Document 6R0zd5dmawwx4VN2d82MQw9K9

c Ad 4v-t (* 1Wu ^oo^ V\c id Geo-r^e <V\A*e-v^) ?/*4fr<\ * XK l wne y (/^/u~ t h o r nr\lJiLnik FR FLUID HEAT SYSTEMS ENGINEERING HEAT TRANSFER DATA A Design Guide For Engineering Low-Cost, Low-Pressure FIRE-RESISTANT HEAT TRANSFER SYSTEMS o<.oeoo!> TOWOLDMON0031110 WATER PCB-00015579 AUv Ov /UuJU<r\ O^ 'vj-Q + TABLE OF CONTENTS Introduction................................................................................................... Properties Important To Heat Transfer Design.................................... Curves; Viscosity/Temperature; Density, Specific Gravity............... Curves; Specific Heat; Thermal Conductivity...................................... Specific Heat ofTherminol Fluids; Relationship To Density............ The Heater..................................................................................................... Therminol System Components............................................................... Pumps, Piping, Valves, Rotary Joints, the Expansion Tank, etc. Testing, Cleaning, Filtering....................................................................... Controls for the Therminol System......................................................... Operation and Maintenance of the Therminol System........................ Typical Therminol Systems....................................................................... Therminol Engineering Data...................................................................... Resistance of Valves and Fittings To Flow of Fluids.......................... Pressure Drop; Heat Transfer Rate, Heat Exchangers........................ Viscosity Conversion Chart....................................................................... Engineering Conversion Factors............................................................... Typical Applications for Therminol Systems........................................ Safety of Handling Therminol Fluids....................................................... Notes............................................................................................................... Page 1 3 4 0 6 8 11 14 10 16 16 .22 29 30 35 .36 .45 .46 47 TOWOLDMON0031111 WATER_PCB-00015580 '--I h o r FR FLUID HEAT SYSTEMS... Delivering High-Temperature Process Heat as a Liquid As recently aB 1941, process engineers were limited to two methods of delivering process heat: DIRECT FIRING or PRESSURIZED VAPOR. Each method had definite draw backs. Direct firing was often unsatisfactory because the heating was uneven, the tempera tures difficult to control, and the processing of combustible materials extremely hazardous. Pressured-vapor, such as steam, required costly, high pressure piping, valves, and proc essing equipment--plus constant chemical "conditioning" of boiler water. Heat energy and temperature loss were common with pres sured-vapor systems because of "blowdowns," condensation, and the inevitable pressure loss with long rune of piping. Today, non-pressurized, high-temperature, fire-resistant heat transfer systems based on Monsanto's THERMI NOD FR Heat Trans fer liquids overcome practically all the de ficiencies and drawbacks of direct firing and pressurized-vapor heating. THERMINOL FR--a series of high-boiling, heat-stable organic liquids, delivers processing heat to single or multi-users as a liquid without pres surizing. THERMINOL fluids are safe and fire resistant. Heating is uniform; and tem perature control is accurate within a range of plue-or-minus 2F. Heat transfer systems now in use for several years have proved THERMINOL fluid heat successful in a wide variety of process heating operations . .. from food cooking to chemical processing, from distillations to drying ovens and in petroleum refining. Design engineers and manufacturers have developed a variety of THERMINOL FR Fluid Systems ranging from small electrically heated units to giant gas or oil fired units-- all capable of delivering heat AS A LIQUID. I 1 I11 II U ; !! K ll H Vi Vi V osoeoo? 1J TOWOLDMON0031112 WATER_PCB-00015581 This manual explains and illustrates the fundamentals of THBRMINOL fluid heat transfer systems design. It list6 materials of construction and components for use with THBRMINOL, and explains how each is "designed in" to make the most efficient system for safe, economical and reliable opera tion. It shows how these systems can be adapted to a wide variety of heating and cooling processes. This engineering heat trans fer data has been compiled to aid the Process Engineer in designing a safe, minimum main tenance system for delivering heat to the points of use in practically any commercial or industrial process --Iher ,FR HEAT TRANSFER LIQUIDS... Monsanto THBRMINOL FR heat transfer liquids are chlorinated biphenyls, manufac tured under exacting process control to pro duce fluids consistent in all properties impor tant to heat transfer. THBRMINOL FR products are unique in that they are actually produced to rigid specifications for thermal stability, specific heat, thermal conductivity, vapor pressure, and viscosity, There are three THBRMINOL FR products, with a range of low temperature fluidity and boiling points that allows the user to select the best balance of fluid properties for a specific use: THERMINOL FR 1 with lowest temperature fluidity -- excellent for processes requiring both heating and cooling THERMINOL FR 2 with optimum balance of properties for use in most common industrial heating applications THERMINOL FR 3 with highest boiling point for special proc essing equipment applications 0* 0*'oo% TOWOLDMON0031113 WATER_PCB-00015582 PROPERTIES IMPORTANT TO HEAT TRANSFER DESIGN .", THERMINOL FR-I . Temperature F. c. SO too 150 WO 250 300 350 400 450 500 . 550 600 650 : 700 10.0 87.8 66 83 121 149 177 204 232 260 268 816 843 871 Cnthalpy BTU/Lb. 4.856 16.66 82.85 4B.07 63.50 79.45 85.84 112.96 130.48 148.52 167.08 186.16 205.79 225.82 Specific Hea Thermal Conduct. BTU/Lb.--*F. BTU/Ft!. Hl.,F./Ft 0.272 ; 0.282 0.291 0.3047 0.3151 0.3255 0.3359 0.3464 0.3568 0.3672 0.3776 0.3880 0.3985 0.4069 0.06098 0.06060 0.06021 0.05976 0.05927 0.05875 . 0.05819 0.05760 0.05697 0.05630 . 0.05560 0.05487 . 0.05409 0.05329 Oenslty Lb./Gal. 11.683 11.458 11.216 10.991 10.760 10.528 10.296 10.065 9.838 9.601 9.870 9.188 8.906 8.676 Viscosity Lb./Hr.--Ft. 745.36 S6.144 15.972 8.2481 5.5270 3.4158 2.4763 1.8898 1.5028 1.2351 1.0428 0.90031 0.79166 0.70731 Vapor Pres. mm. Hg. Absolute 10 27 65 143 201 550 81.9 psla Temperature F. C. 50 100 160 200 250 800 850 400 450 ; 600 550 600 650 700 10.0 37.8 66 83 121 149 177 204 232 260 266 816 343 871 THERMINOL FR -2 Enthalpy BTU/Lb. 4.59 17.61 81.09 45.11 59.43 74.14 89.26 104.61 120.74 137.08 153.85 170.99 188.58 203.45 Specific Heat Thermal Conduct. Density BTU/Lb.--F. BTU/Ft?, Hr., F./Ft. Lb./Gal. 0.257 0.265 0.274 0.2840 0.2922 0.3003 0.3084 0.3166 0.3247 0.3328 0.3410 0.3491 0.3573 0.3654 0.05881 , 12.225 0.05852 12.000 0.05801 11.750 0.05788 , 11.525 0.05748 11.293 0.05703 , 11.062 0.05655 10.830 0.05603 10.598 0.05548 10.367 0.05438 10.135 0.05424 9.903 0.05357 ` 9.672 0.05286 ' 9.440 0.05211 9.208 Viscosity Lb./Hr.--Ft. 7090.6 161.01 27.83 11.971 6.949 4.531 3.201 2.399 1.861 1.529 1.2795 1.0971 0.9596 0.8535 Vapor Pres. mm. Hg. Absolute 6 15 37 84 173 340 615 20.8 psla Temporature C. 50 too 150 200 250 300 350 400 450 500 650 . 600 650 700 10.0 97.8 66 93 121 149 177 (204 232 260 266 816 843 871 THERMINOL FR 3 Enthalpy BTU/Lb. 4.28 16.87 29.06 41.95 55.86 69.20 83.46 98.15 118.26 128.77 144.78 161.11 177.92 192.24 Specific Heat Thermal Conduct. BTU/Lb.--F. BTU/Ft*, Hr., F./Ft. 0.239 0.245 0.256 0.2629 0.2714 0.2799 0.2684 0.2969 0.8054 0.3186 0.8223 0.3306 0.3393 0.3476 0.05700 0.05680 0.05634 0.05620 0.05598 0.05558 0.05513 0.05456 9.05415 0.05850 0.05302 0.05241 9.05176 0.05107 Density Lb./Gal. 13.002 12.760 12.534 12.292 12.061 11.829 11.597 11.366 11.184 10.902 10.671 10.439 10.207 9.976 Viscosity Vapor Pres. mm. Lb./Hr.--Ft. Hg. Absolute 1626.6 101.64 24.262 12.091 7.116 4.669 3.306 2.476 1.937 1.5699 1.3095 1.1188 0.97531 8 9 24 55 114 223 413 735 0408009 3 TOWOLDMON0031114 WATER_PCB-00015583 VISCOSITY-TEMPERATURE CHART # ABSOLUTE VfCSOSlTY. CENTtPOISES DENSITY--LBS./FT? 1 DENSITY AND SPBCIPIC GRAVITY 0 100 200 300 400 500 600 TEMPERATURE F. 04,0801 TOWOLDMON0031115 WATER_PCB-00015584 SPECIFIC HEAT (Hoaon I TOWOLDMON0031116 WATER_PCB-00015585 THERMAL CONDUCTIVITY BTU/HR., FT.l, "F./FT. SPECIFIC HEAT BTU/LB., --thorSPECIFIC HEAT OF FR Its Relationship to Density Specific heat--the quantity of heat required to raise the temperature of a material one degree, compared to the heat required to raise a like mass of water one degree- compares the material with water, pound for pound. When comparing specific heat values of THERMINOL FR liquids with correspond ing values of other heat transfer fluids, it is important to note that the density of THERMINOL is much higher than the den sity of other fluids commonly used in heat transfer. In consequence, the heat capacity of THERMINOL fluids is greater than imme diately apparent from the specific heat values. In transferring heat, a volume of fluid is circulated to give up or absorb heat and the heat capacity of that volume of fluid is the factor that determines the heat transfer ca pacity of the system. When a comparison is made on a volume basis (as illustrated below), THERMINOL liquids are comparable to other organic liq uids and superior to some: SPECIFIC HEATS OF VARIOUS FLUIDS at ROOM TEMPERATURE Pounds/ Cal. Specific Heat Heat Capacity (BTU/lb./ (BTU/gal./ F.) BF.) THERMINOL FR 2 Organic Fluid "A" Petroleum OH 12.03 8.62 7,9 0.276 0.37B 0.378 3.32 3.33 2.96 t> ( THE FLUIDS THERMINOL FR liquids are unique. They permit installation of a non-pressurized sys tem operating with o liquid which has no fire point, and will not support combustion. THERMINOL FR liquids are so fire-resist ant they have been listed with Underwriters' Laboratories! Because of this extreme fire resistance and its recognition by insurance companies, impor tant savings can be made in designing a processheating system around THERMINOL FR fluids. The savings include not only the lower capital cost of non-pressurized equip ment, its simplified installation and lower maintenance; but. also elimination of some of the costly safety devices required in equip ment circulating a flammable fluid at or above its fire point. These economies show up both in the type of components needed and in the layout of the system. Still another unique property of THEKMINOL fluids is their unusual chemical inert ness. They are among the most oxidationresistant compounds known. This inertness prevents the formation of oxidation sludges if the hot fluid comes in contact with air. This extends the useful service life of the heat transfer fluid; occasionally allows economies in design. However, THERMINOL FR fluids are not intended for use in open vessels but in properly vented, closed systems. 0408012 TOWOLDMON0031117 WATER_PCB-00015586 Chemically, THERMINOL FR fluids are resistant to strong acids, mild alkalies, and dilute solutions of strong alkalies. THERMAL STABILITY THKRMINOl FR fluids are thermally stable. ri'hey are manufactured to meet strict thermal stability specifications. Each produc tion run is tested in Monsanto's laboratories with special equipment developed by Monsanto to assure that these fluids meet the high standards of thermal stability. Any material which does not meet these standards is rejected, It is characteristic of almost all organic mate rials to undergo chemical change when ex posed to high temperatures for long periods of lime. The type of chemical change depends upon the molecular structure of the fluid; the degree of change depends on the temperature, and the length of time of exposure. TH KRMINOL FR fluids resist chemical change up to temperatures of 600F. and show no measurable change after years of exposure to such temperatures. Exposure to temperatures above 6006F.--even localized overheating will only cause some formation of "high boilers": molecules of THERM1NOL FR will join together to form larger molecules quite similar to the original material, but higher in viscosity and in boiling point. These high boilers are soluble in the fluid up to reasonable concentrations; so overheating only increases the fluids' room temperature viscosity slightly, When a concentration of approximately 5-10 percent "high boilers" has been formed, however, the viscosity begins to rise quite sharply. With this change, small but measurable amounts of dry hydrogen chloride gas are evolved. This should be removed from the system by appropriate venting. When THERMINOL Fit fluids operate at high bulk temperatures, or, where some local over heating may occur, the system should be designed to prevent moisture from condensing in the vapor spaces where this hydrogen chloride gas is being vented. When the hydrogen chloride is dry, it has little or no effect on metals in the system. However, if the hydrogen chloride dissolves in moisture, an acid corrosive to certain metals is formed. A properly designed heater and distri bution system operated at or below 600F.f will allow use of the same fluid for many years. While THERMINOL FR fluids normally are operated to a maximum temperature of 600F. --systems specially designed for operation at higher temperatures have proved successful. At higher temperatures--"high boiler" forma tion with attendant viscosity increase is, of course, accelerated and a shorter service life must be expected. However, side stream dis tillation can be employed to constantly re move higher boiling materials while the sys tem is in operation. Periodic make-up is added to replace the quantity of the high boiler material removed. An alternate procedure for higher tempera ture operation, which is sometimes more suitable for smaller installations, is periodic replacement of the THERMINOL charge, reclaiming the used fluid by straight take over distillation. (Monsanto should be con tacted for details regarding this procedure.) On systems containing only 50-100 gallons of THERMINOL, it is usually most economical to periodically discard the entire charge and replace it with new fluid. THERMINOL SYSTEM DESIGN When designing a THERMINOL FR system it is important to remember this fact: THE FLUID CAN BE NO BETTER THAN THE SYSTEM! THERMINOL FR liquids are ideally suited for high temperature preci sion heating and temperature control applica tions, but only if the heater and distribution system are properly designed, constructed and operated. While there is nothing profoundly different or complicated about a THERM INOL system, certain design parameters must be rigidly observed if the system is to operate trouble-free, efficiently, and with realization of the full benefits of heat de livered by a liquid. D i< y i. o Ic \ 'T ei ` u i( ic 0<00i3 I TOWOLDMON0031118 WATER_PCB-00015587 u- ' ! THE HEATER The heater is the most critical component in a THERMINOL system. Accordingly, the heater should be selected with great care! Two basic heater designs for THERMINOL fluids are available: the liquid tube and fire tube types. In liquid tube heaters, the THERMINOL is pumped through the tubes at a definite flow rate as it is heated; in fire tube types, THERMINOL flows through the "shell" of the heater surrounding the fire tubes. When operating temperatures of 500F. (or higher) are required, a liquid tube type heater is to be preferred . .. unl-ess a specific design is devised to force a steady flow over the heat donor surfaces. Since THERMINOL fluids transfer heat in liquid form, they do not form vapor to ac celerate convection circulation. To avoid hot spots in a THERMINOL heater, the fluid Bhould be pumped over the heating surfaces ^thflt no area of stagnant fluid occurs. ^iid velocities over the heat donor surfaces should be relatively high; generally 4 to 10 feet per second. This helps avoid both exces sive fluid film temperatures and also reduces the quantity of fluid in the high temperature film that is in direct contact with the heat donor surface. The illustration shows the effect of fluid velocity on film temperature and indicates i the importance of this design requirement. EFFECT OF LIQUID VELOCITY ON FILM TEMPERATURE DURING HEATING Importance of Fluid Velocity and Film Tem perature through Heater A bulk fluid temperature of 600F. and a maximum film temperature of 640F. assures long service life of THERMINOL FR fluids. Note the significance of "maximum" film temperature: heating is not uniform in fired TOWOLDMON0031119 WATER_PCB-00015588 ! heaters, and maximum conditions--not aver age--must be used to determine the recom mended 640F. ceiling. Example: The film coefficient for THERMINOL in a given heater is 250 BTU/hr. sq. ft., 0F., and the fluid temperature is 570F. The average radiant absorption rate is 9,000 RTU/sq. ft.., hr. The maximum ra diant absorption rate is 17,000 BTU/sq. ft,, hr. The average film temperature is then 570 H 9'r0 - 606F., 250 but the maxmium film temperature is 17,000 570 4 638F. 250 Past experience shows that when purchasing a heater, the buyer should insist that design and capacity provide optimum film tempera ture for the fluid. The method of Lobo and Evans is useful in calculating film temperatures in radiant heaters. When electric heaters are used--heat flux is more even. However, it is important to re member that all of the heat from the electric element passes into the fluid. The watt-density on the surface of the heater tube and the fluid velocity past the tube should be in proper balance to avoid excessive THERMINOL film temperatures. Watt-densities in the range of 8 to 10 watts per square inch with a minimum velocity of 4 feet per second are suggested. However, watt-densities in the 18 to 22 watt per square inch range have proved satisfactory in properly designed installations. Heaters for THERMINOL should meet local code requirements. However, the fire resist ance of THERMINOL FR fluids will often permit important economies in the design and placement of fired heater equipment. With gas-fired heaters, the THERMINOL unit need not be placed outside of the building or isolated in a fireproof structure unless the use process requires such precaution. Steam or inert gas smothering devices can generally be eliminated and a vapor tight firebox to retain smothering gases is not necessary. The fuel for THERMINOL heaters is purely optional. Gas- or oil-fired heaters, and elec tric resistance heating are all used with success. Coal-fired heaters are generally not recommended because of their slow response to change of load at the heat source. The over-all thermal efficiency of a fired heater will generally be comparable to steam boilers of similar size. Efficiencies of 75 to 80 percent can be expected when convection sections are added. Efficiencies of 60 to 70 percent are achieved with only a radiant section. Lobo. W. E., and J. E. Evans, Trans. AlChE. 35. 743 (1939) * 0*106015 TOWOLDMON0031120 WATER_PCB-00015589 THE HEATERS TOWOLDMON0031121 WATER_PCB-00015590 In selecting pumps for a THERMINOL system, it is important that the pump ca pacity and pressure head be sufficient to circulate the fluid at the rate demanded by the particular installation. For large flow rates, the fluid circulating pump should gen erally be the centrifugal type and any one of a number of brands of standard high tem perature centrifugal pumps designed for hot liquid service is suitable. Dean Brothers, Worthington, Ingersoll-Rand and Chempump for example, are all used satisfactorily. For most THERMINOL systems, cast steel pumps are best. Pump manufacturers usually specify that above 450F. fluid temperatures, a water jacketed, deep stuffing box or me chanical Beal and water-cooled bearings be used. Mechanical seals are used widely today. It is suggested that with a stuffing box, eight rings of packing be provided. Durametallic No. D-110, Garlock No. 736 and equivalent packings are satisfactory for the pump, and an open, non-overloading impeller is desirable to handle the cool, relatively viscous liquid at start up. When a new system is first put into operation, a slight leakage may be noticed at the pump packing. It is not advisable to tighten the pump gland, however, until the system has heated up close to the temperature of operation. Canned pumps such as Chenipump Series T require no 6eal and have proved very service able in THERMINOL systems. Small gear pumps are also used successfully in THERM INOL FR service because the fluids have good high temperature lubricating properties. However, gear pumps characteristically de crease in pumping capacity after extended use. When gear pumps are used, care should be taken in selecting the capacity so there is a margin that will assure adequate flow through the heater. Regardless of the type of pump selected, the flow rate should be checked regularly against its performance when new. To avoid shaft trouble and leakage at the seals, it is important to provide adequate expansion joints and to support the piping in a way that avoids stresses on the body of the pump. Direct-connection pumps driven by 1,750 rpm. motors are most commonly used. Each pump should be fitted with a control to switch off the burner in case of pump failure. If expansion loops are used in the pump suction piping, they should be horizontal or vertically downward. They should not be vertically upward, for in such a position they form a trap which can collect air and non condensibles, and seriously hamper the pump's performance. PIPING... The most important factors in the piping layout for a THERMINOL FR system are; (A) Proper sizing for the required flow rate and (B) minimizing pressure drop. Because the system will undergo temperature changes, K I r o'.oeoi' "I TOWOLDMON0031122 WATER_PCB-00015591 adequate expansion joints and loops to relieve expansion and contraction stress are essential. Generally, Schedule 40 seamless steel pipe is used with THERM 1NOL FR systems. It is characteristic of most organic fluids (includ ing THERMINOL) to have a tendency to leak through joints and fittings at high tem peratures unless these fittings are very tight. Therefore, flanged joints should be used sparingly to minimize potential leak points. Threaded connections are used with THERM I NOR FR up to a one-inch maxi mum size. Care is required in cutting the threads to assure a proper fit; a clean, new die is recommended. Careful attention to threading procedure should provide a good threaded connection. It is not wise to rely upon the use of pipe dope to eliminate leak age. However, pipe dope should be used. Q-seal (Quigley Company, Inc.); Plastiseal (Johns Manville); and Crane's No. 425 are all used successfully in THERMINOL FR systems. In larger size pipes, welded connect ions should be used wherever practical. Careful layout and use of curved sections of pipe can mini mize the welded or flanged connections re quired. When a flanged connection is made, 150 pound raised face flanges are recom mended. The flange should be backwelded to the pipe and proper gasketing used. Spiral wound (Spiratalic or Flexitallic) asbest os and stainless steel gaskets are good. Small lip spiral wound gaskets are preferred over the wide lip type, because they allow better compression with the 150 pound flange. Garloek short fiber, pre-cut and cured as bestos gaskets have also proved satisfactory. H i6 recommended that high temperature bolts, such as Crane Triplex steel bolts, which do not stretch, be used. All high points in the piping system should be provided with vent valve connections. VALVES... One hundred and fifty pound cast steel valves with deep stuffing boxes are satisfactory for TH EltM 1N OE systems. Cast steel ball valves designed for high temperature (such as offered by Hills McCanna have also proved very effec tive, particularly where quick open-and-close action is desired. ROTARY JOINTS... It is wise to take particular care in the in stallation and maintenance of rotary joints in order to assure long service life and mini mum leakage. Install such joints with proper flexible connections to assure alignment at all times. Rotary joints should not be operated in a new' system until the system has been thoroughly cleaned of abrasive particles which could score the sealing faces and cause leak age. Rotary joints such as those manufac tured by the Johnson Corp. and Perfecting Service Co. are satisfactory with THERMINOL FR. THE EXPANSION TANK... Proper design of the expansion tank for the THERMINOL system is quite simple, but is also very important to proper system operation. Characteristic of most organic liquids, THERMINOL expands in volume about 4 percent for every 100F. temperature rise. In heating THERMINOL from room tem perature (70F). to 600F., the fluid in the system expands about 20 percent, Therefore, the expansion tank should be large enough to accommodate about 20 percent of the total volume of the entire system, including the fluid content of the heater, piping and all heat users. The tank should be sized so it is about one quarter full when the system is cooled to 70F. and three quarters full when the system is at a maximum operating temperature. The expansion tank should be fitted with a sight glass at the "full" range and with a float operated, low-level switch to shut off the burner in case of accidental fluid loss in the system. Place the expansion tank in the circuit on the pump's suction side --above the highest point in the system. The expansion tank also serves as the major venting point of most THERMINOL sys- 0<,O8l8 TOWOLDMON0031123 WATER_PCB-00015592 terns. The temperature of the fluid in the expansion tank is much lower than the bulk fluid temperature in the system. Connect the expansion tank to the system with a small diameter line to avoid thermal recirculation. However, make this line large enough to readily pass the flow caused by expansion and contraction in the system and to permit recirculation of fluid for moisture removal as explained below. Because THKKMINOL Fit fluids are fire resistant, the vent need not be isolated from potential sources of ignition. However, the vent should be out of doors, particularly away from working areas, to eliminate pro longed or repeated contact will) the vapors. Care should be taken to prevent the entry of atmospheric moisture into the system as the expansion tank `breaths' air. The vent can be equipped with an air dryer, such as a calcium chloride pot or other desiccant. An alternate procedure would be to blanket the expansion tank with nitrogen. However, if this is done, the THKKMINOL system should be dried thoroughly before the system is sealed with nitrogen. In systems using THKKMINOL above 600F. (or in systems where accidental high film temperatures may occur in the heater) some provision must- be made for venting any hydrogen chloride gas formed in the system and to assure that the system remains dry. Gas or water vapor will not escape readily through the "cold seal'' connecting the ex pansion tank to the THKKMINOL system. It is advisable to provide a pipe to feed a small side stream of hot THKKMINOL through the expansion tank as illustrated at right to allow hydrogen chloride and water vapor to flash from the fluid. A small stream of hot THKKMINOL from near the pump discharge should be piped directly into the vented expansion tank, so it enters the tank above the highest liquid level. A globe valve should be installed in the line to permit throttling the flow to the desired rate. Experience shows this simple procedure to be extremely effective and completely satisfac tory for removing hydrogen chloride and moisture from the THKKMINOL system. Analysis of samples drawn from systems operating with such a device show that the THKKMINOL fluid maintains minimum acidity and holds moisture at the low levels equivalent to newly manufactured fluid, even after prolonged periods of operation. Provision should be made to prevent moisture from condensing in the vapor space above the liquid level in the expansion tank and in the vent. It is advisable to trace and insulate the expansion tank and the vent so that any moisture accidentally entering the system will remain as a vapor and will not condense, This will prevent corrosion of steel and eliminate the need for higher cost alloys. The use of non-metallic vent pipe is also recommended. Polyester piping (available from Fibercast), resin lined steel piping or other non-metallics resistant to THKKMINOL vapors and to hydrogen chloride are commercially available and have been used with great success. NOTES... The expansion tank and vent should be traced and insulated. If steam is not available at the site, hot THERMINOL fluid can be passed through steel tracing tube. 0408019 *' i i* 1 1 * r v 1 c * r s 13 TOWOLDMON0031124 WATER_PCB-00015593 TESTING FOR LEAKAGE... When a new system has been installed, it is important to test for leaks. Probably the most widely used technique is to check for leaks with ammonia gas.. In this method, the system must be relatively dry and sealed. All vent valves should be closed and a tem porary pipe cap or slip blank installed at the expansion tank vent and at other points where there is no valve. Ammonia gas is fed into the sealed system followed by air under pressures up to ten pounds per square inch. Any leakage areas can be readily detected by the escape of ammonia. Tiny amounts of ammonia vapors can be made visible as white smoke by directing a 6mall stream of hydrogen chloride gas over each joint or fitting, and around each welded connection. Any leakage points can be marked, tightened, and then the system purged free of ammonia with plenty of air. A satisfactory alternate procedure is Halogen Testing: in this procedure, introduce one pound of Freon F-l 2 or Freon F-22 for each fifty cubic feet of volume of the system, Carefully introduce air not exceeding 10 psig of pressure. At this air pressure, the con centration of Freon will be sufficient to give a sensitive test. Attach a halide torch to an acetylene tank and light it. Using the 14 inch flame as a probe, explore for leaks by passing the end of the flame along seams and joints. If a leak is present, the escaping Freon will be drawn into the acetylene flatue turning it green. A large leak will produce a violet color. Leak testing with water is not recommended. Though effective, it creates a problem of introducing a large amount of water into the THERMINOL system which will be hard to remove. CLEANING THE SYSTEM... After testing for leaks and making any re quired adjustments, the system must be thoroughly cleaned. A new' system will contain dirt, weld and mill scale and other foreign particles. Unless re moved, these particles will be carried in sus pension by the circulating THERMINOL. They may "lodge" in valves, controls, mechancial seals, rotary joints and other mechan ical equipment, causing faulty operation or component failure. When purchasing the heating equipment, the supplier should be requested to clean the equipment as thoroughly as possible using brushes, wiping rags and suitable solvents, such as tri- or perchlorethylene. When completed, fill the system with the operating charge of THERMINOL. Bring the system up slowly to approximately 200F. At this temperature, the viscosity of THERMINOL will be very low. The turbu lence from this low viscosity, plus the excel lent solvent action of THERMINOL fluid, will further dean the system. Circulate the warm THERMINOL through the system without operating rotary joints (if they are installed in the system). FILTERING... Install a strainer, made of ordinary fine mesh screen backed up with H" screen, in the pump suction of the new system. As foreign materia) collects, this screen should be peri odically removed and cleaned. When, after several days during which the strainer col lects no material, remove it permanently from the line. The system should be heated and cooled for a minimum of two cycles with the suction screen in place, since the resultant expansion and contraction will loosen mill 0^oao2 TOWOLDMON0031125 WATER_PCB-00015594 scale. The screen may be placed in the main stream line, gasketed between two flanges. K is advisable, when operating where solids and contaminants might enter the system, to permanently install a high temperature filter on a by-pass line that can be isolated with valves for periodic cleaning. CONTROLS... Controls for heating systems using THERM1NOL should be installed both on the heater itself and on the heat-using units. A wide variety of thermal-operating controls are available, and any reliable standard equip ment is satisfactory. Install heater controls to regulate the firing mechanism in direct proportion to the re quired output. These controls should increase or decrease the heat in-put to maintain the THERMINOL at the operating temperature required by the heat-demand of the user. Small units may be operated satisfactorily by relatively simple "on-off" or "high-low" con trollers; larger units will operate more uni formly if equipped with modulating tem perature controls. Install user controls to regulate the flow of the heat transfer fluid in proportion to the heat-consumption of the heat-using equip ment. In a multiple-user system, separate controls should be installed on each consum ing unit, to assure the proper heat-delivery. Safety Controls. In addition to activating controls, the heater must also be fitted with the proper safety controls to meet the local code requirements. Safety controls should include: a. High temperature cutoff at the heater outlet... to shut off the burner in the event of an excessive temperature rise. b. High tube wall temperature cutoff. A thermocouple sensing element should be installed in contact with the radiant heated surface at the highest temperature point in the heater and protected as much as possible from direct or reflected radiation. Such a controller is usually of the on-off type with the switch wired into the flame safety circuit so that the burner is shut down when the switch opens. Aside from protecting the tube bundle, this safety con trol protects the THERM1NOL fluid from overheating. c. Low flow cutoff. This control will shut down the burner should flow rate drop below design rates, or if a loss of flow occurs due to pump mal-function or failure. Equip burners with regular automatic ignition controls and flame failure controls. In wide range firing operations, an over-fire draft con trol will increase the economy of the opera tion. Electric power failure and instrument air failure Bafety controls are also desirable. In general, the practice of "fail-safe" instru mentation and control is essential: use good quality indicating and recording gauges, with scales calibrated for the particular limits of operation for best reading accuracy. d 1 s C n l t ii 11 i) ) c i ,1 ii n h g r c >1 n a If TOWOLDMON0031126 WATER_PCB-00015595 OPERATION AND MAINTENANCE OF THE THERMINOL SYSTEM... The following recommendations are intended only as guides. These suggestions are sup plemental to the equipment manufacturer's recommendations as they relate to the par ticular heater or the user equipment in the installation. The following comments on start-up, shut-down, power failure precau tions, and periodic fluid check-ups apply generally to all sizes and types of equipment. NEW SYSTEM START-UP... For a new installation, or an existing system that has been drained and is idle: 1. Check the safety and control devices. Check the safety and control devices for proper installation, proper range settings for the operation, and actual operation (by manually activating the instrument). For protection of the over-all system and for predictable long fluid life, it is vital that all instruments and controls perform properly. 2. Check for leaks (see section on leak testing, page 14.) 3. Pull Vacuum on System. a. The vacuum should be pulled from a point of high elevation in the system; usually at a point just below the expansion tank. Prior to drawing a vacuum, close all valves to the expansion tank; dose all valves and vent connections to the atmos phere; close all valves to non-pressure equipment in the system (such vessels may collapse under vacuum) and open all valves in the interconnecting piping of the system. b. Turn on vacuum equipment and evacu ate the entire system (including the "users") to 26-27 inches of mercury vacuum (if possible), or until the absolute pressure of the system has reached the limit of the available vacuum equipment. c. Shut off vacuum equipment. 4. Charge the System with THERMINOL. a. Fill the expansion tank with THERM INOL, and introduce the fluid slowly into the system through the expansion tank valve until the tank is almost empty. Close the valve and again fill the tank. Open the valve allowing the fluid to enter the system and repeat until it no longer flows by gravity. b. Open all valves then start the main circulating pump in accordance with the manufacturer's recommendations, Observe the liquid level in the expansion tank re peating "a" above until the system has been filled. The thermal expansion of THERMINOL must be allowed for in determining the cold charge level. (A 20% expansion can be expected when heated to 600F.--as a guide, the expansion tank should be 70-75% full at the hot operating condition.) c. Circulate the THERMINOL fluid through the system for about 3 to 4 hours to eliminate air pockets and to assure com plete fill of the system. BEFORE FIRING HEATER, BE SURE THAT THERMINOL IS CIRCULATING FREELY. 5. Fire Heater. a. On new installation start-up, or after prolonged shut-down, bring the system up to temperature slowly--about 100F. per hour. This will prevent thermal shock to heater tubes, lube/header joints, refrac tory materials, etc., and allow operators to check the functioning of instruments and controls and become familiar with the equipment's operation. The slow heat-up will also allow any moist ure trapped in the system to escape as a vapor. b. Bring system to operating temperature and put "users" on the line. DAILY START-UP ... when equipment has been shut down overnight or for week ends, follow this procedure: 1. Start the circulating pump and check the expansion tank level to see that the * 0408022 TOWOLDMON0031127 WATER_PCB-00015596 rj ifYi'-'ii' THERMINOL is ai the proper cold-start level (H-iull). of safety controls and temperature limit controls. 2. Start burner at the "low" flame setting 3. Inspection of heater tubes, burner, refrac and continue full circulation until the tory linings. I THERMINOL bulk temperature reaches A. Periodic inspection of heater surfaces. 180F. 3. Turn heater up to full heat, 5. Inspection of water cooling at the circu lating pump. SHUT-DOWN . . . should be performed as follows to avoid overheating: 6. Repacking of stuffing boxes (according to manufacturer's specifications). 1. Shut off burner completely with circulating pump still operating. Continue to run the pump at full capacity for at least 30 minutes to dissipate residual heat in the combustion chamber of the burner. 2. Shut off circulating pump after M hour, and switch off all heater electrical controls. COLD WEATHER PRECAUTIONS... When the THERMINOL system is exposed to low ambient temperatures, it is often most practical to leave the system "idling." Turn the burner to "low" position, and allow the fluid to circulate continuously at about 200F. The unit will then be "at. ready" for imme diate high-temperature operation, and the viscosity of the fluid will remain low and workable. IN CASE OF POWER FAILURE... The burner circuit should be shut down by the heater controls. When the power comes on, run the circulating pump for a few moments to eliminate any vapor pockets that might have been formed by the fluid remain ing sialic in the hot combustion chamber. If there is no knocking in the piping system, full-lire may be resumed immediately if the fluid temperature is above 180F. 7. Semi-annual or annual sampling and anal ysis of THERMINOL, Under normal operating conditions, it should not be necessary to check on the condition of the fluid more than once or twice annually. The analysis for fluid condition is a simple test of fluid viscosity. The exact viscosity limits will be affected by the specific mode of operation and can vary somewhat from sys tem to system. Monsanto should be contacted to determine specific values for the intended operation. Most users do their own testing; some have the viscosity determination made by an outside laboratory. A simple test kit for in-plant testing of THERMINOL is available at a low cost. Customers can have their fluid tested by Monsanto free of charge. For sampling con tainer and application data form, write to: MONSANTO COMPANY FUNCTIONAL FLUIDS MARKETING ORGANIC CHEMICALS DIVISION ST. LOUIS, MISSOURI 63166 Analysis results will be returned to the cus tomer with complete recommendations for improving or continuing the performance of THERMINOL heat transfer liquid. PERIODIC CHECK-UPS ... The regular maintenance inspection schedule should include the manufacturer's recom mendations, as well as inspection of the THERMINOL. Following is a listing of in spection check-points: 1. Lubrication of moving parts. 2. Operating fidelity and accuracy of readings `A n y, n ............... I I 0^0602 3 TOWOLDMON0031128 WATER_PCB-00015597 TYPICAL t h e r mJjrLoulL FR SYSTEMS THE HEATING PLANT i Figure 1 above Illustrates a typical basic heating "plant" for a THERMINOL FR system. Note the use of instruments to control THERMINOL temperature leaving the heater and by-pass flow control to assure adequate flow through the heater regardless of "user" demands. 0i,o8or<' I TOWOLDMON0031129 WATER_PCB-00015598 HEATING A SINGLE USER: WITH LOW LIMIT CUTOFF TO BURNER . .: . Note that the user temperature can be controlled by either (a) rate of flow of THERMINOL to the user, or (b) temperature of THERMINOL, varied by fuel input to the heater. HEATING MULTIPLE USERS: I Rl FIG. 3 PUMP FRC=FLOW RECORDER CONTROLLER WITH LOW LIMIT CUTOFF TO BURNER Note that each user can be controlled at a different temperature by control of the flow of THERMINOL and therefore the rate of flow of heat offered. (H080^e> TOWOLDMON0031130 WATER_PCB-00015599 uiiUwAaji&Mi HEATING OR COOLING SEVERAL USERS SIMULTANEOUSLY PUMP 0* 0'0 lb 0 TOWOLDMON0031131 WATER_PCB-00015600 TEMPERATURE CONTROL BY BLENDINO FLOW RECORDER CONTROLLER WITH LOW LIMIT CUTOFF TO BURNER Single heater system provides varying THERMINOL temperatures to users ... Finds application for processing heat-sensitive materials. 0008027 TOWOLDMON0031132 WATER_PCB-00015601 |- h e r mJjnLDuk FR ENGINEERING DATA The design and installation of THERMINOL indirect heating systems requires a heat balance between the user(s) and the heater. The amount of heat which will be absorbed by the user in a given time depends upon the over-all heat transfer coefficient, the heat transfer area of the user, and the mean temperature difference between THERMINOL and the process or area being heated. In processing most organic chemicals, oils, food cooking --the rate of heat transfer is usually dictated by the process and not by the heating medium. However, in designing a system--it is important to know the heat transfer coefficient of THERMINOL. This is affected by a number of variables, probably the most important of which is flow rate. The following curves provide engineering data on THERMINOL heat transfer coefficients as a function of flow rate .. . and pressure drop as a function of flow rate ... in various common sizes of pipes and tubes. NOTE : The following charts depicting heat transfer coefficients and pressure drops for various sizes of pipes and lubes are available in full page reproduction for greater accuracy in inter pretation. Write to: Monsanto Company Organic Chemicals Div. 800 N. Lindbergh Blvd. St. Louis, Mo. 63166 o^oei^e | TOWOLDMON0031133 WATER_PCB-00015602 THERMINOL PR-1 HEAT TRANSFER COEFFICIENTS INSIDE SCHEDULE 40 PIPE HEAT TRANSFER COEFFICIENT BTU/HR., FT.*, F.--INTERNAL 10 SO 80 40 50 70 100 200 800 500 1000 2000 4000 6000 FLOW--G.P.M. HEAT TRANSFER COEFFICIENTS INSIDE TUBES HEAT TRANSFER COEFFICIENT BTUfHR., FT.*, F,--INTERNAL 0408029 |23 TOWOLDMON0031134 WATER_PCB-00015603 THERMINOL FR-2 HEAT TRANSFER COEFFICIENTS INSIDE SCHEDULE 40 PIPE 20 30 40 50 70 100 200 300 500 FLOW--G.P.M. 2000 4000 0000 HEAT TRANSFER COEFFICIENTS INSIDE TUBES (\ 7 10 15 FLOW--G.P.M. 0*08030 TOWOLDMON0031135 WATER_PCB-00015604 THERMINOL FR-3 HEAT TRANSFER COEFFICIENTS INSIDE SCHEDULE 40 PIPE HEAT TRANSFER COEFFICIENTS INSIDE TUBES 1000 900 700 j 600 f 500 i 400 FLOW--G.P.M, o^oa03i TOWOLDMON0031136 WATER_PCB-00015605 PRESSURE OROP~P.S.f. PER 100 FEET THERMINOL FR-1 PRESSURE DROP IN SCHEDULE 40 PIPE PRESSURE DROP IN TUBES D) C 0^08032 TOWOLDMON0031137 WATER_PCB-00015606 THERMINOL FR-2 PRESSURE DROP IN SCHEDULE 40 PIPE PRESSURE DROP--P.S.I. PER 100 FEET 1 1.5 2 8 4 5 7 10 15 20 FLOW--G.P.M. 80 40 60 80 100 O'.OBO*3 27 | TOWOLDMON0031138 WATER_PCB-00015607 THERMINOL FR-3 PRESSURE DROP IN SCHEDULE 40 PIPE <) ') i PRESSURE DROP--P.S.t. PER 100 FEET 1 1.5 S 3 4 5 7 10 15 20 FLOW--G.P.M. 80 40 60 BO 100 I28 TOWOLDMON0031139 WATER_PCB-00015608 RESISTANCE OF VALVES AND FITTINGS TO FLOW OF FLUIDS frrpy-owr^ A simple way to account for the resistance offered to flow by valves and fittings is to add to the length of pipe in the line a length which will give a pressure drop equal to that which occurs in the valves and fittings in the line. jQQQ 2000 Example: The dotted line shows that the resistance of a 6*inch Standard Elbow is equivalent to approximately 16 feet of 6-inch Standard Steel Pipe. fiS) tandard jgh Side Standard Elbow or_ run of Too reduced % W Medium swoop Elbow run of Tec reduced % 0 ft. 50 K -I 20 " Sudden Enlargement _ #> I------d/D-X r -- . d/D-X d/D-54 EN** Ordinary Entrance fc S t'A< S3 i [Sudden Contraction V \L.d/D-tf \\--d/D-K d/D-/ O *'A~ Z 2- t y.- ixH *-E \ Long Sweep Elbow or t run of Standard Tee 0i,0B03t> TOWOLDMON0031140 WATER PCB-00015609 PRESSURE DROP AND HEAT TRANSFER RATE FOR HEAT EXCHANGERS Parti PROCEDURE TO OBTAIN PRESSURE DROP SHELL SIDE OF TUBULAR EXCHANGERS WITH THERMINOL FR-2 1. Enter Chart No. i with GPM @ overage flow ing temperature--read average shell side velocity. . 2. Multiply average shell side velocity with battle correction (Be--Chart No. 3) to obtain cor rected velocity. 3. Enter Chari No. 3 with corrected velocity-- read uncorrected pressure drop. 4. Correct pressure drop-3 above--for temper ature, tube diameter and tube length. Example: THERMINOL FR-2 400F. 20" Shell %" Tubes on 15/16" Baffles 12" Pitch Tubes 16' Long 400GPM . 1. Chart No. 1 400 GPM--20" shell--2.7 ft/sec. average velocity. 2. Chart No. 8 12" Baffle Pitch--0.6 correction 2.7 ft/sec. x 0.6 = 1.62 ft/sec. corrected ve locity 3.1.62 ft/sec. In 20" Shell = 4.1 PSI uncorrected pressure drop. 4. Correct for temperature, tube size and length. Pressure Drop = 4.1 x 1.2 x 1.0 x 1.33 = 6.54 Ans. Part II PROCEDURE TO OBTAIN HEAT TRANSFER RATE SHELL SIDE OF TUBULAR EXCHANGERS WITH THERMINOL FR-2 1. Enter Chart No. 1 with GPM at average flow ing temperature--read average shell side velocity. 2. Multiply average shell side velocity with baffle correction (Bet, Chart No. 2) to obtain cor rected velocity. 3. Enter Chart No. 2 with corrected velocityread uncorrected h. 4. Correct h--(3 above)--for temperature and tube diameter. Example: THERMINOL FR-2 300 20" Shell 1"on1K" Baffles 10" Pitch 350 GPM 1 1. Chart No. 1 350 GPM--20" Shell = 2.35 ft/sec. average velocity. 2. Chart No. 2 10" Baffle Pitch--0.875 correction 2.35 ft./sec. x 0.875 = 2.06 ft./sec. corrected velocity . ' 3. 2.06 ft./sec. Chari No. 2 = 225 uncorrected h. 4. Correct h for temperature and tube diameter. 225 x 0.61 x 0.88" = 121 Ans. Part III NOTES: a. Tubes to be on triangular pitch on 54" on 'to"; 1" on 1 b. All baffles cut 1 row of tubes past horizontal centerline. c. Charts have base condition--54" on Baffles at 8" pitch. THERMINOL FR-2 at 550ftF. Data on shell side pressure drop and coefficients Courtesy of Struthers Wells Corporation. t. k o<.083b <t>) i I TOWOLDMON0031141 WATER_PCB-00015610 ' h r (**. * l % r......... ' , Nom. Shell Diameter Inches 8 10 24 Tube Length Feet 8 8 12 16 UNIT SELECTION CHART arrangement yr o.d. on No. of Tubes 36 36 68 . 114 114 164 BIO 286 348 432 432 652 'W Trl. Surface Sq. Ft. 24 48 89 150 224 322 412 562 684 650 1132 1710 %" O.D. on No. of Tubes 26 26 48 82 62 120 152 208 252 314 314 474 W Trl. Surface Sq. Ft. 20 40 75 129 193 283 358 490 593 740 985 1485 1' O.D. on No. of Tubes 14 14 26 48 48 66 82 110 138 174 174 268 1%" Tri. Surface Sq.Ft 15 30 55 101 208 346 546 0408037 TOWOLDMON0031142 WATER_PCB-00015611 CHART NO. 1 AVERAGE SHELL SIDE VELOCITY ( ) C G.P.M. @ AVERAGE FLOWING TEMPERATURE *)> <1 0N0B03B 32 TOWOLDMON0031143 WATER_PCB-00015612 BAFFLE PITCH--INCHES CORRECTED SHELL SIDE VELOCITY--FT./SEC. CHART No. 2 HEAT TRANSFER SHELL SIDE 0400039 33 | TOWOLDMON0031144 WATER_PCB-00015613 CHART No. 3 PRESSURE DROP 8HEI.C SIDE I UNCORRECTEO PRESSURE DROP-PSl ooeo`.o IC TOWOLDMON0031145 WATER_PCB-00015614 KINEMATIC VISCOSITY, IN CENT!STOKES VISCOSITY CONVERSION CHART (Converting Kinematic and &aybolt Viscosity to Absolute Viscosity) `10.000 2,000-; 1,500 1.000- 5,000 000 - 4.000 700 -3,000 (/) 000 o g 600 -3 -2,000 O 400 CO 1,500 300 b -1,000 V> 200 4 ou 150-3 -760 > E- 2,000 .1,000 - 900 -600 TOO -500 500 - 400 100 00 eo-g: 70 60 40-3. 30- 20 -100 so -so TO 10 -60 0 05 8 7 -i 50 ' 6 45 ifi - loo aO. - so p -50 Z - 70 g -60 W - 50 5 - 40 . -80 . - 20 S O(0 > ? 0.9 2. to 0.8-^ 4 0<i080m 35 g TOWOLDMON0031146 WATER_PCB-00015615 ENGINEERING CONVERSION FACTORS MULTIPLY i,-l ..y.1 '... si,.. BY TO OBTAIN .1.-. ATMOSPHERES ATMOSPHERES ATMOSPHERES ATMOSPHERES ATMOSPHERES ATMOSPHERES British thermal units British thermal units British thermal units British thermal units British thermal units British thermal units British thermal units Btu/cu. ft. Btu/hr. Btu/hr. sq. ft. Btu/(hr. sq. ft. 0 F.J Btu/(hr. sq. ft. 0 F.) Btu/(hr. sq. ft. 0 F.) Btu/(hr. sq. ft. 0 F.) Btu/(hr. sq. ft. F.) (Btu/hr. sq. ft.)/( F./in.) (Btu/hr. sq. ft.)/( F./in.) (Btu/hr. sq. ft.)/( F./ft.) (Btu/hr. sq. ft.)/( F./ft.) (Btu/hr. sq. ft.)/( F./ft.) Btu/min. Btu/min. Btu/min. Btu/lb. Btu/lb. mol. Btu/lb. F. 14.70 2116.8 760 29.92 33.90 1.033 x 10' 778.2 107.6 1055 0.2520 3.930 x I0-1 2.930 x I0-J 0.5556 8.90 3.927 x 102.712 4.882 1.0 1.356 x t0 ` 5.68 x 102.035 x I0 3 12.4 3.445 x 10" 4.13 x I0-S 0.0173 14.88 12.97 0.02358 0.01758 0.556 0.556 1.0 lb./sq. in. Ib./sq. ft. mm. Hg. in. Hg. ft. of water kg./sq. meter ft. ib. kg.-meters joules kg.-cal. hp. hr. kw. hr. P.C.U.* kg.-cal./cu. meter hp. kg.-cal./hr. sq. meter kg.-cal./(hr. sq. meter 0 C.) P.C.U.*/(hr. sq, ft. 0 C.) gram-cal./sec. cm.2 0 C. watts/cm.2 0 C. watts/sq. in. F. (kg.-cal./hr. sq. meter)/( C./cm. (gram-cal./sec. cm.8)/!0 C./cm.) (gram-cal./sec. cm.2)/( C./cm.) (watts/cm.2)/( C./cm.) (gram-cal./hr. cm.8)/(0 C./cm.) ft. Ib./sec. hp. i. gram-cal./gram gram-cal./gram mol. gram-cal./gram 0 C. 0C l OAOBO^Z TOWOLDMON0031147 WATER PCB-00015616 # 1. ENGINEERING CONVERSION FACTORS fc, & 4. i & MULTIPLY *>l >1 BY Btu/sec. Btu/sec. Btu/sec. Btu/iec. Btu/sq. ft. Btu/sq. ft. CALORIES CENTIMETERS CENTIMETERS cm. Hg. cm. Hg. cm. Hg. cm. Hg. cm. Hg. cm. Hg. cm./0 C. cm./sec. cm./sec. cm./sec. cm./sec. cm./sec. CENTIPOISES CENTIROISES CENTIPOISES CENTIPOISES cubic centimeters cubic centimeters cubic centimeters cm.8/sec. cm.*/sec. cm.8/sec. cm.*/sec. cm.8/gram cm.8/gram mol. CUBIC FEET CUBIC FEET 778.2 1.4147 1.0549 107.6 0.2712 2.712 See gram-cal. 0.3937 0.0328 0.01316 0.1934 27.85 136.0 5.353 0.4461 0.2187 1.969 0.032BI 0.036 0.60 0.02237 0.01 2.42 6.72 x 10 -4 3.60 0.06102 3.531 x 10-' 2.642 x I0-* 2.119 x I0-S 0.0864 0.01585 3.6 0.01602 0.01602 0.02832 7.481 TO OBTAIN ft. Ib./sec. hp. kw. kg.-meter/sec. gram-cal./cm.2 kg.-cal./sq. meter in. . atm. Ib./sq. in. Ib./sq. ft. kg./$q. meter in. of water ft. of water in./0 F. ft./min. ft./sec. km. /hr. meters/min. mph poises lb./ft. hr. Ib./ft. sec. kg./meter hr. cu. in. cu. ft. gal. cu. ft./min. cu. meter/day gal./min. liter/hr. cu. ft./lb. cu. ft./lb. mol. cu. meters gal. 0'080`i3 I TOWOLDMON0031148 WATER_PCB-00015617 ENGINEERING CONVERSION FACTORS ipiff MULTIPLY K % * *, f^s* BY ' r > TO OBTAIN CUBIC FEET CUBIC FEET cu. ft. gas (60 F. at 1 atm) cu. ft./lb. cu. ft./min. cu. ft./min. cu. ft./sec. cu. ft./sec. iq. ft. CUBIC INCHES CUBIC INCHES CUBIC INCHES CUBIC INCHES CUBIC METERS CUBIC METERS cu. mcters/day degrees/sec. degrees/tec. ERGS FEET FEET ft. of water ft. of water ft. of water ft. of water ft. of water ft. of water ft./min. ft./min. ft./min. ft./m)n. ft./sec. ft./sec. ft./sec. FOOT POUNDS FOOT POUNDS FOOT POUNDS FOOT POUNDS 1 28.32 62.43 2.636 x I0-* 42.43 472.0 0.1247 448.8 0.030S 16.39 $.787 x 10 * 0.01639 4.329 x 10'* 35.31 264.2 11.57 2.778 x I0-B 0.1667 1.0 x 10-' 30.48 0.3048 0.0295 2.242 0.8826 304.8 62.43 0.4335 0.508 0.01667 0.01829 0.01136 1.097 18.29 0.6818 1.285 x I0-8 3.239 x 10-4 3.766 x 10-7 5.05 x 10'7 liters lb. of water lb. mol. 1 cm.*/gram cm.*/sec. gal./sec. gal./min. liters/see. cm.1 cm.* cu. ft. liters gal. cu. ft. gal. em.*/sec. rev./sec. rpm joules cm. meters atm. cm. Hg. in. Hg. kg./sq. meter Ib./sq. ft. Ib./sq. Sn. cm./sec. ft./sec. km./hr. mph km./hr. meters/min. mph Btu kg.-cal. kw. hr. hp. hr. II *Pound-C#nl!gr*d Unit jew? 44. iy"Vff '*?*', 0i 0I TOWOLDMON0031149 WATER_PCB-00015618 IjjlWr v--cm,v li ENGINEERING CONVERSION FACTORS MULTIPLY flHHHE BY TO OBTAIN ft. Ib./min. 3.03 x I0'6 hp. ft. Ib./min. 2.26 x 10-' lew. ft. Ib./sec. 0.0771 Btu/mln. ft. Ib./sec. ft. Ib./sec. 1.818 x 10-' 0.01943 hp. kg.-cal./min. ft. Ib./sec. 1.356 x I0-* lew. GALLONS (imperial) 1.201 gal. (U.S.) gal. (U.S.) 231 cu. in. gal. (U.S.) 0.1337 cu. ft. gal. (U.S.) 3785 cm.8 gal. (U.S.) gat./hr. 3.785 3.71 x I0-8 liters cu. ft./sec. gal./min. 2.728 x I0-1 cu. ft./sec. gal./min. 0.227 cu. meters/hr. gal./min. 0.06309 Hters/sec. gal./min. of water 500.8 Ib./hr. of water SRAMS f GRAMS 980.7 2.205 x I0"s dynes ib. gram mole gas 2.24 x I04 cm.8 gas (0 C. and 760 mm.) gram-cal. gram-cal./gram 3.968 x I0-* 1.8 Btu Btu/lb. gram-cal./gram mol. 1.8 Btu/lb. mol. gram-cal./gram 0 C. 1.0 Btu/lb. o F. gram-cal./cm.* 3.687 Btu/sq. ft. (gram-cal./cm.*)/cm. 1.452 (Btu/sq. ft.)/in. gram-cal./(sec. cm.* C.} 7.373 x 10s Btu/(hr. sq. ft. 0 F.) (gram-cal./sec. cm.*)/( C./cm.) gram-cm. gram-cm. gram-cm. gram-cm. grams/cm. grams/cm.* grams/cm.8 grams/cm.* grams/cm.* grams/cm.1 grams/cm.? 2.903 x 10s 9.294 x 10-B 980.6 7.233 x 10-' 2.342 x I0"8 5.60 x 10 * 1.0 62.43 0.07355 10 0.394 0.03281 (Btu/hr, sq. ft.)/( F./in.) Btu ergs ft. lb. kg.-cal. Ib./in. specific gravity at 4 C. Ib./cu. ft. cm. Hg. kg./sq. meter in. of water ft. of water ..... i st,,. 040804!) |39 TOWOLDMON0031150 WATER_PCB-00015619 engineering conversion factors MULTIPLY grams/cm.* grams/cm.* grams/cm.* HORSEPOWER HORSEPOWER HORSEPOWER HORSEPOWER HORSEPOWER tip. (boiler) hp. (boiler) hp. hr. hp. hr. hp. hr. hp. hr. hp. hr. hp. hr. hp. hr. INCHES in. Hg. In. Hg. in. Hg. in. Hg. in. Hg. in. of water in. of wafer in. of water in. of water in. of water in. of water In./0 F. KILOGRAMS KILOGRAMS KILOGRAMS KILOGRAMS kg .-meters kg.-meters kg.-meters kg.-mefers BY 9.676 * 10 0.01422 2.046 42.41 3.3 x I0` 550 10.7 0.7457 3.3479 I0` 9.804 2.545 x 10* 1.98 x 10* 2.684 x 10' 641.2 2.737 x I0 0.7457 1.414 x 10s 2.54 0.03342 1.133 0.4912 70.73 345.3 2.458 x 10--> 0.07355 0.1869 25.40 0.03613 5.202 4.572 9.807 x 10* 70.93 2.205 1.102 x 10-' 9.302 x 10-* 7.233 2.344 x 10 * 2.724 x I0-" $ iiWxtiV:/file.'Sb.'.1: v-iv 'i'jL-.n,,.# _...i. , TO OBTAIN atm. Ib./sq. In. Ib./sq. ft. Btu/min. ft. ib./min. ft. lb./sec. kg.-cal./min. lew. Btu/hr. lew. Btu . ib. joules kg.-eal. kg.-meters kw. hr. P.C.U.* Camtm> . ft. of water Ib./sq. in. Ib./sq. ft. kg./sq. meter atm. in. Hg. cm. Hg. kg./sq. meter Ib./sq. in. Ib./sq. ft. cm./ C, dynes poundals ib. tons (short) Btu f. ib. kg.-cal. kw. hr. As. *Pound>C*ntigrftd Unit 0*08^ TOWOLDMON0031151 WATER_PCB-00015620 itAS. ENGINEERING CONVERSION FACTORS v.. . i. MULTIPLY kg.-meter* kg./cu. meter kg./cu. meter kg./meter kg./sq. meter kg./sq. meter kg./sq. meter kg./sq. meter kg./sq. meter kg./sq. meter KILOMETERS KILOMETERS km./hr. km./hr. km./hr. km./hr. KILOWATTS KILOWATTS KILOWATTS KILOWATTS KILOWATTS KILOWATTS kw. hr. kw. hr. kw. hr. kw. hr. kw. hr. Itw. hr. LITERS LITERS LITERS LITERS LITERS liters/gram mol. liters/hr. Uters/kg. liters/min. liters/mln. ...... BY 5.165 x IO- 1.0 x IO- 0.06243 0.6720 9.678 x I0-' 7.355 x I0-8 3.281 x IO-> 2.896 x I0-* 0.2048 1.422 x I0-8 3.281 x IQ8 0.6214 27.78 54.68 0.9113 16.67 56.92 4.425 x I04 737.6 1.341 14.34 1 x I0 3.413 x I08 2.655 x I06 1.341 3.6 x I0 860.5 1.895 x 10s 1 x I03 0.0353 61.02 0.2642 1.057 16.02 0.2778 0.01602 6.0 x I0< 5.885 x 10-< TO OBTAIN P.C.U.* gram/cm.8 Ib./cu. ft. ib./ft. atm. cm. Hg. ft. of water in. Hg. Ib./sq. ft. Ib./sq. in. ft. mi. cm./sec. ft./mln. ft./sec. meters/min. Btu/min. ft. Ib./min. ft. Ib./sec. hp. kg.-cal./min. watts Btu ft. lb. hp. hr. joules kg.-cal. P.C.U.* cm.3 cu. ft. cu. in. gal. (U.S.) ql. (liq.) cu. ft./lb. mol. cm.Vsec. cu. ft./lb. cm.yhr. cu. ft/sec. ' ........ - - .,! .. . .V.'../*. 0^060^7 Pound-CentIgr*d* Unit 41 | TOWOLDMON0031152 WATER_PCB-00015621 engineering conversion factors MULTIPLY liters/min. liters/min. liters/sec. cm.r METERS METERS meters/0 C. meters/min. meters/min. meters/min. meters/min. meters/sec. meters/see. meters/sec. OUNCES OUNCES OUNCES (fluid) OUNCES (fluid) oz./sq. in. POISES POUNDS POUNDS POUNDS lb. molt gas tb. of water lb. of water lb. of water/hr. lb. of water/hr. Ib./cu. ft. Ib./cu. ft. Ib./cu. In. Ib./ft. Ib./ft. hr. Ib./ft. hr. Ib./gal. Ib./in. Ib./sq. ft. lb.Att. ft. BY 15.851 4.403 * 10-s 32.8 3.281 39.37 1.824 1.667 0.05468 0.06 0.03728 196.8 3.6 2.237 28.35 0.0625 1.805 0.02957 1.732 t 4.448 x I0B 453.6 32.17 379.4 0.01602 0.1198 2.669 x 10-4 1.997 x I0~3 0.01602 16.02 27.68 1.488 4.13 x I0-S 0.413 0.1198 178.6 0.01602 4.882 TO OBTAIN gal./hr. gal./sec. cu. ft./see. sq. ft. . In. ft./ F. cm./sec. ft./sec. km./hr. mph ft./min. Icm./hr. mph grams ib. cu. in. liters in. of water gram/cm. sec. dynes grams poundals cu. ft. gas (60 F. cu. ft. gat. cu. ft./min. gal./min. grams/cm.* kg./cu. meter grams/cm.* kg./meter grams/cm. sec. centipoises grams/cm.s grams/cm. ft. of water kg./sq. meter t) o'.oeo'.B TOWOLDMON0031153 WATER_PCB-00015622 ENGINEERING CONVERSION FACTORS Im^mm 5jH*' ' ;v-*-v,tp * /* o MULTIPLY BY Ib./sq. ft. Ib./sq. in. Ib./sq, in. Ib./sq. in. Ib./sq. in. Ib./tq. in. Ib./tq. in. REFRIGERATION--STD. TON SQUARE CENTIMETERS SQUARE CENTIMETERS SQUARE FEET SQUARE FEET SQUARE FEET SQUARE INCHES SQUARE INCHES SQUARE INCHES SQUARE KILOMETERS SQUARE KILOMETERS SQUARE METERS temperature C. 273 temperature C. 17.8 temperature F. 460 temperature F. --32 TONS (long) TONS (long) tont (metric] tons (metric) tons (short) tons (short) tons (short)/sq. ft. tons (short)/sq. ft. tons (short)/sq. Sn. tons ($hort)/sq. in. tons of refrigeration WATTS WATTS WATTS 6.944 IO-> 0.06804 2.307 2.036 51.7 703.1 144 200 1.076 I0-* 0.1650 929 144 0.0929 6.452 6.944 x )0-J 6.452 x I0-J 1.076 x 107 0.3861 10.76 1.0 1.8 1.0 0.5555 1.016 x 10* 2.24 x 10 1 X 10* 2.205 x 10* 907.2 2 x 10* 9.765 x 10* 13.89 1.406 x 10s 2 x 10 See refrigeration 0.05692 1 x 10' 44.26 TO OBTA Ib./sq. In. atm. ft. of water in. Hg. mm. Hg. kg./sq. meter Ib./sq. ft. Btu/min. sq. ft. sq. in. sq. cm. sq. in. sq. meters cm.* sq. ft. sq. meters sq. ft. sq. mi. sq. ft. abs. temp. 0 K. temp. F. abs. temp. R. temp. C. kg. lb. kg. ib. kg. Ib. kg./sq. meter Ib./sq. in. kg./sq. meter Ib./sq. in. Btu/min. ergs/sec. ft. Ib./min. mt- 0408049 6 1 TOWOLDMON0031154 WATER_PCB-00015623 i ENGINEERING CONVERSION FACTORS MULTIPLY WATTS WATTS WATTS WATTS WATT HOURS WATT HOURS WATT HOURS WATT HOURS WATT HOURS WEEK WEEK WEEK YEARS (common) BY 0.7376 1.341 x 10-5 0.01434 1.0 x I0-8 3.413 2.655 x 10* 1.341 x I0-3 0.8605 367.1 168 1.008 x 10' 6.048 x I05 8.76 x 10 TO OBTAIN ft. Ib./sec. hPkg.-cal./min. lew. Btu n. ib. hp. hr. kg.-cal. kg.-meter hr. min. sec. hr. STEEL PIPE DIMENSIONS--'CAPACITIES AND WEIGHTS* Nominal Outside Wall ft. dim, Schedule thick in. No. ness, in. a 0540 40 H 0.675 40 Vi 0.640 40 Vi 1.050 40 1 1.315 40 IV. 1.660 40 IK 1.990 40 2 2.375 40 2K 2875 40 3.500 40 3H 4.000 40 4 4.500 40 5 5.563 40 6 6625 40 8 6625 40 10 10.75 40 12 1275 40 .036 .091 .109 .113 .133 .140 .145 .154 .203 .216 .226 .237 .258 .260 .322 .365 .406 'Based on A. S A. Standards 836.10. Inside diem.. in. Cross sectional metal, sq.In. sectional area, SQ. fl. .364 .493 .622 .824 1.049 1.380 1.610 2.067 2.469 3.0E8 3.548 4.026 5.047 6.065 7.961 10.020 11.938 .125 .167 .250 .533 .494 .669 .799 1.075 1.704 2.228 2.680 3173 4.304 5.984 6.396 11.90 15.77 .00072 .00133 .00211 .00371 .00600 .01040 .01414 .02330 .03322 .05130 .06870 .08840 .1390 .2006 .3474 .54 75 .7773 Ciicumference, It, oi surface sq.ft, per It., of length Outside Inside .141 .0954 .177 .1293 .220 .1630 .275 .2158 .344 .2745 .435 .362 .498 .422 .622 .542 .753 .647 .917 .804 1.047 .930 1.178 1.055 1.456 1.322 1.734 1.590 2.258 2.090 2.814 2.620 3.338 3.13 Capacity it 1ft. per sec. velocity U. S. Lb per hr. gal. per water min. .323 ,596 298.0 .945 472.5 1.665 632 5 2.690 1,345.0 4.57 2,285.0 6.34 3,170.0 10.45 5,225.0 14.92 7,460.0 23.00 11,500.0 30.60 15,400.0 39.6 16,800.0 62.3 31,1500 900 45,000.0 155.7 77,850.0 246.0 123,000.0 349 0 174,500.0 Weight of pipe per fl. Ib. .5? .85 1.13 1.66 2.2B 2.72 3.66 5.80 7.58 9.11 108 14.7 190 26.6 40 5 53.6 I 1 I 1 1 I I 1 1 1 1 I 1 1 0A080S0 t) TOWOLDMON0031155 WATER PCB-00015624 Indirect, liquid heating with THEKM1N0L FJt systems is recommended wherever lowpressure, high-temperature proc essing-requiring safe, uniform delivery of heat--is needed. Here are a few typical applications. # LIQUID HEATING SYSTEMS... CHEMICAL PROCESSING ... especially where flammable materials are handled. VARNISHES AND RESINS PROCESSING ... where a single "circuit" with multiple users and varying temperatures is desirable. PLASTICS AND RUBBER MOLDING ... where uniform heating, rapid temperature flux, and pin-point control is essential. BITUMINOUS MATERIALS HEATING ... for maximum safety where explosive gases and volatile fumes occur. FOOD PROCESSING ... for controlled, quality "cooking" of potato chips, pre-cooked soups, other foodstuffs. MATERIALS CONVERSION ... to heat corrugating rolls, crimping presses, calenders. METALS TREATING OVENS ... for heat-treating metals such as titanium and vanadium; for "seasoning" weldments, castings and forgings. MALT COOKING AND LIQUID DISTILLATION ... for efficient indirect heating of distillation equipment. o^oeoM |45 TOWOLDMON0031156 WATER_PCB-00015625 i^e sliA .' iSi I therm ?iu ilk FR SAFETY ST UA . IDLING On the basis of animal toxicity studies, THEHMINOL FH may be considered only slightly toxic from the standpoint of acci dental massive skin exposure or accidental ingestion. Similarly, single exposures to high concentrations of vapors (when heated suffi ciently to volatilize) or high concentrations of decomposition products (if the fluid is accidentally discharged into the fire chamber) are not serious hazards because the irritating character of such concentrations preclude vol untary exposure. Repeated or prolonged skin exposure should be avoided since THEHMINOL FR acts as a solvent for fats and oils of the skin. Re moval of these natural, protective barriers can lead to drying and chapping such as occurs with exposures to paint thinners. More important, THEHMINOL FK may be ab sorbed if it is allowed to remain on the unbroken skin. For these reasons, we recom mend that the skin be washed with soap and water if there is contact. A skin burn resulting from accidental contact with hot fluid should be treated in the normal manner for any thermal burn due to hot oils. Because of its low vapor pressure, there is no significant vapor inhalation hazard when THEHMINOL FH is at room temperature. For example, there is no vapor exposure prob lem while transferring the fluid from its ship ping container to the heat transfer system. On the other hand, the vapors emitted by THEHMINOL FK heated to elevated tem peratures are injurious on prolonged exposure. It is indicated that the "threshold limit value" or atmospheric vapor concentration which cannot be safely exceeded (on a daily basis) is 0.5--1.0 milligrams of THEHMINOL FK vapor per cubic meter of air in the workroom. In heat transfer installations, the fluid must be used in a closed system free from leaks with the expansion tank vented to the out doors. Accordingly, there should be little or no opportunity for workers to come in con tact with vapors. 04080b2 TOWOLDMON0031157 WATEFLPCB-00015626 0400US3 TOWOLDMON0031158 WATER_PCB-00015627 TOWOLDMON0031159 WATER_PCB-00015628