Custom Built Heaters

HEATCO make Air Duct Heaters are used for process gas heating, drying ovens, air pre-heating, paint drying and curing, heat treating and more. Various terminal housings and control options available. Air duct heaters are designed for heating low-pressure air or gases. HEATCO make series air duct heaters are constructed with stainless steel tubular elements mounted in a stainless/ MS flange with operating temperatures up to 700° C. These electric process heaters can be designed to fit rectangular ductwork and can be supplied with transition sections when used on circular or smaller ducts. FEATURES Element can be individually replaceable on site without the need of any special tools. Termination Box if required can be made weatherproof to IP:66 & IP: 67. Various type of over temperature cut-outs available such as Thermostat, RTD or Thermocouples. TYPICAL APPLICATION Air Handling Units, Space Heating, HVAC Duct Heating, Drying Oven, Furnace Heating.

We manufacture Electrical Process Heaters. The diverse heating require tailor made solutions which we can provide.All our heaters are designed according the various international codes upon customer demand. The heaters can be delivered as a flange mounting for tank heating or as an inline flow though heater for heating up:

• Hot water
• Thermal oil
• Heavy fuel oil
• Marine Diesel oil
• Lubricating oil
• Air & Gas Heating Explosion Proof Terminals Cover are supplied on demand.

A complete control system with sensors and can be delivered with the heaters. In co-operation we design complete skids in which the heaters are integrated. Range: 3.0 KW to 212.5 KW

Heatco make High Watt Density Split Sheathed Cartridge Heaters uses less power, runs more efficiently and survives more that that of cylindrical type conventional Cartridge Heaters. Due to its elongation capability it clutches the mould when energized leaving no air gap and contracts when it cools down parting the following advantage.

• Maximizes Heat Transfer
• Easy Maintenance
• Reduces the Cost of operation

 

The construction of Heatco make High Watt Density Split Sheathed Cartridge Heaters eliminates ceramic cores typically found in conventional cartridge heaters. Heatco with its continuous in house research and possessing highly-specialized manufacturing techniques compacts fused magnesia around the heater coil in such a way that increases dielectric strength and heat transfer away from the coil which results in significantly longer heater life. The heaters contract when de-energized, eliminating bore seizure and the need for expensive drill-outs.

Advantages High Density Split type Cartridge Heater:

• Easily Replaceable
• Longevity
• Fast Heat Transfer
• Higher Watt Densities
• Higher Operating Temperature

Standard Dimensions of Heatco make High Watt Density Cartridge Heater

Though we have a standard range of Heatco make High Density Split Sheathed Heater we usually manufacture tailor made cartridge heaters as per the requirement of our clients to match their heating requirements in lieu to the size.

 

Applications :

• Dies & Moulds
• Package Sealing
• Liquid Heating
• Food Services

The Mica wound Strip & Band Heaters that we are providing are fabricated giving careful consideration of watt density that is necessary in the design in industrial heating elements. There is much variation in the range of watt density & each electric mica wound strip heater and band heaters has its own individual watt density properties.

HEATCO designs and builds your heater control panels. We can supply heater control panels from indoor area to a hazardous area on any offshore platforms. We utilize high quality components and workmanship to ensure reliability and performance. Our heater control panels are designed to provide accurate and safe controls for an electric heater. The internal of the control panels consist of three independent but inter-related systems. They are control system, safety shutdown system and power distribution system. The control portion would handle all logic, remote interface and temperature control loop. Each control portion includes: indicating temperature controller, over temperature controller, main disconnect switch, individually fused contactor circuits, control voltage transformer, power indicating lights, and heater selector switches all mounted in a IP: 54 enclosure or as required by the clients. Each control center is factory tested before shipment. The safety shutdown system is designed to monitor and shutdown the heater during unsafe operation. Finally, the power distribution portion regulates the electrical power to the heater based on the requirement from the control system. Supply voltage can vary from single phase 120/240VAC to three phase 380/415/440VAC.

FEATURES:

• Handle operated, fused power disconnect
  
• Lockable thru-door handle
  
• 120 volt, fused control voltage transformer
  
• Thermocouple sensing temperature controller
  
• Door mounted heater selector switch
  
• Individually fused branch circuits
  
• Pre-set high limit controller
  
• Sensor break protection
  
• Terminal strip

CUSTOM OPTIONS

• Interlocks
• Special Voltages
• Special Tagging
• Special Temperature Controllers
• Remote Inputs, Outputs
• Ampere Meters
• Local/Remote Switch
• Enclosure Heaters
• Timers, Recorders, Monitors,
• Alarm Indicators
• Motor Starter Circuits
• Enclosure Light.

Ideal for generating steam and heating gases and liquids in pressure vessels and tanks, flanged immersion heaters are hairpin-bent tubular elements welded or brazed into a flange and provided with electrical enclosures. Heatco flanged immersion heaters are available in a wide selection of flange sizes and with a variety of electrical enclosures. Application Guidelines U Length: Up to 120" Power ratings: Up to 400 kW Flange material: Brass, Steel, or SS Sheath material: Cu, Steel, SS, or Incoloy. Industrial immersion heaters come in a standard set of basic configurations:

• Over the side - even heating of fluids or freeze protection
• Flange - for boilers and fluid tanks
• Pipe insert or bayonet - indirect heat to viscous materials such as those found in food manufacturing
• Circulation/in-line - fast-acting, low-wattage applications such as engine preheating
• Screw plug - fluids such as in rinse tanks, chemical baths and caustics Heating elements are also manufactured in a flat tubular configuration or a round tubular design.

The most versatile of all electric heating elements, the tubular heater is capable of being formed into virtually any configuration. The basic design consists of a helical coil of nickel-chromium resistance wire embedded in a magnesium oxide insulating material. The cross section design of the metal sheath assures maximum strength and rigidity. The tubular design also permits ready bending and forming to fit a wide range of applications, without damage to the heating coil or insulation material.

Copper Sheath: For water heating & for heating water solutions which are non-corrosive to copper.

 

Steel Sheath: Immersion in oils, molten salt baths, alkaline cleaning solutions, tars and asphalt. Suitable for casting into aluminum.

 

Stainless Steel Sheath: Corrosive liquids, food processing equipment.

 

Incoloy Sheath: Air heating, radiant heating, cleaning and degreasing solutions, plating and pickling solutions, corrosive liquids.

 

Other sheath materials are also available for application considerations. Commonly specified are SS 304, SS 316, SS 321 & Incoloy tubes along with titanium for severely corrosive solution heating.

Bolt Heater is designed primarily to pre-heat large, drill holding bolts or studs. The Bolt Heater is used in the assembly or servicing of hydraulic presses, turbines or other equipment where a high concentration of heat is needed to expand, then wrench tighten tie rods. The parts cool and contract, resulting in the nut being drawn even tighter. A terminal box of octagon or circular shaped is fixed on the top where the terminals are provided and an insulated wooden handle is provided for shoving the heater inside/ outside the tunnel. Three conductor cord with plug assembly is available with our Bolt Heaters. We manufacture Bolt Heaters in the form of Split Sheathed Heater complete with Terminal Box & holding and an insulated wooden handle. Applications Power Plants Shipyard Press & Die Manufacturer

ORDERING INFORMATION :

• DIAMETER
• OVERALL LENGTH
• WATTS
• VOLTS
• HEATING LENGTH
• TERMINAL CONFIGURATION
• QUANTITY

We also manufacture and export high quality electrical heat chambers and ovens which are widely used in different industries for a variety of purposes. We only use genuine raw material in the production process and subject our final products to stringent quality checks in order to make sure that high international standards are followed. Some of the pertinent features of the products are mentionedelow:

 

• Power efficient
• Low maintenance
• Long service life

Circulation Heaters provide a ready-made means to install electric heating within a very short period of time & labour. This is accomplished combining heating elements, vessel, insulation, terminal enclosure, mounting brackets and inlet and outlet connections into a complete assembly. Made from pressure rated flange, heater assemblies mated with a pressure vessel( tank) circulation heaters are designed to heat forced circulation air, gases or liquids. Since the fluid directly passes over our heating elements assembled in the shell it delivers fast response and even heat distribution.

We in Heatco can meet all your circulation heater assembly needs with Made- to Order Units. These units can be made from a wide range of heating element sheath materials, wattages, vessel sizes and materials, pressure rating, terminal enclosures and controls & can be made for both vertical and horizontal mounting.

Heatco make Refractory Charged replaceable type Cartridge Heaters are made from Ceramic Insulators which are for used for both Vertical & Horizontal operation.

The heating elements are fitted inside the bobbin of the ceramic insulators as per the rating & the voltage provided by the client for their use.

 

A tie rod is fitted in between which keeps the ceramic insulators in line with the element. The connection is made from Brass or SS as per the current drawn.

 

These Refractory Charged replaceable type Cartridge Heaters are housed in a metallic sheath as per the functioning of the heaters. While placing orders for such type of Heaters the clients must confirm the following:

 

• Place of Use
  
• Mode of Operation
  
• Rating ( Watt) & Voltage
  
• Terminal Block details
  
• Dummy or Non Heating Zone

 

HEATCO make REPLACEABLE CARTRIDGE HEATERS are made from long-lasting and high quality refractory materials which are mounted horizontally in a metallic tube as per design to suit its application. These are easily replaceable once the Cartridge Heater gets worn out. In standard production the heating element is made from Ferro-Chrome or Nickel/Chrome heating elements.

 

Length of unheated zone (Lm), is to be determined by the customer.TECHNICAL DATA: Lenght (L) [mm] Diameter (Ø) [mm] Voltage [V] Max. temperature [°C] Heating power [W] Max. Surface load [W/cm2] 200 - 4000 12; 16; 25, 30, 32; 35,36, 38,41, 45 etc. 220; 230; 380; 3x380; 400; 3x400 or different 500 0.25 KW to 10.0 KW AREA OF APPLICATIONS: Heating of : Air, Oil, Water etc. Used in : Confectionery; Electroplating Plants; Quenching oil baths, Drying Ovens, Degreasing bath.

Heatco make Ceramic Band Heaters were developed & still being carried on to meet industrial requirements to withstand high temperature and for long life. They are ideally suited to comply with today's new resins, which calls for ever-increasing process temperature. Ceramic Band Heaters design consist of a helically wound resistance coil made from 80/20 nickel/chrome wire, evenly stretched and precisely wounded through a specially designed ceramic insulating beads forming a flexible heating mat. The ceramic heating mat along with ceramic fiber insulation is placed on a stainless steel housing made with serrated edges providing maximum flexibility for easy installation. The following technical data are required for manufacturing Ceramic Band Heaters. Length of Heater, ID of Heater, Rating: Watt & Volt, Location of Thermocouple Hole & its dia, Type of Terminal Connection: Bolt type, Plug Type, Lead type, U cut if any & position of U cut.

A thermocouple is fundamentally a pair of electrical conductors of dissimilar metals so joined as to produce a thermal emf when the junctions are held at different temperatures. The two junctions are termed as 'Hot' and 'Cold' junction. The cold junction is terminated on ther temperature measuring instrument. There are various types of thermocouples. The most commonly used along with its range are given below.

Element	Type	Range
Copper/Constantan	(Simplex/Duplex)	'T'	100°C - 400°C
Iron/Constantan	(Simplex/Duplex)	'J'	100°C - 800°C
Chromel/Alumel	(Simplex/Duplex)	'K'	100°C - 1100°C
Platinum-13% Rhodium / Platinum	(Simplex/Duplex)	'R'	200°C - 1600°C

The platinum resistance thermometers known as RTD operates on the principal of change in electrical resistance of platinum wire as function of termperature and it normally operates between the range of -200°C to + 500°C. Ordering Information If you are in any doubt as to the type of cable or element needed - ask for our advice. We will be pleased to help. Give us a call. Please Note: Our Accessory range is always under review. Should you have any special requirements, contact us for advice. How to Order:

• Aplication
• Temperature Reqd
• Type of Element
• Size of Element
• Conduit Entry
• Process Connectio