code - Applies to all vessels operating at over 15 PSIG.
  • NFPA 70 - National Electric Code
  • NFPA 79 - Electrical Standard for Industrial Machinery 
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Heat Standard Design Practices

 

PIPING SYSTEM STANDARD PRACTICES: Threaded and/or welded construction, Seamless Schedule 40 & extra heavy piping, threaded/socket and butt weld fittings, raised & flat face flanges, spiral wound gaskets, high strength studs and nuts, bronze & forged steel valves, pneumatic, hydrostatic, and hot functional leak tests of piping. 

BENEFITS: Meets material requirements of ANSI B31 Piping Code, reduces need for maintenance, meets requirements of insurance providers, ensures material compatibility with heat transfer fluids 

INSULATION STANDARD PRACTICES: Use of non-wicking cellular glass, fiberglass, or rubber insulation on heater chamber and all internal piping, jacketing with PVC. 

BENEFITS: Increases energy efficiency, reduces energy cost, meets insurance requirements, meets personnel protection safety codes 

EXPANSION TANK STANDARD PRACTICES: Located at the highest point of a system, designed as a pressure vessel, oversized venting, air-bleed vent, liquid level gauge, nitrogen blanketed based on fluid vapor pressure, ASME stamped as required by code. Pre-charged Bladder Tanks can be substituted in place of expansion tanks and are typically located on the skid up to temperatures of 240°F    

BENEFITS: Facilitates system fill, venting and start up, meets codes and insurance requirements, reduces maintenance, increases fluid life, meets requirements of thermal fluid manufacturers. 

HEATER STANDARD PRACTICES: Stainless-steel heater elements. Heat flux density from 38 to 43 w/in2 based on fluid film temperature, flow baffles to increase velocity over elements, chamber designed as a pressure vessel, high-limit sensor on element sheath, ASME stamped as required by code. 

BENEFITS: Increases life of heater, meets codes and insurance requirements, reduces maintenance, increases fluid life, meets requirements of thermal fluid manufacturers.  

PUMP STANDARD PRACTICES: Centrifugal pump with air-cooled mechanical seals, TEFC motors, flanged or NPT connections, flow- and head-pressure based on application requirements. 

BENEFITS: Reduces risk of over-pressure condition, increases fluid life, reduces maintenance, meets requirements of fluid manufacturers. 

CONTROLS STANDARD PRACTICES: NEMA rated enclosures, main power disconnect, branch circuit protection, SCR power control, high-limit safety controller, digital temperature controller, appropriate conduits to each component, fused control voltage transformer, built to NEC. 

BENEFITS: Increases energy efficiency, better temperature control, increases heater life, increases fluid life, meets codes and insurance requirements, reduces maintenance, meets requirements of fluid manufacturers.  

OPTIONAL COOLER STANDARD PRACTICES: Parallel or In-Series cooling circuit, ASME shell & tube or plate & frame style heat exchanger, 3-way diverting control valve or 2-way cooling media control valve. 

BENEFITS: Eliminates thermal shock, better temperature control, longer equipment life, increases safety, meets codes and insurance requirements, reduces maintenance. 

HOT FUNCTIONAL TEST STANDARD PRACTICES: Prior to shipment, water/water-glycol systems are filled and given an operational test at the system’s design temperature. The customer is invited to witness this factory test. 

BENFITS: Ensures functionality of all components and controls, eliminates potential start-up problems, Opportunity for customer inspection and training. 

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