c h r o m a lo x - thorne and derrick uk · 2009-01-22 · process industries around the world. the...

Chromalox®

PRECISION HEAT AND CONTROL

Building Precision Electric Heat and Control Systems for Process Industries Around the World

PRECISION ELECTRIC HEAT AND CONTROLDESIGNED WITH OUR CUSTOMER IN MIND

In 1915, Chromalox introduced the world’s first metal-sheathed heating element. Since then, we havegrown from just a manufacturer of heating elements to a global force in the design and implementationof electric heat and control systems that meet the requirements, certifications, codes, and standards ofprocess industries around the world.

The Chromalox DifferenceSome companies simply build heaters andcontrols. Chromalox does more. We providevalue-added heating solutions for diverseprocess industries by designing equipmentspecifically for customers’ needs. Chromalox is vertically integrated in manufacturing capabil-ities and offers full design and engineering forvirtually any electric process heat and controlapplication. We become a partner in helping you to save time and money before startup,

Power Generation• Fuel gas heaters

• Combustion air heaters

• Turbine pre-heaters

Petrochemicals• Fuel gas heaters• Seal gas heaters• TEG reboilers• Mole sieve regeneration

heaters• Continuous catalyst

regeneration heaters

Pharmaceutical• Hot oil heat transfer systems

• Line heaters

• Steam boilers and superheaters

• Heat tracing

Water and Wastewater Treatment• Water line heaters

• Air drying heaters

• Trace heating

Food Processing• Water line heaters

• Steam generators

Marine• Compartment comfort heaters

• Intake air duct heaters

• Air recirculation duct heaters

• Lubrication and fuel oil heaters

a partner who works with you to maximize effi-ciency and minimize downtime, and a partnerwho provides the field service and technicalsupport you need to get the job done.

No Other Manufacturer of Heat andControl Products Serves More IndustriesChromalox provides precision heat and controlsystems for more processes throughout theworld than anyone. Here is a sampling of theprocesses and industries we serve.

• Methanol heaters• Wellhead fluid separation

heaters

• Knock out drum vaporizers• Heat tracing

• Chlorination heaters• Regeneration heaters• Air heaters• Reduction heaters• Penex moliex heaters• Steam superheaters

• Lube oil console heaters

• Anti-condensation heaters

• Energy dissipation units

• Heat tracing

• Fuel oil pre-heaters

• Water heaters

• Lube oil purifier heaters

• Fuel oil transfer system heaters

• Lube oil settling and sump tank heaters

• Defrost heaters

• Galley steam boilers

• Laundry steam boilers

• Hazardous area heaters

• Wastewater heaters

• Trace heating

• Tank heaters

FPSO and Offshore Platforms• TEG reboiler

• Lube oil heaters

• Fuel gas heaters

• Crude oil heaters

PRECISION ELECTRIC HEAT AND CONTROLDESIGNED WITH OUR CUSTOMER IN MIND

In 1915, Chromalox introduced the world’s first metal-sheathed heating element. Since then, we havegrown from just a manufacturer of heating elements to a global force in the design and implementationof electric heat and control systems that meet the requirements, certifications, codes, and standards ofprocess industries around the world.

The Chromalox DifferenceSome companies simply build heaters andcontrols. Chromalox does more. We providevalue-added heating solutions for diverseprocess industries by designing equipmentspecifically for customers’ needs. Chromalox is vertically integrated in manufacturing capabil-ities and offers full design and engineering forvirtually any electric process heat and controlapplication. We become a partner in helping you to save time and money before startup,

Power Generation• Fuel gas heaters

• Combustion air heaters

• Turbine pre-heaters

Petrochemicals• Fuel gas heaters• Seal gas heaters• TEG reboilers• Mole sieve regeneration

heaters• Continuous catalyst

regeneration heaters

Pharmaceutical• Hot oil heat transfer systems

• Line heaters

• Steam boilers and superheaters

• Heat tracing

Water and Wastewater Treatment• Water line heaters

• Air drying heaters

• Trace heating

Food Processing• Water line heaters

• Steam generators

Marine• Compartment comfort heaters

• Intake air duct heaters

• Air recirculation duct heaters

• Lubrication and fuel oil heaters

a partner who works with you to maximize effi-ciency and minimize downtime, and a partnerwho provides the field service and technicalsupport you need to get the job done.

No Other Manufacturer of Heat andControl Products Serves More IndustriesChromalox provides precision heat and controlsystems for more processes throughout theworld than anyone. Here is a sampling of theprocesses and industries we serve.

• Methanol heaters• Wellhead fluid separation

heaters

• Knock out drum vaporizers• Heat tracing

• Chlorination heaters• Regeneration heaters• Air heaters• Reduction heaters• Penex moliex heaters• Steam superheaters

• Lube oil console heaters

• Anti-condensation heaters

• Energy dissipation units

• Heat tracing

• Fuel oil pre-heaters

• Water heaters

• Lube oil purifier heaters

• Fuel oil transfer system heaters

• Lube oil settling and sump tank heaters

• Defrost heaters

• Galley steam boilers

• Laundry steam boilers

• Hazardous area heaters

• Wastewater heaters

• Trace heating

• Tank heaters

FPSO and Offshore Platforms• TEG reboiler

• Lube oil heaters

• Fuel gas heaters

• Crude oil heaters

UNRIVALED DESIGN AND ENGINEERING CAPABILITIES FOCUSEDON YOUR COMPLETE HEAT AND CONTROL SOLUTION

Comprehensive Engineering CapabilitiesFocused on Your ApplicationOur complete engineered systems

• Reduce installation labor

• Shorten startup time

• Ensure proper operation to specification

MANUFACTURING THAT LEADS THE INDUSTRY

Chromalox maintains nine state-of-the-art manufacturing plants throughout the world with more than 682,000 square feet of manufacturing capabilities

Our manufacturing capability features computer-controlled, automated machinery to help ensuretightly controlled, repeatable standards of quality.With ASME welding capability in-house since1953, Chromalox has gained more in-plantexperience than any other electric heatermanufacturer to perform welding correctly.Our high-unit-volume ASME production in circulation heaters, steam boilers, and heattransfer systems gives Chromalox the

Resources to help Save You Time and MoneyOur in-house engineering and software capabilitiesallow us to design user-friendly interfaces. Theseadvanced designs can reduce your business train-ing time and expense, as well as increase repeat-able operation. In addition, Chromalox has trainingtools and resources to assist you with installation,startup, and operation.

Among the software Chromalox employs are:

• Finite element analysis by Cosmo Works

• AutoCAD, Inventor, and 3D Solid Works

• AutoCAD electrical drawing scanning and rastering capability

• COADE for ASME, wind, and seismic loading

• HTFS heat exchanger dynamic modeling

• PLC programming and testing

experience base to perform ASME welding at a level of excellence unsurpassed in ourindustry. Chromalox equipment has operated to pressures as high as 5,000 psi and hasreached process temperatures of 1,400ºF. In-house manufacturing has produced equip-ment more than 20 feet in length, more than 5 feet in diameter, and weighing several tons.

Our other equipment capabilities include, among others:

• Pulsed MIG (GMAW) welding technology

• Gas tungsten arc welding (GTAW)

• Shielded metal arc welding (SMAW)

• Flux cored arc welding (FCAW)

• Robotic plasma cutting

• Semi-automatic pipe coping

• Hydrostatic testing

• Full CNC machining

BENCHMARKS OFTHE INDUSTRY’S

DESIGN ANDENGINEERING LEADER

• Chromalox introduced the world’s first metalsheathed heating elementover 90 years ago

• Chromalox engineers3,600 unique, newproducts every year

• Chromalox has more than700,000 customer designson record

• Chromalox in-house labcertifies product for bothCSA and UL requirements

BENCHMARKS OFTHE INDUSTRY’SMANUFACTURING

LEADER

More than 75 Chromalox engineers–includingUL- and CSA-certified professionals-are avail-able and ready to help you integrate our prod-ucts into your application and achieve thesebenefits. At their disposal is our full range ofengineering capabilities, including:

• Application expertise

• Heating technology selection

• Feasibility and detailed design of processloads and systems

• Design for skids or packages

• Safe or hazardous area selection

• Heat transfer design using the latest software

• Materials selection

• Pressure vessel design

• Mechanical and electrical design

• Control and instrumentation system design

• Project engineering management

Follow-Through with Complete On-SiteEngineering Service and Support

Chromalox provides highly qualified personnel for site commissioning and operational servicinganywhere in the world. Our engineers are exten-sively trained for onshore and offshore facilitiesand possess the required medical and safety certifications. They can commission the mechani-cal, electrical, instrumentation, and control equipment for any system we build.

Custom Design for Special Needs

Chromalox can design heating solutions for anyunique requirement. Our engineers will custom-design the right product to meet your applicationneeds. Drawing on the more than 700,000 top-level designs we have on file, we will design anexisting product or design and manufacture acompletely new one to fit your needs. Chromaloxwill help you produce prototypes for new prod-ucts and systems, developing innovative designin the shortest possible turnaround time.

• Chromalox has 90 years ofexperience making heatingelements

• Chromalox produces 3,383miles of tubular elementsin North America alone. . .nearly the diameter of the moon

• Chromalox makes enoughheating cable each year

to stretch from Northern Italy to

the tip of Sicily

• Chromaloxemploys morethan 1,000

production personnel at 9

manufacturing plants on 2

continents

• Chromalox manufacturingproduces more than 3million stand-alone itemseach year

UNRIVALED DESIGN AND ENGINEERING CAPABILITIES FOCUSEDON YOUR COMPLETE HEAT AND CONTROL SOLUTION

Comprehensive Engineering CapabilitiesFocused on Your ApplicationOur complete engineered systems

• Reduce installation labor

• Shorten startup time

• Ensure proper operation to specification

MANUFACTURING THAT LEADS THE INDUSTRY

Chromalox maintains nine state-of-the-art manufacturing plants throughout the world with more than 682,000 square feet of manufacturing capabilities

Our manufacturing capability features computer-controlled, automated machinery to help ensuretightly controlled, repeatable standards of quality.With ASME welding capability in-house since1953, Chromalox has gained more in-plantexperience than any other electric heatermanufacturer to perform welding correctly.Our high-unit-volume ASME production in circulation heaters, steam boilers, and heattransfer systems gives Chromalox the

Resources to help Save You Time and MoneyOur in-house engineering and software capabilitiesallow us to design user-friendly interfaces. Theseadvanced designs can reduce your business train-ing time and expense, as well as increase repeat-able operation. In addition, Chromalox has trainingtools and resources to assist you with installation,startup, and operation.

Among the software Chromalox employs are:

• Finite element analysis by Cosmo Works

• AutoCAD, Inventor, and 3D Solid Works

• AutoCAD electrical drawing scanning and rastering capability

• COADE for ASME, wind, and seismic loading

• HTFS heat exchanger dynamic modeling

• PLC programming and testing

experience base to perform ASME welding at a level of excellence unsurpassed in ourindustry. Chromalox equipment has operated to pressures as high as 5,000 psi and hasreached process temperatures of 1,400ºF. In-house manufacturing has produced equip-ment more than 20 feet in length, more than 5 feet in diameter, and weighing several tons.

Our other equipment capabilities include, among others:

• Pulsed MIG (GMAW) welding technology

• Gas tungsten arc welding (GTAW)

• Shielded metal arc welding (SMAW)

• Flux cored arc welding (FCAW)

• Robotic plasma cutting

• Semi-automatic pipe coping

• Hydrostatic testing

• Full CNC machining

BENCHMARKS OFTHE INDUSTRY’S

DESIGN ANDENGINEERING LEADER

• Chromalox introduced the world’s first metalsheathed heating elementover 90 years ago

• Chromalox engineers3,600 unique, newproducts every year

• Chromalox has more than700,000 customer designson record

• Chromalox in-house labcertifies product for bothCSA and UL requirements

BENCHMARKS OFTHE INDUSTRY’SMANUFACTURING

LEADER

More than 75 Chromalox engineers–includingUL- and CSA-certified professionals-are avail-able and ready to help you integrate our prod-ucts into your application and achieve thesebenefits. At their disposal is our full range ofengineering capabilities, including:

• Application expertise

• Heating technology selection

• Feasibility and detailed design of processloads and systems

• Design for skids or packages

• Safe or hazardous area selection

• Heat transfer design using the latest software

• Materials selection

• Pressure vessel design

• Mechanical and electrical design

• Control and instrumentation system design

• Project engineering management

Follow-Through with Complete On-SiteEngineering Service and Support

Chromalox provides highly qualified personnel for site commissioning and operational servicinganywhere in the world. Our engineers are exten-sively trained for onshore and offshore facilitiesand possess the required medical and safety certifications. They can commission the mechani-cal, electrical, instrumentation, and control equipment for any system we build.

Custom Design for Special Needs

Chromalox can design heating solutions for anyunique requirement. Our engineers will custom-design the right product to meet your applicationneeds. Drawing on the more than 700,000 top-level designs we have on file, we will design anexisting product or design and manufacture acompletely new one to fit your needs. Chromaloxwill help you produce prototypes for new prod-ucts and systems, developing innovative designin the shortest possible turnaround time.

• Chromalox has 90 years ofexperience making heatingelements

• Chromalox produces 3,383miles of tubular elementsin North America alone. . .nearly the diameter of the moon

• Chromalox makes enoughheating cable each year

to stretch from Northern Italy to

the tip of Sicily

• Chromaloxemploys morethan 1,000

production personnel at 9

manufacturing plants on 2

continents

• Chromalox manufacturingproduces more than 3million stand-alone itemseach year

SHEATHOVERTEMP 1

SHEATHOVERTEMP 2

SHELLOVERTEMP

Beyond custom product engineering, Chromalox remains a leader in designed systemsbecause we control the manufacturing process from the first component to the finishedproduct. While some companies simply assemble purchased parts, our vertical integrationof product manufacturing allows tight control of all procedures. Because Chromalox manu-factures the component parts, we can adjust to meet customers’ critical requirements.

Pressure VesselsChromalox has maintained an ASME-quality program in-house since 1953. Chromaloxpressure vessel approvals also include PED certification required by the EuropeanUnion. This experience and dedication to quality ensure safe and reliable operationfor many years of service.

SensorsChromalox manufactures its own control sensors, such as thermocouples,allowing us to custom-design sensor lengths, sizes, temperature ranges, etc.

Power ControlsChromalox can design power control components neededto meet the process demands. Options can include contac-tor control for a cost effective design all the way throughfull SCR control of a temperature-critical process.

Final AssemblyChromalox brings all of the manufactured componentstogether to complete the final system. This includes electrical wiring to NEC/IEC standards, mechanical fit-ups,and even a customized paint scheme, if desired.

Having control from the very beginning of every step of the process, Chromalox can ensurethat the highest quality is designed and manufactured into each product and allows us toproduce systems that are tailored to our customers needs and requirements.

Heavy-Duty Heating ElementsChromalox manufacturers its own heating elements in systems to exacting standards. This not only allows tight quality control of the heating element, but allows Chromalox to ensure that themost cost-effective design is used for our customers. Flange- or screw-plug-mounted tubular typeheating elements available in stainless steel, copper, or INCOLOY* sheathing to suit corrosionresistance requirements.

InsulationChromalox insulates each pressure vessel to ensure efficient operation. Jacketing is then installed to provide protection and complete the product.

ControllersChromalox offers a range of process controllers with an abundance of options from which to choosein meeting customers' needs. Choices range from simple "set-it-and-forget-it" controls, to digitalcontrol and output, to a sophisticated, fully customized Chromalox intelliPANEL™ control system.

Completed PanelChromalox fully assembles the controllers and power control components into a finished product.Our manufacturing facility in Tennessee is dedicated to controls production and is committed toensuring 100% functionality in each completed product. The advanced Chromalox® intelliPANEL™

control panel is the industry’s first process/power control with a color touchscreen display. It makescontrol measurement, instruments, alarm configuration, control algorithms, start-up, and troubleshoot-ing easy while providing the widest array of diagnostics available today.

Skid Frame ConstructionEach frame is designed to handle rough shipping conditionsand relocations during installation. Chromalox in-housedesign software can also ensure that framing is constructedto meet any other design conditions a customer may needsuch as wind or seismic loading.

Terminal EnclosureTerminal enclosures are available for general-purpose, moisture-resistant, and explosion-resistantapplications.

Outer JacketConstructed of heavy gauge painted steel sleeving thatcontains high-temperature thermal insulation to reduceheat loss from the heating chamber.

Heating ChamberPipe chamber has a flanged or threaded end to receive the heater assembly and closed at the opposite end.

*INCOLOY is the registered trademark of Huntington Alloys Corporation.

OutletMounting Lugs