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Electrical Heaters

Tristar believes in engineering products which last for generations. Rigorous quality assurance programs incorporating rigid testing standards for each product enables Tristar to deliver products that give long life & trouble free service.

Tristar manufactures Electric Heaters custom designed to meet your requirements. All our heaters are made to order which allows you to invest in the perfect match for your application.


Immersion Heaters

Immersion heaters are used to maintain or raise the temperature of fluids in tanks or process vessels. These are installed preferably at a level below the outlet of the tank/vessel so that the heater is fully submerged in the liquid at all times. Heater capacities are determined based on the application, dimensions are decided based on the availability of space and allowable watt densities. Immersion Heaters can be used to heat gasses or fluid ranging from water to corrosive solutions, oils with varying viscosities in an open or enclosed tank. Immersion heaters can be classified on the basis of direct heating and indirect heating.

  • Direct Heating – Tubular Heaters
  • Indirect Heating – Cartridge Type

Within tubular we have a range of tube diameters to suit your application watt density, similarly in cartridge type we can provide Open Bobbin type or SS Sheath cartridge type.

Tristar Heaters are available in various mounting options

  • Threaded Screw plug
  • Over the Side
  • Flange – Standard and customized

Tubular Heaters

Tubular Direct Immersion Heaters are specifically designed for direct contact heating of water, oils, viscous liquids, solvents, process solutions and gases. As all heat is generated within the liquid or process, virtually 100% heat transfer is achieved. Further, various options permit very tight process temperature control. The variety of mounting options available such as threaded screw plug connections, flanges or simple over-the-side designs make them versatile for use anywhere.

Features

  • Designed for use in tanks and pressurized vessels, they are easy to install and maintain to provide heat for many processes.
  • The direct immersion method is energy efficient and easily monitored and controlled.
  • These heaters are available with heating elements made of copper, steel, stainless steel, cast iron, titanium, and PFA coated.
  • A wide selection of kilowatt ratings, shapes and mounting methods are available to suit many different types of applications

Threaded Screw plug immersion heaters consist of tubular elements brazed or welded to the plug/tube sheet. They are screwed to a coupling welded on the tank or to the threaded opening in the tank wall.

Over the side immersion heater are designed to be installed on the top of the tank with the heated portion immersed along with side or the bottom.


Flanged Immersion Heaters

Flanged immersion heaters can be manufactured using tubular elements or cartridge element inserted in a seamless pipe welded to the flange. In this case the flange also acts as a tube sheet on which the pipes are welded. Flange Heaters are installed by bolting to a matching flange welded to the tank wall (nozzle). These are designed for use in tanks and pressurized vessels.

Flanged immersion heater with cartridge elements is preferred for tanks holding viscous substances. The cartridge elements can be easily replaced without dismantling the heater body or draining the tank.

Applications where Flanged immersion heater with cartridge heating elements is preferable.

Applications

  • Oil Storage Tanks
  • Water Storage Tanks
  • Cleaning and Rinsing Tanks
  • Boiler Equipment
  • Heat Transfer Systems
  • Process Air Equipment
  • Food Processing Equipment Warming Equipment
  • Plating Baths
  • Asphalt
  • Heavy weight Fuel oil
  • Heavy weight lubricating Oil Tar
  • Molasses
  • Other high viscosity Materials

Advantages of Tristar Heaters

  • Customized to suit your requirements taking into consideration process parameters.
  • Optimal watt density for long trouble-free life, no charring / coking of fluid.
  • Even Heat distribution over the surface of the element avoiding hot spots
  • Easily replaceable without dismantling the heater body or emptying the contents of tank, feature on request.
  • Various temperature control and measurement devices.
  • Two thermostats one for Safety and another for Control or RTD for Control.
  • 1 kW to 200 kW single heater, higher capacities can be designed and manufactured

Suction Heater

Suction or Outflow Heaters are ideal for storage tanks where they are used to draw viscous liquids / oils at a pre requisite temperature. For large Tanks these heaters are installed horizontally, these can also be used to maintain the temperature of the tank by circulating the heated oil back to the tank. These heaters have the capacity of Instant Heating within minutes from a Cold Start. These are custom built to suit application requirements. Available capacities of these heaters are from 3 KW to 200 KW.Suction heaters are also known as outflow heaters.

Suction Heater are specifically designed to heat only that amount of material that is to be pumped from a large storage tank. The outlet nozzle is attached to the pump suction. The heater heats the material inside the heater body which is then drawn through the heater into the suction side of the pump.

Application Outflow / Suction Heaters

Used in tanks from which viscous fluids are to be pumped.

  • HFO / FO
  • Asphalt
  • Molasses
  • Tar
  • Other high viscosity Materials

Features

  • Designed to heat viscous fluid as it flows through the heater to bring it to pumpable temperature
  • Used in large storage tanks to provide for quick flow through heating of viscous materials
  • Preferable Watt density offered 0.75 to 1.5 w/cm² or 4.8 to 9.6 w/in²
  • Two thermostats one for Safety and another for Control
  • RTD available on request
  • Replaceable heating element type to be able to replace when required without emptying the contents of the tank
  • Element construction - Tubular or Cartridge
  • Connection type - Flanged

Advantages of Tristar Suction / Outflow Heaters

  • Heating elements easily replaceable without dismantling the heater body
  • Replacement of heater elements without draining the tank
  • Customized to suit your application taking into consideration process parameters.
  • Optimal watt density for long trouble-free life, no charring / coking of fluid.
  • Two thermostats / RTD one for control one for safety
  • 1 kW to 200 kW single heater, higher capacities can be designed and manufactured

The selection of a proper heater for your process is a crucial, it involves selection of the mounting, appropriate heating element sheath material to withstand temperature, corrosion etc. and correct watt density to ensure long, trouble free service and preserving product integrity. We would be happy to help you with selection of the correct heater. Please let us know the following details.

  • Media to be heated
    • Viscosity
    • Specific heat
    • Density
    • Corrosive properties
    • Contaminants or pH level in the media
  • Pressure
    • Operating Pressure
  • Temperature
    • Operating Temperature
    • Ambient Temperature
  • Volume to be heated
  • Flow rate (For Outflow and Inline Heater)

Inline Heater

Inline heaters instantly heat fluids that are passed through the heater. Upon exiting the heater, the fluids are consumed for their intended use and or are recirculated to further heat the fluid.

These heaters are designed to heat flowing fluids including gases. Inline heaters consist of heating elements welded or Brazed to a tube sheet which rests on a vessel with a matching flange. The vessel consists of inlet from where the fluid enters the vessel chamber and moves over the heating elements picking up heat evenly towards the outlet on the other end of the vessel. These heaters offer high efficiency since most of the heat is generated within the fluid.

Inline Heaters can be designed and manufactured in various configurations depending on the application requirements

Tubler elements, Cartridge Elements, SS Sheath Open Bobbin Elements.

Construction

Inline Heaters with Tubular Heating Elements

In this type of heater the heating elements are tubular. The tubular elements are brazed or welded to the tube sheet/ sleeve. Rest of the construction is common.

Inline Heaters with Cartridge / Open Bobbin Heating Elements

The heating elements can be cartridge or open bobbin which are inserted in casing pipes, these pipes are welded to the tube sheet. It is easy to replace these elements as they are not welded or brazed. Heater body need not be disassembled to replace the elements.
Cartridge Elements when inserted into casing pipes offer a large heated area to the liquid or semi-solid to be heated. Material such as oil, wax, fats and bitumen require low heater surface temperature to prevent product degradation. For these applications cartridge type inline heater is ideal. As these elements are designed to have a very low watt density on the casing pipes thus they ensure a longer life for the elements.

Application

Liquid Heating:
Inline heaters are used to raise the temperature of the liquid in the pipeline instantaneously. Gas Heating:
Electric heaters provide a cost effective means for heating air and common industrial gases such asArgon, Helium and Nitrogen amongst other gasses. Steam Superheating Heaters are used to increase the enthalpy and quality of steam. Inline heaters are used to make up for losses on steam distribution line.

Features

  • Available with Tubular Elements, Open Bobbin or Cartridge Elements.
  • Optimum Heat Transfer
  • Easy replacement for open bobbin and cartridge heaters.
  • Optimal watt density for long trouble free life, no charring / coking of fluid
  • Available from 3 kW to 500 kW
  • Custom made to suit your requirements
  • Two thermostats one for Safety and one for Control.
  • RTD is available on request.
  • Long trouble-free service

Inline Vertical Heater

Inline Horizontal Heater


HFO Heaters – Fuel Handling System Heaters

Electric heaters are used to reduce the viscosity of HFO / Fuel oil to make it easily pumpable and also to raise to the required temperature for Burner.

Generally, a complete fuel handling system would require

  • Immersion heaters in the HFO Storage Tank to maintain the HFO temperature in the tank.
  • Outflow / Suction heaters in the tank, to raise the temperature to make it flowable.
  • Inline Heaters in the pipeline before the burners, to raise the temperature for ignition.

Tristar designs and manufactures all the heaters required to optimise power utilisation for your plant. Please let us know the Tank Capacity and flow rates for us to design and quote for the heaters.


Ship Heaters

Electric heaters are used to reduce the viscosity of Bunker oil to make it easily pumpable by raising the temperature.

Electric heaters can be used to heat oil, jacket water and other fluids when steam generators on ship are shutdown.

Tristar designs and manufactures all the heaters required to optimise power utilisation for on your ship. Please let us know the application and we will help you find an optimal solution.

Heaters with DNV certification available on request.


Air Heaters

As the name suggest, Air heaters are used to heat the air to remove moisture, maintain or raise temperature of an enclosed space and many such applications. Tristar manufactures Air heaters to suit your application. Tristar Air heaters are tubular heater elements with fins to increase the heat transfer area. Size of the tube and fins will depend on the application.

Our Heaters can be used in Ducts or as standalone heaters to heat air for various applications such as maintaining room temperature, humidity in the room, drying of paint, motor windings etc. We custom design the heaters to suit application. Various mounting options are available.


Paint Drying Air Heater

Paint Drying Air heaters are built for the purpose of drying paint faster. This is done by heating the air which in turn raises the temperature of the enclosed space or a small portion on which the heated air is directed. Our standalone Paint Drying heaters come with Fan and instruments to regulate the temperature required.


Flameproof Heaters

We can provide Immersion, Inline / circulation and Outflow heaters to be used in Hazardous areas with explosion proof Terminal box and Junction box.

The heaters are custom design to suit the application and the area they are installed in. Please contact us for more details on the explosion proof heaters.

Electric Heaters – Built to suit your application.

Design Code - ASME Sec VIII Div I

Material of Construction

  • Screw Plugs- Brass and SS 1” to 3" BSP or NPT
  • Flanges - As per ANSI B16.5, CS, SS 304, SS 316
  • Heating Elements( Casing Pipes / Tubular Elements) - Copper, CS, Passivated SS, SS 304, SS 316, SS321, Incoloy, and Titanium and Teflon / PTFE (Polytetrafluorethylene) coated.
  • Body Shell - CS, SS 304, SS316, SS321 etc.
  • Resistance Wire – Kanthal
  • Temperature Controls and Safety - Thermostats, RTD, Thermocouple and PID
  • Accessories - Drain Valve, Pressure Gauge, Pressure Relief Valve, Flow Switch, Pressure Switch, Pump Interlock Relay, Low Liquid Cutoff.

Electrical Tests - Resistant Test, Insulation Test, High Voltage Test, kW, Voltage and Amphere Test, Hydrostatic Test(Inprocess).

Applications where tubular elements are used

  • Water Heating , Process Solutions
  • Heat Transfer Oil Heating
  • Fuel Oil / Water Pre Heating
  • Heavy oils Tank heating
  • Freeze Protection
  • Steam, Air and Gas Heating
  • Boiler equipment, Process air equipment, Food Processing equipment, Plating Baths, Cleaning and Rinsing tanks, etc.
  • Jacket water heating

Applications where cartridge / open bobbin heating elements can be used.

  • Large Diameter tank content Heating
  • Heavy weight Fuel oil / Asphalt
  • Fuel Oil Preheating / Jacket Water Heating
  • Plating Baths, Cleaning and Rinsing tanks

Cartridge Heater Elements

The concept of cartridge is unique, it is made up of Metal Sheathed i.e. of SS 304 and which is then filled with thermally conductive magnesium oxide (MgO) so as to ensure maximum thermal conductivity, high electrical resistance & better life. We have a unique Parallel Coil Design, as the internal coils are arranged with a suitable number of parallel coils of rated wattage for lower watt density on heating coils, uniform cartridge heating, thus eliminating chances of a total burn out.

Our cartridges are factory sealed and are tamper proof. These cartridges can be replaced without any removal of heater body or shut down. These heaters are ideally suited for tank installations / pressure vessels etc where the fluid is to be maintained at a particular temperature. In the event of an element failing the other elements on the heater will compensate for the loss. In the event of the whole heater replacement, one has to only replace the cartridge elements leaving the heater body connected to the tank without having to empty the contents of the tank.


Open Bobbin Heater Elements

Bobbin heaters when inserted into a casing pipes, offer a large heated area to the liquid or semi-solid to be heated. Material such as oil, wax, fats and bitumen require low heater surface temperature to prevent product degradation. For these applications the Bobbin heater is ideal. A feature of this type of heater is that it may be removed for repair or replacement without draining the contents of the vessel. In this kind of heaters the elements/insulators are made from typical properties of ceramics such as cordierite, steatite and etc. These have excellent physical, thermal & electrical properties. These elements are very easy to replace. As these elements are designed to have a very low watt density on the casing pipes thus they ensure a longer life for the elements.

These heaters come in the following two designs i.e. Inline Vertical Heaters and Inline Horizontal Heaters.

Features

  • Insulators made from typical properties of ceramics such as cordierite, steatite, etc.
  • Excellent physical, thermal and electrical properties.
  • Easy replacement.
  • Very low watt density on casing pipes ensures longer life of elements.
  • Available from 3 kW to 240 kW
  • Watt Density: 1 w/cm² to 1.5w/cm² (6.45 to 9.6 w/in².)
  • Custom made to suit your requirements
  • Two thermostats one for Safety and another for Control

Tristar’s Unique Advantages.

  • Selection of appropriate watt densities. (See Note Below)
  • Long life metallic cartridges / open bobbin elements used.
  • Longer cartridges up to 6 meters used to cover large surface in tanks
  • Easy replacement of cartridges without oil shutdown
  • Precise temperature regulation for optimum performance.
  • Custom - Designing, Fabrication and Testing facilities

NOTE: Watt density / heating density is expressed in watt / cm2 experienced by media to be heated, over the outside surface area of encasing metallic pipe.