Department Editor: Kate Torzewski

Heat Transfer System Design

piping layout
The possibility of leakage through joints and fittings is characteristic of most organic heattransfer fluids unless the fittings are extremely tight. System design should minimize the number of connections in the piping layout. The best way to prevent piping leakage is to weld all connections. Use of threaded fittings is strongly discouraged due to their tendency to leak. Where access is necessary, raised-face flanges with weldneck joints or equivalent raised-face flanges should be used, as shown in the table below.
Flange Use when type
Class 150 Max. operating temp. < 350F, Operating range < 300F (175C), Operating range < 300F (170C) Max. operating temp. > 350F, Operating range > 300F (175C), Operating range > 300F (170C)

pumps
 Centrifugal pumps with cast or forged steel casings are typically appropriate for systems with large flowrates  Positive displacement pumps frequently can handle smaller flowrates of less than 100 gal/min  Sealless pumps (canned motor or magnetic drive) avoid the installation of mechanical seals A typical centrifugal pump can be expected to deliver operational head of about:

 Use cellular glass insulation, which is resistant to fluid saturation, in areas of the system where leaks are likely to develop  If a leak develops, remove the insulation, and contain the fluid until the leak can be repaired  On vertical runs of pipe where occasional leaks can develop at flanges, install protective tight-fitting caps to divert any fluid leakage outside the insulation  Install valve stems horizontally or in a downward position so that any stem leakage does not enter the insulation

materials of construction
where g is gravitational acceleration in m/ s2, D is the rotor diameter in m and n is the rotor speed in rpm. Pump manufacturers usually specify that above 450F (230C), a cooled, jacketed stuffing box or a cooled mechanical seal should be used. Secondary sealing with vent and drain glands is suggested to collect fluid leakage and to provide space for inerting the outside of the seal. Inert blanketing of the seal with steam or nitrogen eliminates oxidation deposit formation, which can lead to seal leakage. This secondary sealing provides additional safety in the case of sudden seal failure. Some fluid leakage at the seal is common in mechanically sealed pumps. For those applications where the small leakage is undesirable, consider the use of a sealless pump. When selecting a sealless pump, the designer must consider the impact of heat generated by the motor stator relative to the vapor pressure of the pumped fluid. On pumps with a stuffing box, at least five rings of packing should be provided, such as laminar graphite rings. If expansion loops are used in the pump suction piping, they should be installed horizontally. System materials of construction must be compatible with the heat transfer fluid in use. Materials of construction must also be selected on the basis of their suitability for operation throughout the systems temperature range (see table below). The usable ranges are based on the low temperature at which the material becomes brittle and the high temperature at which the material begins to lose mechanical strength. It is advisable to practice fire-safe construction when designing organic heat-transfer-fluid systems. Fire resistance addresses the ability of a piping system to remain free of damaging leaks when exposed to external fire. A piping component is typically considered to be fire resistant when it is able to withstand exposure to 1200F (650C) for 30 min.
Static seals
Fluoroelastomers Flexible graphite

Recommended gasketing
Metalinserted flexible graphite gaskets

Class 300

Flexible graphite-filled spiral-wound gaskets

Typical temperature range

10F ( 25C) to 400F (200C) 325F (200C) to 800F (425C)

Factors affecting the leak performance of the flanges include the ability of the flange bolting to effectively seat the gasket and the ability of the flange to withstand external moments in the piping system. All piping layouts should take into account the expansion and contraction of the piping with temperature, according to the equation , where is the materials coefficient of thermal expansion. It is vital that the stress placed on the system during its expansion from ambient to operating conditions not exceed allowable stress limits.

Piping
Copper Carbon steel Low alloy steel Stainless steel 325F (200C) to 350F (175C) 20F ( 30C) to 800F (425C) 150F (100C) to 800F (425C) 325F (200C) to 800F (425C)

filters
Before startup of a new system, install a wire mesh strainer of approximately 120-micron mesh size in the pump suction. Piping systems should also be designed with provisions for the installation of a sidestream filter. Filters that have generally been employed for these applications are glass fiber string-wound cartridges or cleanable sintered-metal filters in the 130-micron range.
3. Systems Design Data, Pub. #7239193 ver. C, Solutia  Inc., 2002. 4. System Design and Maintenance, Pub. #TBS 10-25  (E), Solutia Inc., 1998. 5. Liquid Phase Design Guide, Pub. #7239128C,  Solutia Inc., 1999.

insulation
Normal high-temperature insulation, such as calcium silicate, mineral wool and cellular glass, can be used in heat transfer fluid systems. However, fluid-saturated insulation is a potential fire hazard at the temperatures often encountered while operating such systems. Organic heat transfer fluids generally can exhibit a slow oxidation reaction with air in the presence of porous insulating materials at temperatures above 500F (260C). To minimize the fire hazard potential in insulation systems:

References

1. Wagner, W., Heat Transfer Technique with Organic  Media, Grfelfing-Mnchen: Technischer Verlag Resch KG, 1977. 2. Gamble, C.E., Cost Management in Heat Transfer  Systems, Chem. Eng. Prog., July 2006 pp. 22-26.

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