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  1. Understanding Finish Requirements for Shell and Tube Heat Exchangers

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    When hiking, it is important to understand the terrain before setting out. Scaling the Rocky Mountains is far different than taking a leisurely stroll around the block. And the physical endurance required for each will provide drastically different results.

    This is just as true in stainless-steel manufacturing and finishing procedures.

    Metals are not completely flat, as they appear. When looked at under a microscope, there are peaks and valleys over the entire surface, much like the peaks and valleys of a mountain range. The average of those peaks and valleys is referred to as the Ra value. The higher those peaks and valleys, the duller of a finish. The lower the peaks and valleys, the shinier the finish.

    The Ra and grit (size of the abrasive) will result in different internal and external design features and function of Enerquip’s thermal designs. Finishes can be optional but are often required for different applications and industries. We can help you determine the best option for your solution.

    Enerquip’s Stainless Steel Finish Options

    Painted Finish (Exterior)

    Depending on the customers preference, we can paint the exterior of our shell and tube heat exchangers. This is done by thoroughly cleaning the exterior, then sanding, priming, and painting the exterior to a uniform finish.

    Sand Blasted Finish (Exterior)

    Sand blasting involves propelling small particles of abrasive material, such as sand, at high speed against the surface being treated. This process removes the top layer of the material, leaving a matte or satin finish with a uniform texture. Sand blasting is commonly used to create a specific surface texture for aesthetic or functional purposes.

    When sand blasting isn’t required, an unpolished or mill finish may be all you need.

    Mill Finish (Interior or Exterior)

    Mill finish surfaces are “as-machined” with an unpolished, matte appearance. This is the standard, basic supply condition for all stainless steel. The welds are cleaned to remove discoloration where accessible.

    This type of finish does not meet sanitary finish requirements and cannot be used in food contact. Threaded connections can be used on the tube side for non-sanitary applications such as hot water sets.

    For sanitary applications, some kind of polishing will be required. Keep reading to learn about those.

    Sanitary Finish (Interior or Exterior)

    Polishing involves using abrasive materials, such as polishing compounds, to smooth and shine the surface. This process removes surface scratches and other imperfections and creates a high-gloss, mirror-like finish. From a cost perspective, polishing the exterior of an Enerquip heat exchanger to 40Ra is more cost effective than its less aesthetically appealing mill finish counterpart.

    This sanitary finish uses a 150-grit abrasive and appears as a semi-polished, brushed surface.

    Enerquip’s product contact surfaces are 32Ra or better, except for the tubes which are ASME SA-249 bright annealed. Our exterior finish is 40Ra or better.

    This finish is acceptable for food, beverage and CIP.

    3-A Sanitary Finish (Interior or Exterior)

    The 3-A dairy finish uses a 180-grit abrasive and meets the 3-A Dairy Sanitary standard 12-08 finish requirements of 32Ra or better, including SA-213 seamless tubing. Our exterior finish is 40Ra or better.

    This is the finish requirement for dairy applications.

    BPE/Pharmaceutical Standard (Interior or Exterior)

    The BPE standard was created to instill continuity and standardization in the pharmaceutical industry. Our Biopharmaceutical designs meet ASME BPE-2022 standards. Enerquip’s double (gap-type) tubesheets feature SA-213 seamless tubing and sloped foot supports for draining. Units are bright polished, and process or surface roughness can be specified, including:

    • SF1 20Ra, SF2 25Ra, SF3 30Ra (mechanically polished)
    • SF4 15Ra, SF5 20Ra, SF6 25Ra (mechanically and electropolished)

    Electropolish (Interior or Exterior)

    This finish is uniform, highly reflective, and smooth. The process of electropolish involves immersing the stainless steel in an electrolyte bath in which the metal acts as an anode, removing a layer of metal and smoothing the surface.

    If you’re looking for a thermal solution, leave the design specifics to us. Call 715-748-5888 or email sales@enerquip.com today.

    More from the Enerquip Blog

  2. Herman Promoted to Enerquip’s Director of Business Development

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    Enerquip is excited to announce the promotion of Ron Herman to Director of Business Development. He previously led Enerquip’s Sales Engineers; a role recently assumed by Troy Weik.

    A customer-focused seasoned sales leader, Herman enjoys the challenge of leading business development efforts to meet aggressive growth plans. Since joining the Enerquip team in 2010, his competitive nature and technical knowledge have allowed him to develop sales initiatives for rapid profitable growth.

    “Enerquip has been so fortunate to have Ron’s determination and knowledge on the team for the past decade,” says Jeannie Deml, President & CEO at Enerquip. “We’re excited to see what the next decade holds.

    Throughout Herman’s extensive career, he’s specialized in commercial negotiations, national account management, custom thermal design of stainless steel and high alloy process equipment, strategic alliances, process solutions, and project management.

    “I have a sincere interest in developing solutions that make customers’ operations run better,” says Herman. “I enjoy bringing peace of mind, trust and confidence to the clients I work with.”

    A graduate of the University of Wisconsin – Stevens Point, Herman earned his Bachelor’s degree in Paper Science Engineering & Business.

    Ron and his wife, Becky, reside in Medford. They have five adult children and four grandchildren. Herman’s hobbies include hunting and fishing, spending time at his cabin, and growing trophy whitetails.

  3. Weik Joins Enerquip’s Sales Leadership Team

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    Enerquip is pleased to announce Troy Weik has joined its team as Sales & Channel Manager. In this role, Weik will provide leadership to Enerquip’s highly skilled and engaged sales engineers, while also fostering relationships with business partners and representatives.

    Weik has stepped into the shoes of Ron Herman, who has accepted the opportunity to focus on new business strategies as Director of Business Development.

    Weik brings 30 years of process engineering and operations management experience to Enerquip. Most recently, he worked as Director of Sales & Marketing at Membrane Process & Controls in Edgar and before that was Director of Operations at A&B Process Systems in Stratford.

    He’s gained experience in a variety of areas including sales, engineering, operations, and project management. Over his career, Weik has worked with partners in the dairy, food, beverage, chemical, and pharmaceutical industries.

    “We’re so excited to welcome Troy to the Enerquip team,” says Jeannie Deml, President & CEO at Enerquip. “The knowledge and experience he brings will help bolster our already stellar sales team.”

    A graduate of the University of Wisconsin – Madison, Weik earned his Bachelor’s degree in Industrial Engineering. A native of Park Falls, Weik has called Marshfield home since 1997. He enjoys hunting, fishing, being outdoors, and Badger sports. Weik, his wife, Kari, and their children appreciate everything northern and central Wisconsin has to offer, including lake life.

    “I am thrilled to assume this new role with Enerquip,” says Weik. “I’m excited to bring the best shell and tube heat-exchanger solutions to our current and future customers.”

  4. Benefits of Tank Coils with Helically Wound Fins

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    Tank heating coils are an imperative component of the industrial heating equipment your facility relies on every day. As experts in the industrial heating industry, we’ve spent decades honing our craft and developing efficient, innovative heating technology that our clients and customers can rely on.

    We take great pride in creating tank heating coils that are engineered to meet our client’s needs while also being among the most reliable and longest lasting on the market.

    In the decades we’ve spent designing and manufacturing hot oil heating equipment, it has been proven over and over again that tank coils featuring helically wound fins are the best way to go.

    Here, we’ll delve into exactly what makes helically wound fins the best option when it comes to tank heating coil design.

    Advantages of Helically Wound Tank Coil Fins

    There are a handful of key benefits to tank coils with helically wound fins. These advantages include:

    Better Heat Transfer

    Our experience with heating coils used in various applications has proven that horizontally installed helically wound fin tubes have nearly double the heat transfer rate compared to horizontally installed longitudinal fins.

    If you’re looking to transfer heat more effectively within your tank, investing in tank coils with helical fins is a good option. The heat transfer coefficient for a helically finned pipe is about twice that of a longitudinally finned pipe. As a result, it will take about half as much surface area for a helical finned tank coil to do the same heating as a longitudinally finned tank coil.

    Reduced Cost

    Cost is often an important deciding factor when it comes to selecting industrial heating equipment for your plant or facility. Despite the fact that tank coils with helically wound fins tend to be the better option from an operational and performance standpoint, they are also typically the better option from a cost standpoint.

    As mentioned above, because tank coils with helically wound fins can deliver twice the amount of heat transfer to the tank product when compared to coils with longitudinal fins, half as many coils are required to achieve the same result. For this reason, they typically cost less to both manufacture and install, which can result in significant savings. Combined with their higher efficiency, which can provide savings over the long run as well, this is a compelling advantage in favor of helical fins.

    Higher Efficiency

    Speaking of higher efficiency, tank fins with helically wound coils are significantly more efficient than both tank coils with longitudinal fins and bare pipe tank coils.

    a helically wound coil after decades of proper use

    A tank coil with a helical fin after decades of use. Proof that fouling does not occur when using the right fin and operating the tank coils the right way!

    Because tank coils with helically wound fins have 2x better heat transfer than tank coils with longitudinal fins, they operate much more efficiently, which can result in energy savings in the long run.

    When it comes to bare pipe coils, adding helical coils can provide 12x greater surface area per foot of pipe. This means you can heat a tank much more efficiently and will need significantly less pipe to heat the tank, which can provide cost savings as well.

    Reduced Coking

    One of the biggest advantages of tank heating coils with helically wound fins is the lack of coking that occurs. Tank coils with longitudinal fins have stagnant flow areas that occur between the fins. These ‘dead spots’ are prime targets for coking.

    Because of their unique design, tank coils with helical fins are significantly less likely to coke. Reduced coking means you’ll have to worry less about tank coil replacement. Helically wound tank coils can last for decades without requiring repair or replacement.

    Need Tank Coils You Can Rely On? Invest in Tank Coils with Helically Wound Fins.

    With more than 30 years of experience building heating equipment for a wide variety of industries and applications, we’re confident in saying that tank coils with helically wound fins are the way to go if you’re looking for an efficient and reliable solution.

    Interested in learning more about tank heating coils? Read on.

    Industrial Tank Heating Coil FAQs

    Tank Heating Coils Designed for Long-Lasting Efficiency

    Benefits of Enerquip’s Tank Coil Design

    Have questions about tank coils for your specific industry or application? Let’s talk! Just give us a call at (715) 748-5888 or contact us online to get the conversation started.

  5. Industrial Heat Exchanger FAQs

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    Heat exchangers are key elements of industrial heating systems for facilities in a variety of industries. Alongside other major pieces of industrial heating equipment, like thermal fluid heaters, heat exchangers serve to transfer heat between fluids and gases, making various processes possible. 

    Looking to learn more about heat exchangers? You’ve come to the right place. Here, we’ll delve into the basics of heat exchangers and answer some commonly asked questions about these important industrial heating system components.

    Answers to Frequently Asked Questions About Heat Exchangers

    What Do Heat Exchangers Do? 

    In the simplest of terms, heat exchangers transfer heat between fluids of different temperatures within the context of an industrial process. 

    What Are Heat Exchangers Typically Used For? 

    The industrial uses of heat exchangers vary widely, especially given that they are used in many different industries and processes. 

    That being said, heat exchangers often work in conjunction with other heating system components in order to regulate the temperature of viscous fluids like oil and asphalt. There are a few different types of heat exchangers, each used in a slightly different way to transfer heat between materials. 

    What Are The Different Types of Heat Exchangers? 

    Industrial heat exchangers come in a variety of sizes and styles, including: 

    • Bayonet Heaters: This type of heat exchanger attaches to the side of a tank. They have the capacity to heat an entire tank filled with fluid.
    • Shell and Tube Heat Exchangers: These heating system components are designed to heat fluids from outside the storage tank through the use of hot oil or steam.
    • Suction Heaters: These are designed to heat fluids as they are pumped, rather than heating an entire storage tank of material at once. They use hot oil or steam.  

    You can learn more about the specifics of each type of heat exchanger here.

    How Can You Determine Which Type of Industrial Heat Exchanger You Need? 

    The main way to figure out which type of heat exchanger will work best for you is to think about the application it will be used for. Uses vary from industry to industry, so another good option is to talk to others in your industry to determine which option has worked best for them. 

    It’s also a good idea to reach out to an industrial heating equipment company (like us) to find out if there might be a specific heat exchanger or customized solution that will work best for your scenario. 

    This resource is a good place to start when it comes to choosing the best heat exchanger option for your facility.

    Can Heat Exchangers Be Customized?

    Absolutely! While many companies offer standardized heat exchanger options, heat exchangers are customizable and can be custom built if necessary. 

    If you’re looking for a custom solution to work for your facility, don’t hesitate to reach out. We often build completely customized solutions for our clients so we are used to designing equipment that meets specified needs and specifications. 

    What Are Some Signs That My Industrial Heat Exchanger is Failing and Might Require Replacement? 

    There are a number of signs to look for that may indicate that your current industrial heat exchanger is failing. A few signs include: 

    • Loss of efficiency
    • Change in the rate of heat transfer
    • Physical damage, such as cracks or erosion
    • Leaking fluid

    If you come across any of these signs, it’s worth further investigation to determine the cause and correct the issue, either through repair or through heat exchanger replacement.

    Looking for Additional Details About Industrial Heat Exchangers?

    Interested in learning more about our industrial heat exchangers? These resources are a good place to start: 

    Industrial Heat Exchangers from Enerquip – Find additional details about the various heat exchangers we offer, including customized solutions.

    What Type of Heat Exchanger Do You Need? – Explore the similarities and differences of the various heat exchangers we have available to determine which option may be right for your facility and application. 

    Have a question about heat exchangers that you don’t see answered here? Just give us a call at 715-748-5888 or request a quote and we will be happy to provide the information you’re looking for! 

    Interested in other FAQs about thermal fluid heating equipment? Check out our other industrial heating system FAQ pages here.

  6. What is ASTM Code and Why Does It Matter?

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    Shopping your options for industrial heating equipment? No matter what industry you’re in, there are many codes and standards to carefully consider as you’re deciding which type of heating system will work best for your facility. 

    Here, we will provide a general overview of ASTM code so you can understand what it is, its importance when it comes to industrial heating systems, and why it matters when you’re shopping for equipment for your facility.

    What is ASTM Code?

    ASTM currently stands for ASTM International but was originally an acronym for American Society for Testing and Materials. ASTM is an organization that defines and publishes technical standards related to the quality of materials that can be used in the manufacturing of various products and pieces of equipment.

    ASTM code is made up of the standards that have been developed by committees within ASTM. These standards are designed to improve both the safety and quality of products intended for consumer and industrial use.

    The standards developed by ASTM are often adopted into other codes and are made mandatory by other regulations. ASTM does not enforce the requirements they have established for the materials and products to which they apply. 

    It’s important to note that ASTM code is relevant outside of the industrial heating industry as well. It is not an industry-specific code. 

    Why is ASTM Code Important for Facilities Using Heating Equipment?

    While ASTM code may not be specific to the heating equipment industry, it is still relevant and important to those shopping for hot oil heaters and other heating system components. If the equipment you’re investing in meets ASTM standards, this ensures that it is built with high quality, approved materials.

    ASTM standards are highly regarded. If you consider only equipment that is ASTM code compliant, you can shop with confidence knowing that the heater or heating system you ultimately invest in will meet high standards for quality and durability. This is a significant advantage, especially given that industrial heating equipment is such a sizable investment.   

    What Other Codes and Standards Are Relevant to Heating Equipment?

    Besides ASTM code, there are a variety of other codes and standards that are relevant to the industrial heating industry. If you’re in the market for new hot oil heating equipment, here are a few other standards and affiliations you may want to pay attention to as you’re shopping your options: 

    API Specifications – API standards are especially relevant to the oil and natural gas industries. They encourage safe operating practices and outline equipment specifications that are geared towards ensuring that facilities operate as safely as possible. 

    ANSI Code – Like ASTM code, ANSI code is not specific to the industrial heating industry, but it is still very relevant to those investing in large scale heating equipment. ANSI guidelines help to standardize the features, performance levels and safety of products created in the United States.

    ASME Code – ASME code (also known as ASME Boiler & Pressure Vessel Code) regulate the design, development and manufacture of boilers and pressure vessels that are used in a variety of industries. These are important safety and quality standards for heating equipment.

    AISC Membership – AISC stands for the American Institute of Steel Construction. This organization works with its members and affiliates to increase the domestic use of structural steel manufactured in the USA, and develops codes, standards, and specifications that govern the structural steel industry throughout the US and beyond.

    Code-Compliant Commercial Heating Equipment You Can Count On

    At Enerquip, we are passionate about designing and manufacturing sanitary and industrial heating and cooling equipment our customers can rely on. We know our stuff when it comes to the codes and standards that govern our industry, as well as the industries we serve. 

    If you’re shopping for heating equipment for your plant or facility, we can help you shop with confidence knowing that the equipment you invest in satisfies the appropriate and required standards for your industry. 

    Have questions about industrial heating equipment codes? Give us a call today at (833) 516-6888 and we’d be happy to discuss, or contact us online to get the conversation started. 

    Interested in learning more about the codes and standards that may be relevant to your equipment? Be sure to check out our resources about heating equipment codes and standards for helpful insight, as well as code comparisons to help you understand the similarities and differences between the various guidelines.

  7. Why You Shouldn’t Wait Until the Last Minute to Replace Your Hot Oil Heater

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    With hot oil heaters and industrial heating systems in general being such a significant investment, it’s not surprising that many facility managers are tempted to wait until the last minute to replace equipment. 

    But while it’s understandable in theory, in practice it’s actually not the best idea. 

    Although it may seem sensible to utilize your existing equipment until it’s no longer possible to do so, it’s actually much more advantageous to replace your hot oil heating equipment before it has lost functionality and your facility is left in the lurch. 

    Why shouldn’t you wait until the very last minute to replace your industrial hot oil heater? We explore a few key reasons why you should take action to upgrade your equipment before your hot oil heater truly fails.

    7 Reasons You Should Consider Replacing Your Industrial Hot Oil Heater BEFORE It Fails

    There are many benefits to replacing equipment before it becomes completely obsolete or loses functionality. Here are 7 of the many reasons you should take action sooner rather than later if you’re anticipating having to replace your industrial thermal fluid heater.

    The longer you wait, the longer your facility will be operating at less-than-ideal efficiency.

    Efficiency tends to fade as equipment ages. As a result, older equipment functions less efficiently in many cases – and if your older equipment is beginning to show signs that it is in need of replacement, there’s a good chance your facility’s efficiency is suffering.

    The sooner you replace your hot oil heater, the sooner you’ll upgrade your efficiency. You’ll lose efficiency for longer-term if you choose to wait on heater replacement. 

    Dysfunctional equipment raises additional safety issues.

    If you continue operating an industrial hot oil heater that’s on its way out or is damaged or defective in any way, you’ll find that serious safety issues can arise. It’s always better to replace sooner and avoid potentially dangerous and catastrophic problems caused by a heater that’s no longer functioning at 100%.  

    Outdated hot oil heaters with issues fail more frequently.

    With equipment that’s aging, approaching obsolescence, or just not functioning entirely correctly, chances are you’ll see an uptick in unexpected and unplanned equipment failures. Sometimes, especially with large-scale, imperative pieces of equipment like industrial hot oil heaters, it’s better to cut your losses and replace the equipment before unplanned facility outages start to take a toll on your plant’s profitability and productivity. 

    Unexpected equipment failures can cause unplanned facility outages.

    It’s often easier to plan ahead for an outage than it is to have to accommodate an unexpected outage last minute due to the failure of a piece of equipment.

    As a result, despite the fact that equipment replacement is an inconvenience that you may be tempted to put off as long as possible, a planned replacement and facility shutdown is actually much more convenient than an unplanned one! Being proactive about hot oil heater replacement gives you significantly more control over the situation.

    Repair or replacement may become more challenging the longer you wait.

    As equipment ages, it becomes more and more challenging to find compatible system components or suitable replacement parts. When failure occurs and upgrades are necessary, you may find that the upgrades are more challenging and/or more intensive the longer you have waited to address them. For this reason, upgrading your industrial equipment sooner rather than later is often advantageous.

    Not planning ahead for equipment replacement can mean increased facility downtime.

    Planning ahead for a repair – rather than waiting for a complete failure to necessitate it – can ultimately reduce facility downtime. Again, you’ll still have to handle the equipment upgrade, but doing so on your timeline and with some preparation can reduce plant downtime which can help you keep profits and productivity up despite needing to tackle a large-scale repair.

    Delaying a replacement can ultimately make replacement more expensive.

    Yet another perk of planning ahead for a replacement is cost-savings. If you handle your equipment replacement in a timely manner – before failure is imminent and you need to handle the situation urgently – you can avoid paying more to expedite the process. 

    While upgrading an industrial hot oil heater is certainly costly, there is a financial incentive to handle equipment replacement responsibly and ahead-of-time. Having to handle the situation as an emergency, which may require expedited equipment delivery, overtime for installation professionals, and other added expenses, can have costly consequences.   

    Don’t Wait To Replace Your Industrial Hot Oil Heater!

    If your heater – or another piece of your industrial heating system – is on its way out, resist the temptation to put off repair or replacement. There could be significant consequences for doing so, and there are numerous advantages to handling equipment upgrades in a timely fashion. It’s almost always beneficial to have handled your hot oil heater upgrade sooner rather than later! 

    Think a hot oil heater upgrade might be around the corner for your facility? Here are some signs to look out for that can indicate it’s time to upgrade.

    Wondering if repair or replacement is the right choice for your heating system? Review some key things to consider when it comes to repair vs. replacement here.

    Ready to take the first step towards securing a hot oil heater replacement for your plant? We’re here to help! Our team has decades of experience custom designing heaters for facilities in various industries. We can help you find the thermal fluid heater you need to keep your plant up and running! 

    Give us a call at (715) 748-5888 or contact us online to get the conversation started.

  8. Steam Generator FAQs

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    Thinking about investing in a new steam generator for your facility? If you’re early on in the process of shopping for this new piece of equipment, you likely have some questions in mind that you’re mulling over. And we’ve got answers! 

    As leaders and innovators in our industry, we know a lot about what it takes to build efficient, durable industrial heating equipment. Our products have been known to last for decades! 

    In the market for a steam generator? Read on to find answers to some of the most commonly asked questions we hear about steam generators. 

    Answers to Frequently Asked Questions About Steam Generators

    How do steam generators compare with boilers?

    Steam generators can meet a facility’s steam needs without the requirement of a boiler operator in most cases. This can contribute to a significant cost savings when compared to a boiler system, which often requires the presence of a licensed boiler operator that can cost a company six-figures each year.

    Enerquip Steam Generator

    Enerquip Steam Generator

    Additionally, steam generators don’t require an emissions permit while most boilers do. Securing a permit can be a huge headache for facilities that rely on boilers, so avoiding that headache by choosing a steam generator instead can be hugely advantageous.

    Steam generators also don’t have a burner, which means facility operators who choose steam generators over boilers can avoid the challenges of running gas lines, gas fuel trains, burners, the burner panel, and all the controls. 

    Boiler burners require a lot of maintenance in comparison to steam generators, which operate using a simple and reliable valve that opens and closes when more or less steam is needed. With fewer moving parts, there are fewer complications and operational issues that can arise.

    Overall, while steam generators and boilers serve similar functions, steam generators are a great alternative for those who need steam for their facility but do not want to invest in a large-scale boiler operation. Those can be very pricey and inconvenient for a variety of reasons, making steam generators the better option in most cases.

    What are the main advantages of steam generators?

    Thermal fluid steam generators offer a number of advantages over boiler systems. Some of these benefits include: 

    1. Affordability: Steam generators are typically more affordable than boilers.

    2. Efficiency: Steam generators heat up and operate more efficiently than some of their alternatives.

    3. Safety: Steam generators don’t produce explosive gases or include a gas fuel train.

    4. Minimal maintenance: Steam generators don’t include a burner, which would need to be serviced regularly. They also have fewer moving parts and operate more simply, which means less potential for operational issues that can slow your facility down.

    5. Fewer permits: Steam generators don’t require a burner or stack permit. This is a big advantage, as securing these permits can be a huge headache.

    6. Cost savings: Steam generators typically don’t require a boiler operator on site, saving your facility thousands of dollars a year since you won’t have to keep an additional professional on your payroll. 

    You can read more about the key features and advantages of steam generators here.

    What types of facilities use steam generators?

    Steam generators can be used in a wide variety of applications throughout various industries. They are versatile pieces of equipment that can be used to create power to fuel many different industrial processes. As such, they are used in dozens of types of facilities, including:

    Are steam generators and boilers the same thing? 

    While they often serve very similar functions and can be used in the same or similar contexts, steam generators and boilers are not the same thing. 

    As mentioned previously, in many contexts steam generators offer a number of advantages over boilers, including cost savings both up front and throughout the duration of operation. 

    Are custom steam generators available? 

    We understand that many facilities are looking for specific and unique solutions that resolve a problem, serve a particular purpose, or are compatible with the existing equipment set up. As a result, we take pride in creating customized industrial heating solutions for our clients and customers. 

    Our steam generators can be custom built to meet the needs of your plant or facility. We’d be happy to work with you to design a steam generator solution that meets your specifications.

    Your Steam Generator Questions Answered!

    Our engineers are proud to build durable, reliable, and long-lasting heating equipment – and with 30+ years of experience doing so, our team has developed a breadth of knowledge that we’d be happy to put to work for your business! 

    Have additional questions about steam generators? Think an Enerquip steam generator might be just what your facility needs to take your efficiency and productivity to the next level? Don’t hesitate to contact us today! 

    Contact us and we’d be happy to answer your questions and/or discuss how our team can design and manufacture a steam generator to meet your facility’s specifications.

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  9. Floating Tube Sheet Straight Tube Exchangers – Advantages and Types

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    Inspecting and maintaining shell and tube heat exchangers is important to ensure that they work efficiently and safely, and to prevent costly downtime from plugged tubes or leaks. In situations where disassembly is preferred to inspect and clean all the parts of the exchanger, plant operators often opt for a floating tubesheet style heat exchanger.

    A floating tubesheet style heat exchanger consists of a removable tube bundle made up of straight tubes, tubesheets, tie rods and baffles. Depending on the weight and length of the bundle, there may also be slides or wheel assemblies to make removal of the tube bundle from the heat exchanger shell easier. The name floating tubesheet comes from the fact that the tubesheet on the tail end of the exchanger is not fixed in place, like the one on the front end of the bundle. It is allowed to “float” inside the shell, which has several advantages – and a couple of drawbacks.

    Advantages of Floating Tube Sheet Exchangers

    The primary advantage of this style of exchanger is full visibility of tube internals as well as the exterior of the tube bundle once it has been removed from the shell, so it can be mechanically or chemically cleaned to remove scale and fouled product. This is accomplished much more readily than a non-removable fixed tubesheet bundle or even a U-tube style bundle.

    This exchanger style also makes tube repairs easier, and if a tube bundle wears out, it can be replaced with a new bundle, rather than replacing the entire exchanger. Bundles can also be upgraded to higher alloys in situations where corrosion is a concern or a cause of previous failures. If more surface area is required, replacement bundles can also be designed with a higher number of smaller tubes. This increases the heat transfer area without increasing the physical size of the exchanger.

    Another advantage of this style of heat exchanger, is that the floating tube sheet allows for thermal expansion and contraction of the tubes and the shell, eliminating the need for a shellside expansion joint. In straight tube exchangers, we must account for this expansion and contraction to prevent tubes from buckling or being pulled from the tubesheets. Shell expansion joints allow for this, but also are typically the longest lead time component during fabrication and also limit options for insulating the exchanger. Eliminating the need for an expansion joint is good for shell integrity as well as the fabrication schedule.

    Considerations for Floating Tube Sheet Exchangers

    The primary drawback to the floating tube sheet design is complexity, which can also add cost. Because the tube bundle is removable in most styles, there are more parts involved in these types of exchangers. There are shell flanges, additional O-rings and gaskets, and retaining rings in some models that add cost and weight to the exchanger. In most cases where these are selected, our clients feel the value of the maintenance advantages outweighs the added cost.

    Because the floating tubesheet and possibly the return channel must fit completely inside the shell in some styles, fewer tubes can fit into the bundle than in a fixed tubesheet model. This may require the shell to increase in diameter in order to provide the same surface area as a fixed tubesheet design.

    Another drawback is a limitation on the pressure rating for the shell side of the exchanger. Because in some styles the only separation between the shell side and tubeside is an O-ring or gasket, this limits the maximum pressure it can withstand. See the chart below per the TEMA (Tubular Exchanger Manufacturer’s Association) Standard for Classes ‘B’ and ‘R’:

    Equipment Calculations

    Four Styles to Consider

    Let’s look at the four types of floating tube sheet style exchangers. TEMA utilizes a three-letter naming convention for exchanger designs, with the first letter describing the front channel/enclosure, the second letter describing the shell design, and the final letter describing the rear channel/enclosure. Among their rear channel descriptors are four different floating tube sheet designs (T, W, P & S style). Each are described below:

    T – Style Floating Tube Sheet

    The T-style exchanger is very similar to a U-tube exchanger, except instead of U-bends at the tail end of the tubes, the tubes are attached to a floating tube sheet with a return channel. The whole rear tube sheet and channel assembly fits within the shell interior.

    Design features and pointers:

    • Removable tube bundle, but reduced tube count since entire floating tube sheet and channel, including its bolt pattern, must fit within the shell inner diameter.
    • Even number of tube passes only – like a U-tube.
    • Has a removable return tube channel and shell channel to gain access to the tubes.
    • No perimeter seal is needed between the bundle and the shell – similar to a U-tube.
    • Must allow enough room between the shell and bolts to get a socket in for nut removal.

    T Style CAD Drawing

    W – Style Floating Tube Sheet

    The W-style exchanger has a floating tube sheet that fits entirely within the shell of the exchanger, with the shell side fluids separated from the tube side fluids by an O-ring.

    Design features and pointers:

    • Removable tube bundle, but reduced tube count since entire floating tube sheet must fit within the shell inner diameter.
    • Only a single pass or 2-pass design can be used, since pass partitions cannot be incorporated into the return channel.
    • Return channel can be machined, flanged & dished or fabricated – with or without a removable cover plate.
    • Cannot be used for 3-A sanitary applications due to the tubeside crevice.
    • Since shell side fluids stop at the perimeter seal around the tube sheet, this design has the greatest risk of cross-contamination between tube side and shell side fluids.

    W Style CAD Drawing

    P – Style Floating Tube Sheet

    The P-style exchanger is the only one of the four floating tube sheet designs that does not have a removable tube bundle. This design’s primary benefit is that it eliminates the need for an expansion joint.

    Design features and pointers:

    • Since the tube bundle is non-removable, there is no reduction in tube count in this style.
    • There is no limitation of number of passes – odd or even.
    • Return channel can be machined, flanged & dished or fabricated – with or without a removable cover plate.
    • Shell side fluids stop at the lantern ring seal at the tube sheet.

    P Style CAD Drawing

    S – Style Floating Tube Sheet

    The S-style exchanger is the most complex and costly of the four options but is popular due to the ability to fully tear down the unit for maintenance, and the lowest risk of cross-contamination between tube side fluids and shell side utilities.

    Design features and pointers:

    • Removable tube bundle, but reduced tube count since entire floating tube sheet must fit within the shell inner diameter.
    • Can be a single pass or multi-pass design. Caution – a single pass requires a mechanical seal on the tail end. Because of this Enerquip only builds these in even pass configurations to lower complexity and risk.
    • The split lantern rings and fit-up of shell girth flanges around the floating tubesheet area add complexity.
    • Includes a removable shell cover and return channel to gain access to the tubes on the tail end.
    • Shell side fluids surround the return channel end, with a separate shell end cover.
    • No perimeter seal is needed between the shell and the bundle – like a U-tube.
    • Less restrictive on pressure ratings (due to lack of perimeter seal).

    S Style CAD Drawing

    Custom Shell and Tube Heat Exchangers from Enerquip

    The experts at Enerquip have experience with all four types of floating tube sheet style heat exchangers. We can assist you with determining the best option for your product and heat exchanger application to meet your heat transfer and maintenance objectives. Contact us or request a quote today.

     

  10. Immersion Heaters – Whitepaper

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    Pasteurization Makes Milk Safe for Consumers

    Knowing how to properly heat a solution or other liquid is critical to the integrity of the liquid. The right method can save time, energy and money. Using an inadequate approach to the task of heating a full tank of solution can have consequences ranging from damaged equipment to increased energy costs.

    In many cases, heating a solution quickly and accurately is essential. The fluid may need to be raised to a specific temperature and kept at that temperature consistently. Sacrificing accuracy can result in overheating and coking.

    There are many ways to heat mass quantities of liquid. Band heaters can be installed around a pipe or tank. Wrap-around heaters can surround a vat. Fluids can be placed in a separate heating vessel. However, each of these options has a drawback. Band and wrap-around heaters aren’t energy efficient. Band heaters can lose up to 40 percent of their wattage input because they aren’t fully in contact with the solution being heated. Instead, a portion of the heater is facing outward, away from the solution and its vessel.

    Other indirect methods, such as using a heated tank or wraparound heaters, take longer to heat up the solution, since the heat-transfer method needs to reach the desired temperature before the liquid can. Heating vessels can also take up floor space, a precious commodity many manufacturers and equipment operators appreciate having. This is also an expensive option, as a new, large piece of equipment will have to be purchased.

    Benefits of Immersion Heaters

    An alternative option to these choices is the immersion heater. These devices come in many shapes, sizes and styles. However, each is advantageous to the manufacturer who wants to effectively heat liquids.

    Buying the proper equipment to heat and process fluids is an essential part of following best practices and keeping standards high. However, it is also one of the more costly aspects of the industry. It is important to keep costs down whenever possible while maintaining quality and quantity.

     Energy efficiency has become a concern for many industries in the past few years. Not only does cutting energy mean reduced operational costs, but it is also better for the environment. Both of these concerns – cost and energy efficiency – are addressed with immersion heaters.

    Immersion heaters impact the solution or fluid from all sides. There is no wasted energy because the heating element is actually submerged in the liquid being heated. This allows the heater to operate more efficiently.

    The heaters’ design also saves space on the production floor. Since the element is placed directly into the vessel holding the liquid, no extra space is used. This makes room for additional necessary equipment or creates more space for equipment operators to work.

    Some versions of immersion heaters also make the cleaning process easier than if larger equipment were used. Over-the-side heaters, typically used when a tank is not outfitted with the required hardware for a bayonet or U-tube heater, are easily taken off the tank. The tank or the heater can then be cleaned and replaced. If the heater needs to be cleaned, this can be done without first emptying the tank, which saves time and resources.

    Types of Immersion Heaters

    Immersion heaters come in various shapes, sizes and styles. Each of them provides the same benefit of heating the fluid from within, saving on energy expenses and creating a more thorough, even heat distribution. They also provide efficient heating and cooling to liquids when needed.

    An immersion heater, often referred to as a bayonet heater, is inserted into the tank from the side.  Therefore, it is in direct contact with the fluid being heated. It is held in place by attaching to a flange connection on the side of the tank. Bayonet heaters are comprised of a tube or group of tubes stabilized with support baffles, with the entire assembly sometimes cradled by foot supports inside the tank.  In most cases, u-tubes are used, as they can readily expand and contract and won’t be damaged by rapid heating or cooling.  Typically, a bayonet heater is used to heat extremely large quantities of liquid.

    Bayonet heaters require the tank to accommodate their installation using flanged or threaded ports. In a flanged design, the tank has a flanged port installed on the side of the tank, and the heater has a matching flange to allow for installation and proper sealing.   A screw-plug design can also be used for smaller heaters, with these being attached through a threaded opening in the tank.

    When the tank does not have a connection for a bayonet heater, an over-the-side immersion heater is able to do the job. These heaters are installed at the top of the tank, rather than the side. The heating element then rests along the side or bottom of the tank.

    Regardless of which style of heater is used, it is usually stationed near the bottom, while being installed high enough to avoid the sludge and buildup that collects on the tank’s floor.

    Immersion heaters can be fabricated in many different metals and alloys, such as copper, steel, cast iron or titanium. Stainless steel is one of the most popular materials used for immersion heaters. According to The Stainless Steel Information Center, the material is a cost-effective option when considering the lifespan of the equipment. Stainless steel is resistant to corrosion and scaling in a multitude of environments. This makes it ideal for use with chemicals, acids and alkaline solutions, as well as in extreme hot or cold temperatures. It is easy to clean and maintain. Manufacturers appreciate this quality, as it is extremely important that all equipment used in the processing of a product is sterile to avoid contamination.

    Because stainless steel is more resistant to corrosion and scaling than its counterparts used in making immersion heaters – and because of its hygienic nature – stainless steel has a longer life span, with relatively low maintenance costs.

    TEMA and ASME Certified

    Users need to know the equipment they are purchasing is of the highest quality. Purchasing and subsequently using equipment that isn’t up to standard can lead to distributing defective products or decreased effectiveness. The Tubular Exchanger Manufacturers Association (TEMA) has the knowledge and understanding of how excellent equipment is made, and has developed a standard for design and manufacture of tubular exchangers.  So, when users purchase equipment from manufacturers who build to the TEMA Standard, they know they are buying quality machinery that meets or surpasses their requirements.

    The American Society of Mechanical Engineers (ASME) brings together engineers from many different disciplines and helps inspire collaboration and research. ASME helps to advance the industry and ensure quality in the work that its members do. For more than a century, ASME has been creating standards to which mechanical engineers must strive to adhere. Today, engineers volunteer to review and improve product requirements to guarantee equipment and practices will result in products safe for consumer use.

    When an immersion heater is built to the TEMA Standard and ASME Code, users know the product was created with the highest standards in mind. Users can trust equipment with these

    Enerquip’s Immersion Heaters

    Enerquip has been providing stainless steel shell and tube heat exchangers to companies in the sanitary and industrial markets, as well as the U.S. military, for more than 40 years. Its line of U-tube immersion heaters is a natural extension of the company’s current product base. The immersion heaters are made according to the standards of both TEMA and ASME. They are made of stainless steel to ensure product quality and safety.