Heater Strip Tech Ref

7/25/2019 Heater Strip Tech Ref

1/8

HT-19

OMEGALUX PREMIUM QUALITYSTRIP HEATERS

FEATURESA choice of sheath materialscapable of operating up to 1500Fsheath temperature to heat variousprocesses economically includerust-resisting iron sheath (750F),chrome steel sheath (1200F),Monel (950F) and Incoloy(1500F).

Refractory-insulated constructionexclusively. By far the most ruggedand best for long, dependable

service.More types and ratings. Moreprecise matching to your powerservice and work load requirements.Special ratings and sizes can bemanufactured readily.

More stocked models. Over 500models are stocked and areavailable for immediate shipment.

Lengthwise and cross sectioncurving. Available on made-to-order only for efficient heat transfer.

Strip and ring heaters can be factoryformed to fit the shape of thesurface to be heated.

Easy installation. OMEGALUXclamping devices and mountingtabs speed installation. Mountingstuds are readily available fromOMEGALUX stock.

More choices of strip heaterterminal locations. To simplifywiring layout between elements andto power lines.

Product to be Temperature Sheath Product AllowableHeated Desired Material Temp Watt

for Products Density

Solids

i.e. molds Up to 1400F Rust Resisting 560F 3platens, dies clamp-on Iron 150F 8pipes, tanks applications

Chrome Steel 850F 7700F 10400F 15

Incoloy 200F 28750F 20

1100F 81350F 3

1400F 2.5

Air/Gases

Free Air Velocity Up to 1400F Rust Resisting 500F 31 ft/sec. Bracket Iron 100F 8Mounted Chrome Steel 950F 7

800F 10500F 15


Free Air Velocity Bracket Rust Resisting 500F 34 ft/sec. Mounted Iron 250F 8

Chrome Steel 1000F 7850F 10550F 15


Strip Heater Selection Guide

Many additional features.Available to adapt heaters to suitspecial applications--made to order.

Trouble-free installations. Little orno maintenance costs.

Controls are part of the totalOMEGALUX package for yourheating job regardless of its type orthe temperature precision you need.

OMEGALUX technical assistance.Your OMEGALUX representativewill be glad to answer yourquestions, to assist in the selectionof heaters, and recommendmethods of installation to assure asatisfactory installation

U.L Component Recognizedand/or C.S.A. Certified.

High quality, coiled alloy resistor wire isuniformly spaced over the width and length ofthe strip heater to assure even heat distribution

Resistor wire is embedded inspecially formulated, high-graderefractory material which bothinsulates the resistor and transfersheat rapidly to the sheath.

Refractory is then compressed torock-hardness and highest densityunder tremendous hydraulic pressureto maximize heat transfer from coil tosheath. Elements are oven cured athigh temperature to semi-vitrify andmature the refractory

Maximum heat transfer from the instant theelement is first energized, is provided by the highemissivity black oxide finish. Elements with shinysurfaces do not transfer heat as well.


2/8

HT-20

Maximum Sheath Temperature

Rust Resisting Iron 750F

Monel 950F

Chrome Steel 1200F

Incoloy 1500F

STRIP HEATERSA Technical Review

APPLICATION OFOMEGALUX STRIPHEATERSOMEGALUX strip heaters are usedprincipally for convection-type airheating and clamp-on installations.When selecting strip heaters foreither, two important factors mustbe considered:

1. The proper sheath material forresisting any rusting and oxidizinginherent in the process orenvironment and for withstandingthe sheath temperature required.Standard sheath materials are rust-resisting iron, chrome steel andIncoloy (NS Series only.) Stainlesssteel and Monel sheaths areavailable at an additional charge.

Maximum work and sheathtemperatures are below.

2. The watt density of the element,or watts per square inch of heatedarea. This should be low for heatingasphalt, molasses and other thicksubstances with low heattransferability; it can be higher forheating air, metals and other heat-conducting materials. (See curveson following pages for determiningallowable watt densities.)

When high operating temperaturesare needed, watt density must belimited in order not to exceed themaximum sheath temperature.Watt density is given in the How ToOrder table for each strip heater.

In general, a viscous material withlow thermal conductivity requires alow watt density. High wattdensities can be used with thinnerliquids and with materials of highthermal conductivity. Prematureloss of the element due to excessivetemperature may result if thematerials heat-take-away ability islow. Also, the material may becharred, carbonized or its chemicalmakeup altered by overheating.

Installation

OMEGALUX strip elements in mostcases can be applied with standardhardware. However, for firm contactand best heat transfer, stockedOMEGALUX strip heater clampsare recommended.

Clamping bands can be used to firmly fastenstrips longitudinally to large-diametercylindrical surfaces.

Connecting Lead Wire

Should be nickel-plated copper,nickel or alloy. Copper will oxidizeand loosen connections. Utilityclamps secure strip elements to flatsurfaces with large radii such aslarge tanks. Threaded studs arewelded to surface, heaters arepositioned, then clamps are bolteddown. Where more than one clampis used, tighten nuts and then backoff 12 turn to allow for expansion.

Heaters may be held in position inplatens and similar objects with a

steel plate recessed to heaterswidth, thickness and positions, thenscrewed to the working plate orsurface.

Easy application of strip elements toovens may be made simply with theuse of welded-on studs andsecondary insulation bushings(see Strip Heater Modificationsand Accessories). Mountingholes in tabs are slotted to allowfor expansion.

SELECTING SIZES ANDRATINGSThe calculation of total heatrequirements for an application isoutlined in the Technical Section.For assistance, get in touch with anOMEGALUX applications engineerwho will be glad to help solve yourheating problem. Once total heatrequirements are established, thequantity, size and ratings can bedecided. Plan for enough heaters topermit even temperature asrequired by the process. Thesensor for the temperature controlshould be clamped to the workingsurface for accurate control. In thecase of air heating, place sensorwhere the desired temperature isneeded, but not too far from heaterto help avoid undershoot andovershoot.

After the specific heater size and

rating has been tentatively selected,the watt density must be checkedagainst the appropriate curves.For example, the OT-4315 chromesteel sheath heater rated 1500watts has a watt density of 11watts/sq. in. and can be operatedat 1200F sheath temperature.If clamped to a work surfaceoperating at 600F, Figure C-1shows that the maximum allowablewatt density is 12 watts/sq. in.Since the watt density of the

OT-4315 is below the maximumallowed, good clamping will providelong service. If the heater selectedhas a watt density higher than thatstipulated by the graph, then thesealternatives could be considered:

1. Use more heaters of a low wattdensity to obtain the required kWcapacity.

2. Reduce the kW capacity neededby reducing heat losses andallowing for a longer heat-up time.

OMEGALUX Strip Heaters shown herewith clamping bands.

CAUTION AND WARNINGFire and electrical shock mayresult if products are usedimproperly or installed or usedby non-qualified personnel.See inside back cover for

additional warnings.


3/876 To Order, Call or Shop Online at omega.comSM

EXAMPLES OF HEATING VESSELSWith Clamp-On Strip HeatersVESSEL HEATINGCALCULATIONSA steel melting pot or crucibleweighing 150 lbs. contains 400 lbs.of lead, and is insulated by 2" ofrock wool and a sheet steel outsideshell of approximately 20 ft2 area.Three sq. ft. of lead surface areexposed to the air. Sufficientkilowatt capacity must be installedto bring the material and containerfrom 4 to 427C (70 to 800F) inone hour, and to heat 250 lb oflead per hour from 4 to 427C(70 to 800F) thereafter.

Melting point of lead = 621FSpecific heat of solid lead =

0.031 Btu/lb/FSpecific heat of molten lead =

0.040 Btu/lb/FHeat of fusion/lead = 10 Btu/lbSpecific heat of steel crucible =

0.12 Btu/lb/FRadiation loss from molten leadsurface = 950 W/ft2 (see Heat

Loss Curves)Surface loss from outside shell of

pot = 66 W/ft2

TO FIND INITIAL HEATINGCAPACITY IN kW:kWh = (QS + QF + QL QC) + (Ls) (H)

3412 2000

Where:

QS = BTU to heat lead to meltingpt. = [400 x 0.031 (621 - 70)]

QF = BTU to melt lead = (400 x 10)

QL = BTU to heat lead from meltingpt. to 800F =[400 x 0.040 (800 - 621)]

QC = BTU to heat container to800F = [150 x 0.12 (800 - 70)]

LS = Surface losses/lead andcontainer = (950 x 3) + (66 x 20)

H = heating time/hrs

kWh = 26836.4 + 41703412 2000

= 7.87 + 2.09

= 9.96

kW = 9.961 (hrs. allowed for heating)

= 9.96

To Find kW Operating

Requirement:

kW = QS + QL + QF + LS

3412 1000

Where:

QS = kW to heat added lead tomelting pt. =[250 x 0.031(621 - 70)]

QL = kW to heat melted lead =[250 x 0.040 (800 - 621)]

QF = Heat of fusion = (250 x 10)

LS = Losses = (950 x 3) + (66 x 20)

kW = 8560.25 + 41703412 1000

= 2.5 + 4.17= 6.67 kW

Therefore, install 9.96 + 20%(contingency factor) 12 kW and useautomatic temperature control. Byallowing a longer heat-up period theinstalled capacity may be reduced.By allowing 2 hours for this initialheat-up period, only 6.01 kW wouldbe required. However, operatingheat requirements are now largerthan heat-up requirements,consequently use 6.67 x 120% or8 kW. This method results in lowerinstallation costs and is preferablewhen rapid heat-up is not of primeimportance. If heat-up is allowed in 2 hrs, for example,surface losses are multiplied by 2 and andtotal kWh is divided by 2 to calculaterequired kW.

FOR CLAMP-ON STRIP ANDRING HEATERS

It was determined above that 12 kWheating capacity was needed forlead melting. It was decided to useType OT strip heaters clamped tothe thermally insulated crucible orpot. Since material is heated to800F chrome steel sheath stripheaters must be used. Refer toFigure C-1 on this page. For amaximum sheath temperature of649C (1200F) the ambienttemperature inside the spacebetween thermal inside the space

between thermal insulation and

vessel will be(800F + 1200F) 2 = 1000F.

From the curve the allowable wattdensity is 8 W/in2. Based on size ofthe crucible, Type OT chrome steelsheathed strip heaters, 24" longwithout mounting tabs, are selected.To determine the number of stripsneeded, and the wattage of eachuse the following formula. Allowablewatts per strip is (overall lengthminus 4" cold sections) x 3.45 in2

per lineal inch of sheath x 8

allowable watts/in2. Thus (2512 - 4)x 3.45 x 8 = 600 watts rounded offto nearest higher 10 watts. Thetotal number of strips required is12,000W 600W = 20 strips. Orderstrips similar to OT2507 in size butrated 600 watts. Stock deliverycould be obtained by using 24standard OT-2405, 500 watt stripswhich would have a watt density of:

500W = 7.35 W/in2

(2334 - 4) x 3.4

If application is to employ 3-phasepower source, total element countshould be a multiple of 3 to permitbalanced electrical load. Stripheaters should be applied to tanksurface by using applicable utilityclamps on 5-inch centers.

0 100 200 300 400 500 600 700 800 900 1 000 1 100 1 2000

2

4

6

8

10

12

14

16

18

20

22

WATTSPERSQUARE

INCH

F AMBIENT TEMP.SHEATH TEMP + MATERIAL TEMP.

2=

WATTAGE RATING OF STRIP = WATTS/SQ. IN. x HEATED SHEATH AREA

Heated length of strip heaters shorter than 30 1/2 in. is 4 in. less than overall length:

strip heaters 30 1/2 in. long or longer have heated length 5 in. less than overall

length. 1 1/2 in. wide strip heaters have 3.45 square inches of surface per linear

inch. 1 in. wide strip heaters have 2.31 square inches of surface per linear inch.

500

1200

1100

1000

900

800

700

600

FSHEATH

TEMPER

ATURE

Figure C-1: Sheath Temperature ofclamped-on OMEGALUX Strip Heaters forvarious ambient temperatures andwattage ratings.


4/8

(750F) for iron and 510C (950F)for chrome steel.

Calculate air velocity through the

heater to verify maximum operatingsheath temperatures will not beexceeded.

kWh = V F

A x 60

Where:

V = Air velocity in ft/sec

F = Air flow in ft3/min = 450 cfm

A = Area of htr. = (1538" x 2158"=2.3 ft2)

V = 450

2.3 x 60

= 3.3 ft/sec

Using Figure C-5 (page 78), basedon an outlet temperature of 66C(150F) and a watt density of 26W/in2, a velocity in excess of 9 ft/secis required to keep the sheathtemperature at permissible levels forthe CAB-152. This is well above theactual velocity and rules out the useof the CAB-152. By applying thewatt density and outlet airtemperature to Figure C-2 (shownbelow) we see that we need aminimum of approximately 3 ft/secair velocity to maintain a maximumof 482C (900F) sheathtemperature. Since this is lowerthan actual velocity, the use ofCAB-1511 is acceptable.*

77To Order, Call or Shop Online at omega.comSM

EXAMPLES FOR HEATING AIR/GASES

HEATING AIR IN DUCTSProblem: A special drying processrequires that we raise 450 cfm of airfrom 4 to 66C (70 to 150F). The

existing ductwork which will be usedfor this purpose is insulated(negligible losses) and measures2' wide by 1' high. Power availableis 240 Volts 3-phase. Calculate therequired kW and select a compatibleheater for this application.

Solution: Under standardconditions air has a specific weightof 0.08 lbs./ft3 and a specific heatvalue of 0.24 Btu/lb/F.

kW = WT x CP x T x 1.2

3412

Where:

WT = Wt of air/hr =(450 x 60 x .08) = 2160

CP = Spec. heat of air = .24

T = Temp. rise F = 80

3412 = BTU to kWh conversion

1.2 = Safety factor

kW = 2160 x .24 x 80 x 1.2

3412

= 14.85

For quick estimates, the followingformula may be used where 3000 isa conversion factor in units offt3 - F/min-kW.

kW = cfm x temp. rise

3000

= 450 x 80 = 12 x 1.2 = 14.4

Or: When airflow (ft3/min) andtemperature rise are known, figureC-7 (page 79) (which shows 15 kWfor this example) may be used. Thiscurve does not include contingency

allowance.

To select the heater:In this application there are a fewchoices to be explored. Firstconsider OMEGALUX CAB Seriesheaters. Knowing the applicationrequired, 15 kW leads us to selecteither the CAB-1511 with chromesteel elements or the CAB-152 withiron sheath elements rated at26 W/in2. The maximum operatingsheath temperatures are 399C

An alternative method to beconsidered would be mountingbanks of finned strip heatingelements in the ductwork. Knowing

that 15kW is required and that ourduct measures 2' wide x 1' highand that a chrome steel sheath isrequired, we can select the properfinned strips.

Using figure C-2 (shown below), themaximum allowable watt density is26 W/in2. Elements with wattdensities of 26 W/in2 or less aresuitable. Since the duct is 2' wide,consider using OTF-2101, 21" long,240 Volts, 1250 watts at 21 W/in2.

No. finned strips required:

= Operating wattsRated W/elem.

= 15,000

1250

= 12 finned strips

Use 12 OTF-2101 finned stripsmounted sideways with narrowedge facing airstream. Total numberof elements installed must bedivisible by 3 so they can beconnected in a 3-phase delta circuit.

*Use of CAB-1511 will require a transitionin the existing ductwork to accommodatethe heater.

100 200 300 400 500 600

4

8

12

16

20

24

28

32

WATTSPERSQU

AREINCH

F AMBIENT TEMP.

WATTAGE RATING of FINNED STRIP-WATTS SQ. IN. x 3.60 x HEATED LENGTHFOR HEATED LENGTH of FINNED STRIP

In calculating heater capacity, usethe maximum ambient temperatureand lowest air velocity. For closegrouping of heaters, use 80%of calculated values.

16F.P.S.DISTRIBUTED

AIRVELOCITY

9F.P.S.

1 F.P.S.orFREEAIR

4F.P.S.

Figure C-2 Allowable Watt Densities/Finned Strips: Allowable finned strip wattageratings for 800 to 900F sheath operating temperature at different air temperaturesand velocities



ALLOWABLE WATT DENSITIES

112" wide strip heaters have a3.45 square inches of surface perlinear inch; 1" wide strip heatershave 2.31 square inches of surfaceper linear inch.

0 100 200 300 400 500 600 700 800 900 1000

WATTSPERSQU

AREINCH

28

24

20

16

12

8

4

16F.P.S.DISTIBUTEDAIRV

ELOCITY

9F.P.S.4

1F.P.S.DISTIBUTED

STRIP HEATER WATTAGE RATING =WATTS /SQ. IN. X HEATED SHEATH AREA

F AMBIENT TEMPERATURE

9F.P.S.

4F.P.S1F.P.S.ORFREEAIR

WATTSPERSQUAREINCH

STRIP HEATER WATTAGE RATING = WATTS/SQ. IN. x HEATED SHEATH AREA1 1/2 in. wide strip heaters have 3.45 sq. inches of surface per linear inch;1 inch wide strip heaters have 2.31 sq. in. of surface per linear inch.Heated length of strip heaters shorter than 30 1/2 in. is 4 in. less than overalllength; strip heaters 30 1/2 in. or longer have heated length 5 in. less thanoverall length. In calculating heater capacity, use the max. ambient temp.

and lowest air velocity. For close grouping of heaters,use 80% of calculated values.


0 100 200 300 400 500 600 700

1

2

3

4

5

6

7

8

9101112131415

16F.P.S.DISTRIBUTEDAIRVELOCITY

0 100 200 300 400 500 600

32

28

24

20

16

12

8

4


WATTS

PERSQUAREINCH

STRIP HEATER WATTAGE RATING of FINNED STRIP = WATTS/SQ. IN. x 3.60 xHEATED LENGTH for HEATED LENGTH of FINNED STRIP

In calculating heater capacity, use themaximum ambient temperature and lowestair velocity. For close grouping of heaters,use 80% of calculated values.

16F.P.S.DISTRIBUTEDAIRVELOCITY

9F.P.S.

4

1F.P.S.ORFREEAIR

Heated length of strip heatersshorter than 3012" is 4" less thanoverall length; strip heaters 3012" orlonger have heated length 5" lessthe overall length. In calculating

heater capacity, use the maximumambient temperature andlowest air velocity. For closegrouping of heaters, use 80%of calculated values.

ALLOWABLE WATT DENSITIES/STRIP HEATERS

Allowable Wattage Ratings that develop 371C (700F) strip heatersurface temperature at different air temperatures and velocities.

Allowable Wattage Ratings that develop 538C (1000F)strip heater surface temperature at different air temperaturesand velocities.

Allowed Finned Strips Wattage Ratings for 316C (600F) sheathoperating temperature at different air temperatures and velocities.

ALLOWABLE WATT DENSITIES/FINNED STRIPS

FIGURE C-3 FIGURE C-4

FIGURE C-5


6/879To Order, Call or Shop Online at omega.comSM

STRIP HEATERS FOR AIR HEATINGProperties of Air/Pressure Drop Curves

1 3 5 7 9 11

KILOWATTS

30

10

0

HUNDRED CUBIC FEET OF AIR PER MINUTE

50

70

90

110

130

150

170

550

F

RISE

500

F

RISE

450F

RISE

400FRISE

300FRISE

250FRISE

200FRISE

150F

RISE

100FR

ISE

350F

RISE

75FRIS

E

50FRISE

600

F

RISE

300 600 900 1200 1500 1800 2100PRESS.DROP-IN.ofWATER(LBS/IN2=

IN.ofWATERx0.036)

1.0.9.8.7.6.5.4.3.2.1

.09

.08

.07

.06

.05

.04

.03

.02.01.009.008.007.006.005.004.003.002

VELOCITY OF AIR F.P.M. (STD.AIR)

TRIPLE ROW OF CAB

DOUBLE ROW

SINGLE ROW

Resistance to Air Flow over OMEGALUX Finned Stripand CAB Air Heaters

Heat Requirements for Air. Based on .08 lbs/cu. ft. Weightand a Specific Heat of .237 BTU/ lb/ F

OTF SeriesFinned Strip Heater

FIGURE C-7 FIGURE C-6

OTF-102 finned strip heater, $68,shown smaller than actual size.See page 90 for details.



HEATER SELECTION NOMOGRAPHS

TO USE CURVE (FIGURE C-8)

1. Select maximum desired operatingair temperature on (D)

2. Choose either chrome steel sheathor rust-resisting iron sheath (points E)on basis of operating conditions

3. Draw straight line through points (D)and (E) to reading on (F) giving maximumallowable watts per square inch

4. Select desired length heater withequivalent watt density or less


1. Select maximum desiredwork temperature on (A)

2. Choose either chrome steel sheathor rust-resisting iron sheath (points B)on basis of operating conditions

3. Draw straight line through points (A)and (B) to reading on (C) giving maximumallowable watts per square inch

4. Select desired length heater withequivalent watt density or less


1. Select a maximum desiredair temperature on A

2. Choose sheath material

to suit operating conditions3. Select minimum anticipated air

velocity on B.

Note:Natural circulation is equal toone foot per second

4. Draw straight line through the pointsselected on A and Bread C forallowable watt density

5. Select required length heaterwith equivalent watt density or less

Selection of Strip Heaters for Clamp-On Applications

1000

900

800

700

600

500

400

300

200

100

0

Chrome Steel Sheath

Rust Resisting Iron Sheath

20

18

16

14

12

10

8

6

4

2

0

A CB

WattsperSquareInch

AirTemp.inF

Selection of Watt Density for Finned Strips

700

600

500

400

300

200

100

0

WattsperSquareInch

Chrome Steel Sheath


15

10

5

AirVelocity-Ft./Sec.

16

9

4

1


16

9

4

1

AirTemp.inF

20

25

30

A CB

Selection of Strip Heaters for Air Heating

700

600

500

400

300

200

100

Chrome Steel Sheath


20

15

10

5

00


16

9

4

1 WattsperSquareInch


16

9

4

1

AirTemperatureinF

D FE

Figure C-8

Figure C-9

Figure C-10


8/8

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