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In the past, thermal systems always had trade-offs that often made the “ideal” system out of reach. Whether budgetary concerns limit the number of temperature sensors, tight space requirements restrict the number of zones or the technology hampers how precise the heating systems are, these systems are often curated with compromise. Here, Sean Wilkinson, Product Manager at industrial technology company Watlow, explores how adaptive thermal systems (ATS) are designed to provide companies with the tools to build the heating systems they need, without forcing compromise.

A great heating system needs a great controller. Of course, better controllers are only worth the investment if it’s possible to achieve better control throughout the system. Improved control requires more sensors, which can be a costly proposition.

But there are ways to get around high costs. High temperature coefficient resistance (TCR) materials respond to temperature changes with a change in resistance. By measuring that change, it’s possible to determine the temperature at that location. Building heaters out of high TCR materials adds a sensing capability, adding measurements to places where they were previously impossible due to space or cost requirements.

Likewise, integrated thermocouple heater (TCH) junction temperature control turns heater power leads into a thermocouple junction. The voltage at this junction varies consistently with the surrounding temperature, so measuring it provides a spot measurement of the temperature at that location. Together, these two technologies offer expanded sensing options without additional wiring or extra controllers.

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Multi-loop control and sensing

Adopting high TCR materials or TCH junction temperature control can lead to an abundance of available data, which can be used to fine-tune processes and operating costs. However, in other systems, the increased capabilities would lead to an exponential increase in necessary wiring, which may not be possible due to space or budgetary requirements.

Watlow, which manufactures industrial heating technology, has decades of experience with thermal systems to help engineers and designers to incorporate ATS technology into a variety of industrial processes and products. Watlow’s multi-loop control uses a multiplex wiring scheme that enables as many as ten times the number of zones per wire when combined with high TCR materials. Increasing zone density allows for unparalleled sensing and control without creating budgetary issues.

Additionally, the company developed a standardised harness for the ATS system, which reduces the complexity of installations and the number of design passes needed before installation can begin.

The power of modularity

ATS’ true power comes from the fact that each system component is beneficial on its own, but together, they can transform a heating process from end to end. Whether designing a system from scratch or redesigning one that has not quite lived up to expectations, ATS brings something new to the table.

Many thermal system design projects reinvent the wheel at each stage of the process. ATS’s modular “off-the-shelf” approach to many components not only lowers cost, but also reduces the number of design iterations needed before implementation to reduce lead time.

However, it is essential to remember that ATS is still customised to the exact needs of each application. Due to that, it represents the best of both worlds. A system that can deliver the accurate temperature control needed for modern manufacturing while avoiding compromises related to cost, space, sensor density and heating control accuracy that other systems face.

ATS is a suite of solutions that can be tailored to specific engineering challenges, and without compromise as previously experienced. Now, ATS’s controllers, heating elements and sensors can help companies achieve breakthroughs in cost, efficiency, precision and data production, which can be used to help drive the next generation of growth within various manufacturing applications. 

About Watlow:

Founded in 1922, Watlow strives to be the leading provider of thermal solutions for the world’s most demanding applications. Utilizing our advanced technology, leading companies apply our thermal systems which are ideally suited for vital applications such as clean and environmentally-friendly energy systems and processes, front-end semiconductor processing and lifesaving medical and clinical equipment. Since 1922, Watlow has grown in product capability, market experience and global reach. The company holds more than 1,100 patents and employs 6,000 team members working in 12 manufacturing facilities and five advanced technology and development centers in the United States, Mexico, Europe and Asia. Watlow covers 95 countries through sales and distribution offices around the world. The company continues to grow, while the commitment remains the same – to provide its customers with superior products and services for their individual needs.

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Industrial organisations can push decarbonisation forward by shifting process heater systems from fossil fuel-burning to electric. This kind of electrification needs to be done with a systems approach in mind — by considering the entire thermal loop. Of all the components needed to switch to electric, control panels are one of the most important. For large-scale applications, control panels need to be designed to maximise reliability, accessibility and safety. In this article, Jeff McClanahan, business segment leader at industrial technology company Watlow, explores why systems approach thinking is key in the manufacturing of components for electrification.

The question of electrification is less of an if or a when, and instead how. Globally, companies are prioritising the reduction of their carbon footprint. There is a huge push across different industries to “go electric” as part of a larger program of decarbonisation. But the details for doing so can be elusive. It’s not as easy as swapping out gas-fired heaters for electric heaters, for example, without also considering the size, location and connectivity of the control panel that will regulate those electric heaters. These considerations will, in turn, have a bearing on how and when the system needs to be maintained, how long downtime lasts and what the prospects are for future expansion.

The point of a systems approach is to take a step back, seeing how different design considerations impact on the system and process might have as a whole, rather than focusing on the functioning or replacement of a single part. A systems approach also has an impact on the business aspects of an industrial process, as it encourages engineers to consider the total cost of ownership when comparing different options.

2023 09 13 115433Meeting challenges at scale

Taking a systems approach to process heating was a foundational consideration behind the design of Watlow’s L and XL WATCONNECT control panels. Here, we take a deeper look at what went into that design as a way of illustrating the power of this kind of thinking.

A systems approach means finding not just one or two solutions to meet a challenge, but finding as many solutions as possible to optimize a given outcome. Take reliability, for example. What are all of the different ways a system can be optimized to ensure near 100 per cent uptime? One way this was done in the design of the WATCONNECT panels was by looking at the thermal design of the system. All systems generate some heat, and excess heat is the nemesis of electronics. Therefore, optimising the system to keep heat under control is critical.

Watlow’s design looked at adding to the insulation of the system, reducing power where possible, and improving the airflow throughout the system. Airflow itself was improved by using high-reliability EC inlet and outlet fans with advanced monitoring, which provide up to twice the airflow compared to industry standard fans. Therefore, by better controlling waste heat within the panel, Watlow can extend the life of the electronic components and significantly increase reliability.

Other design considerations include accessibility options. A smaller panel door in the unit provides access to 90 per cent of the system while still shielding the user from high-voltage components. This allows a person to troubleshoot the system while running, and without the safety concerns that come from opening the panel while “hot.” This also ensures longer uptime, as the panel does not necessarily need to be shut down for investigating smaller issues.

WATCONNECT panels are also designed with solid copper internal power interconnect for less expansion and contraction. This is especially important at high-resistance junctions, because the more this component heats up when made from an alternative to copper, the higher the risk of failure.

Lastly, while the panels are categorised as large, they use only 50 per cent of the space that competitive panels require. This can make it easier to install the panels when space is limited. Or, if replacing current equipment, the savings potentially frees up space for other critical equipment, allowing for future expansion.

Industrial organisations can push decarbonisation forward by shifting process heater systems from fossil fuel-burning to electric. But this is not a simple swap-out. A systems approach must be taken to consider how individual components will affect the entire system.

While control panel technology is nothing new, there are fresh new challenges that come with building control panels for large-scale applications. To be effective in solving electrification challenges, these control panels need to be designed to maximize reliability, accessibility, safety and provide a smaller footprint.

To learn more about Watlow’s electrification solutions, visit watlow.com

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Semiconductor fabrication creates a number of waste gases, which can be corrosive, pyrophoric and potentially explosive. Often, diluting these gases with nitrogen (N2) is an early step in the abatement process to make sure the gases stay below the lower explosive limit (LEL) or reduce corrosive effects. However, the use of nitrogen can cause condensation and deposits, as well as leak out of the system. Here, Rob Johnston, director of the end user business segment at industrial electric heater manufacturer Watlow, explains how this can be prevented.

Abating hazardous gases

One way to abate hazardous gases in process exhaust streams is to dilute them using a less harmless gas. In semiconductor fabrication, nitrogen gas is often used because it is readily available and effective at diluting more hazardous gases prior to other abatement steps.

A good example of this solution can be seen with potentially explosive gases, such as hydrogenated gases. These gases have an explosive range, a specific range of gas concentrations where explosion is likely to occur. Gas concentrations must be kept below the lower explosive limit (LEL), which is the minimum concentration of gas needed to reach this explosive range. But mixing with nitrogen lowers the ratio, making the gas too lean to pose an explosion risk.

That said, when introducing a new gas into the exhaust stream, condensation can cause issues by creating deposits in the system. This eventually creates clogging, leading to unplanned downtime. The addition of nitrogen poses a dilemma, forcing plants to choose potential line shutdown in order to ensure safety — a trade-off no one wants to make.

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An alternative solution

If adding room-temperature nitrogen into a waste stream causes condensation problems, heating the nitrogen can be a sufficient remedy. However, getting nitrogen to temperature has proven to be a tricky engineering problem.

One of the biggest issues is with nitrogen leaks. Introducing a heater into the system can potentially create another place where nitrogen can leak, meaning that not all the nitrogen gets into the waste stream for abatement. If the leak is severe enough, the hazardous gases will not be diluted enough to ensure safety. This means that a potentially explosive gas might still be well within its explosive range.

There is limited space that can be taken up within an existing an abatement system, which limits the number of components, controllers and wires that can be added to the system, especially in multi-chamber setups.

The no-leak last resort

To overcome these challenges, a compact, no-leak heater design can ensure the reliability of exhaust abatement systems in semiconductor fabrication. For instance, Watlow’s FLUENT® in-line heater is designed to allow movement of a fluid or gas over the heater surface without any loss of the fluid or gas through the outer shell.

A no-leak design not only includes a seamless stainless steel outer protection tube, but it also has the heating elements sitting outside of the fluid flow path. As a result, neither the elements nor the wiring penetrate the gas flow path, mitigating the need to weld components in place and thereby create areas where gas can escape. This design ensures that all nitrogen gas is passed along into the process, preventing any from escaping into the sub-fab.

With no leaks present, the correct mixture of gases can be assured, meaning that semiconductor manufacturers no longer need to trade-off between safety concerns and possible downtime caused by the need to flush clogged exhaust systems.

A first step in the abatement of waste gases in semiconductor fabrication should be dilution with nitrogen gas. However, engineers must consider the issues that can arise and consider opting for a solution that covers all potential issues associated with nitrogen heating. In this case, a design that is modelled around eliminating leakage can prevent clogging and downtime.

For more information about the FLUENT® heater, go to watlow.com

About Watlow:

Watlow is a global industrial technology company that uses its world-class engineering expertise, advanced thermal systems and manufacturing excellence to enrich everyday life. Many of the world’s leading companies leverage our technology in vital applications such as semiconductor processing, environmentally-friendly energy solutions and lifesaving medical and clinical equipment, to name a few. Founded in 1922, Watlow’s culture is driven by our purpose of “Enriching Lives Through Inspired Innovation,” enabling us to deliver high-impact solutions that improve our customers’ competitive advantage.

Published in Oil & Gas

Medium or high voltage equipment for industrial applications always carries certain safety risks. Arc flash events are a prime example of a rare, but potentially fatal, situation that can be mitigated with the right technology. As electric process heaters become a popular alternative for larger applications that have historically favored gas-fired heaters, it’s vital to consider how they incorporate arc flash mitigation features. Here, Dennis Long, chief system designer for energy and environmental technologies business unit at industrial heating technology manufacturer Watlow, shares insight into why arc flashes happen and how manufacturers can mitigate their risk.

Concerns about decarbonization, automation and safety have driven many organizations to replace gas fired heaters with larger electrical alternatives. As medium voltage process heaters are relatively novel to many applications, they represent a potential new source of risk that manufacturers must recognize.

Potential risks

An arc flash is an electrical explosion that occurs when there is a short circuit in a system, which can be caused by a build-up of corrosion or conductive dust. If the voltage is high enough, and if there is a path to ground or a lower voltage, the resistance of the air is overcome and results in an arc.

Arc flash events can result in significant damage. As the energy release increases, the risk of fire and injury rises with it. If the energy release is high enough, molten conductor metal and high-pressure plasma energy that can escape from the cabinet, posing a risk to anyone in the vicinity.

The potential arc flash energy is determined by several factors including equipment voltage, available current and the duration of the event. While it may be practical to reduce the potential arc flash energy while limiting voltage or current, overall project cost can make this difficult. Although arc flash incidents are rare, their potential for damage, injury and death makes them a great concern. Some estimates put the incidence of arc flash events between five to ten per day worldwide.

Engineer wears suit to protect from potential arc flashEngineer wears suit to protect from potential arc flash

Reducing the effects

There are three main strategies for minimizing the effects of arc flashes, including increasing the distance from the potential source of an event, reducing the available fault current and decreasing the duration of the event. All strategies can be combined to ensure maximum safety, but this is not practical when considering overall project cost. That said, the duration of the event is the most viable influencer to reduce damage and has the largest impact on the total amount of energy released.

There are two key approaches to compare: arc-resistant cabinets and arc mitigation technologies. Arc-resistant cabinets aim to reduce exposure to arc events by encasing the system in a metal-clad cabinet with a venting system. The heated gas and pressure is redirected through a duct, reducing the energy that could potentially explode. However, a drawback lies in the fact that the cabinet must be closed for the arc-resistant cabinet to work, as many arc events occur during maintenance, when the doors are open.

Mitigation technologies

Instead of redirecting the energy from the event, arc mitigation seeks to reduce the energy of the event itself by limiting its duration. This is done by detecting the arc flash early and automatically tripping the appropriate circuit. This can be done via sensing current, referred to as current arc mitigation, or sensing light, known as optical arc mitigation.

In optical arc mitigation, the light emitted by the arc within the enclosure builds quickly, which can be detected by a photoelectric receptor, even in the early stages of the event. When detected, the signal is then sent to a protective relay, which trips the breaker automatically without the need for human intervention.

One of the main advantages of this approach is that it is independent of the actual magnitude of the arcing fault current. This allows the system to detect arcing in an early stage of its development and trigger the break sooner, which limits the duration of the event and the total energy produced.

On the other hand, current arc mitigation uses current transducers to sense an increase in current produced by the arc. If the transducers are not sized correctly, they may not shut the system down or may be unable to clear the event.

Arc mitigation technologies also reduce damage to equipment, as it can function even when the doors are open and maintenance is being performed. For example, in the Watlow POWERSAFE™ thermal system, sensors can be placed within the thermal controller, SCR node single contact or node, which are protected by a feeder. When the sensor senses an arc flash event in any compartment, the feeder shuts down the lineup to limit damage caused by the arc.

As medium voltage process heaters become more popular, they must be designed with safety in mind. Arc flash mitigation technologies represent the best approach here, as they decrease the duration of arc flash events and hence the energy released, helping to minimize the risk and damage involved.

About Watlow:

Watlow is a global industrial technology company that uses its world-class engineering expertise, advanced thermal systems and manufacturing excellence to enrich everyday life. Many of the world’s leading companies leverage our technology in vital applications such as semiconductor processing, environmentally-friendly energy solutions and lifesaving medical and clinical equipment, to name a few. Founded in 1922, Watlow’s culture is driven by our purpose of “Enriching Lives Through Inspired Innovation,” enabling us to deliver high-impact solutions that improve our customers’ competitive advantage.

https://www.watlow.com/

Published in Power & water
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Tuesday, 17 May 2022 09:58

Solving thermal system complexity

Thermal solutions are a part of almost every industry, from chip manufacturing and medical devices to oil and gas operations. What these diverse industries have in common is a need to design simple, yet responsive systems that can monitor and maintain the precise application of heat. However, this need means that engineers must contend with various complexities. Here, Brandy Phillips, engineering manager at industrial electric heating element manufacturer Watlow, explains how adaptive thermal solutions (ATS) can provide an answer to common heat processing challenges.

Any device or process with a heater needs some degree of thermal control, with some devices or processes needing more precise control than others. That precision is traditionally achieved by adding sensors and controllers to heaters. The more precision needed, the more complex the control apparatus and the wiring becomes.

ATS, which combines sensing, heating and control technologies, represent a different and more innovative approach to controlling thermal performance for complex systems. However, adding the complexity is not always an option, which is where challenges present themselves.

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Complex systems in small spaces

A surface that needs to be heated to within a certain temperature range requires not only several heating elements, but also sensors that can detect the temperature of the surface at various points. Those sensors then deliver that feedback to a controller that then responds by adjusting the power sent to the heaters. If the temperature of the surface fluctuates, the sensors and controller should be able to respond in tandem to maintain the desirable temperature range.

Traditionally, the approach to getting such fine control of the heating surface has been to increase the zone count, which requires the addition of independent sensors, wires and controllers. As the system scales, the complexity grows, but the overall space in which this needs to happen does not. In many manufacturing scenarios, precise control is needed in a confined space, and additional wiring and equipment is not feasible.

Control system challenges

Manufacturers may experience disconnection between their control systems. Different banks of sensors at different points in a process are often connected to separate controllers, which might not be networked in such a way that their activity can be coordinated easily, which results in unresponsive systems.

The above challenge often results in adding an element of unpredictability to the system. The added complexity of additional sensors and controllers will, for some applications, either compromise adaptability or prevent the system from achieving desired thermal uniformity. These, in turn, lead to excess waste and variable material quality.

Unlocking these challenges

Precision and tunability of a thermal system is traditionally achieved by adding sensors and controllers to the system. But there are plenty of applications where this is not a viable option, including semiconductor manufacturing, analytical devices and home medical devices. ATS makes possible a greater degree of control in systems where piling on more components is simply not an option.

Every application is unique, and some can take advantage of many ATS technologies at once while others might use just one. In semiconductor manufacturing, deposition pedestal heaters must reach certain temperatures during the chipmaking process, and temperature uniformity is critical to quality control. The pedestal itself allows little room for extra wires. With high TCR materials and multi-loop control and sensing, individual heaters can be made into sensors, and the number of heating zones can be more than doubled. These zones can be independently controlled, in real time, adjusting heater output to achieve a more uniform surface temperature.

Furthermore, existing medical and analytical equipment often have to meet new agency requirements, like safety specifications for allowed temperatures. Having heaters that can sense their own temperature, when then adjusts power levels via power conversion, helps to keep

temperatures within safe limits.

Watlow, which manufactures industrial heating technology, has decades of experience with thermal systems to help engineers and designers to incorporate ATS technology into a variety of industrial processes and products.

The beauty of ATS is that it is not one solution, but a suite of solutions that can be tailored to specific engineering challenges. Unlocking the benefits of this technology requires a deep understanding of the product or process in question, including the thermal and power requirements of the system.

For more information about ATS, visit watlow.com

About Watlow:

Watlow is a global industrial technology company that uses its world-class engineering expertise, advanced thermal systems and manufacturing excellence to enrich everyday life. Many of the world’s leading companies leverage our technology in vital applications such as semiconductor processing, environmentally-friendly energy solutions and lifesaving medical and clinical equipment, to name a few. Founded in 1922, Watlow’s culture is driven by our purpose of “Enriching Lives Through Inspired Innovation,” enabling us to deliver high-impact solutions that improve our customers’ competitive advantage.

Published in Oil & Gas
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Wednesday, 09 February 2022 10:08

Smartening up temperature control

A smart power controller does what it says on the tin. It is smart because it has a microprocessor and sophisticated programming. It controls power using sensors that monitor voltage and current, adapting and making decisions as conditions change within the parameters of the application that it’s being used. However, it’s a valuable tool that is often overlooked. Here, Erick Rios, product manager for controls at industrial technology company Watlow, explores why smart power control is vital in heating applications.

There are many types of power switches that are used in commercial and industrial applications. Mechanical relays and contactors are ideal for applications where they are not switched very often because they are relatively inexpensive and do not produce much heat. But for precise control of electric heating, these switch types are a poor choice because they wear out and fail quickly if switched frequently. In this instance, smart power controllers are a sensible choice.

Improved performance

Being able to control the output based on the measurement of power delivered to the load improves temperature control performance because it compensates for line voltage fluctuations or even partial load failures faster. This means that there is significantly less deviation from the temperature set point than would occur with the same temperature controller paired with a traditional solid-state power switching product.

The temperature controller and power controller work together. The temperature controller measures the temperature with a sensor and determines how much of the available power is necessary to achieve set point. The power controller interprets the output from the temperature controller and controls the delivered power accordingly. Finally, the power controller adjusts the power delivered for voltage fluctuations and to the best of its ability when there is a partial failure of the heater.

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Process and equipment characterization

The smart power controller measures the line voltage and the current through the load. With that information it calculates the load resistance and how much power is being delivered by the heater. Equipment manufacturers can use this information during commissioning to identify if there is a problem. For example, abnormally high resistance could indicate a poor connection that might eventually cause a premature failure or even a fire if not corrected.

For instance, power controllers can help companies monitor the load parameters during equipment installation and compare the profile with previous known good start-ups. By doing this, they can receive warning of issues localized to the heated zone, allowing preventative action to be taken before a failure occurs.

End users can similarly monitor these parameters overtime and correlate them to good and bad production results.

Integrated communication

Integrating a smart power controller with other automation equipment allows process variables to be monitored remotely and allows operators and line maintenance personnel to quickly locate problems.

Consider this example, from a Watlow customer. A manufacturer of power transmission cables once relied on employees to periodically check the current gauges visually for each zone of extruders that coat the cables. On shifts with lower staffing, faulty product was often the first indication of a problem. The customer replaced the solid-state power controllers in the extruders with the ASPYRE® DT power controllers from Watlow, so they could determine if cable needed to be scrapped or whether production could continue until the scheduled maintenance.

Watlow’s range of heating equipment, including its ASPYRE controllers, is frequently used by heavy duty industrial companies in petrochemicals, heat treatment and power generation. The ASPYRE model is available between a range of 35 to 2,100 amps to support a wide variety of applications. For example, a single high amp ASPYRE unit is ideal for applications using multiple small units with low range amps. 

Overall, the smart features and functionality of smart power controllers enables users to minimize scrap and unscheduled down time — improving operations and output.

To find out more about Watlow’s industrial heating solutions, visit www.watlow.com.

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Monday, 23 August 2021 10:46

Understanding the factors affecting heat loss

Understanding the factors that influence heat loss allows design engineers to better calculate the insulation and power needed to heat a product. Troubleshooting any inefficiencies and reducing heat loss can improve the efficiency of heating systems and save costs. Here, Johann Lainer, senior marketing communications specialist at industrial technology company Watlow, breaks down the factors related to heat loss and explains how to calculate predicted heat loss for your application.

Heat loss is the intentional or unintentional movement of heat from one material to another, which can happen through conduction, convection or radiation. Conduction often occurs when an insulated or uninsulated component is in direct contact with another component, convection occurs when a pipe, electric heater or other component has an air barrier around it, while radiation is when there is no contact and heat moves as waves.

How heat loss happens 

With an understanding of how heat loss occurs, it’s important to then select power and temperature controllers that best suit your heating situation. One way to do this is to account for common heat loss factors. While every scenario will have different factors affecting heat loss and transfer, uninsulated surfaces, vertical or horizontal insulated surfaces and oil, paraffin or water surfaces are common areas of heat loss that design engineers must account for when selecting heating products.

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Factors that influence heat loss can change when relocating a process or make changes to an assembly line. Targeting a facility’s heat loss factors and making necessary adjustments with controlling equipment or insulation strategies keeps your operations running at the same quality and consistency as it was before the change.

In addition, adjusting the temperature of a heater or protecting it from one or more of these heat loss factors can reduce the wattage usage of the system, saving a considerable amount in daily operating expenses.

Emissivity and heat loss

Emissivity is defined as the ability of a particular object or material to emit infrared energy. The emissivity of a heater, thermocouple and insulation can affect the heat loss by radiation. 

This is another piece of the puzzle when determining how much heat is required for a specific application. It’s important to explore the emissivity of the material in the heating process and identify whether the material is a polished surface or has medium or heavy oxide. Even non-metals are emissive, so the specific heat of insulation materials must be checked to see how it can affect overall heat loss.

Calculating heat loss

When working to reduce heat loss, adopting a predictive mindset is advised. Watlow recommends calculating a process or piece of equipment’s expected heat loss based on the location, insulation type and material being heated.

To understand how to calculate heat loss, multiply the convection curve value by a factor of 1.29 for horizontal heating products, whereas vertical pipes should use the direct value of the curve. For bottom surfaces, multiply the curve by 0.63. However, this offers a rough guide and the calculation does not consider other heat loss factors that may affect your product. Original equipment manufacturers (OEMs) need a more accurate way to measure heat loss for their specific product, so alterations known as emissivity values need to be made.

Using the graph is helpful at high temperatures, but as the temperature reaches ambient, or over 21 degrees Celsius, it can be difficult to read. There are two general rules that can help you arrive at a more precise temperature reading.

Firstly, calculate losses from an uninsulated surface close to 1.0 emissivity by dividing the temperature rise above ambient by 200, and secondly, calculate losses from an insulated surface with the approximate thickness of one inch and a thermal conductivity K- value of 0.5 by dividing the rise above ambient temperature by 950.

From controllers to heaters, or whether you’re looking to improve the efficiency of your process, Watlow offers a range of industrial heating equipment and technical guides to help design engineers understand and manage heat loss factors.

Heat loss is influenced by various reasons dependent on the material and application. However, the result remains the same — increased costs and more inefficiencies. Understanding what causes heat loss and knowing how to calculate the predicted loss of your application is key to maintaining productivity.

To find out more about Watlow’s products or to calculate heat loss, visit watlow.com/heat-loss-factors-and-graphs/.

About Watlow:

Watlow is a global industrial technology company that uses its world-class engineering expertise, advanced thermal systems and manufacturing excellence to enrich everyday life. Many of the world’s leading companies leverage our technology in vital applications such as semiconductor processing, environmentally-friendly energy solutions and lifesaving medical and clinical equipment, to name a few. Founded in 1922, Watlow’s culture is driven by our purpose of “Enriching Lives Through Inspired Innovation,” enabling us to deliver high-impact solutions that improve our customers’ competitive advantage.

 

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While investment in clean energy plays a huge part in achieving global climate goals, it must coincide with the further electrification of industrial processes. Even in the oil and gas industry, there is significant room for the decarbonization of processes, particularly in thermal applications. Innovative technologies have solved many of the challenges that previously hindered the implementation of electric process heating, making it an obvious area where companies should focus their efforts. Here, Dennis Long, director of global marketing energy and environmental technologies at industrial technology company Watlow, explains more.

In May 2021, a Dutch court ruled that Royal Dutch Shell must reduce its carbon emissions by 45 per cent, compared to 2019 levels. What makes this significant? The ruling marks the first time that a company has been legally obliged to align its practices and policies with the 2015 Paris climate accord. And it’s believed that more will follow suit.

As producers of traditional fossil fuels, oil and gas companies are recognizing the need to reduce their own carbon footprints. Even as it continues to process and distribute fossil fuels for the world’s energy consumption, the oil and gas sector is limiting its own use of them.

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The Paris Climate Conference and IEA report

Often perceived as the catalyst for action on climate change, the Paris Agreement set the goal of keeping global temperature rise contained to two degrees Celsius above pre-industrial levels.

The agreement also contained measures for the monitoring, verification and reporting of progress toward those targets. In May 2021, the International Energy Agency (IEA) released a new report detailing the steps to achieve net-zero carbon emissions (NZE) by 2050. The report sets out 400 milestones, including steps such as ceasing new construction of coal and oil power plants, phasing out unabated ones by 2040 and calling an end to investment in fossil fuels.

While reactions to the report have been mixed, it is clear that organizations are working hard to envision themselves in the picture that the IEA has painted of the future. For example, the Qatar-based trade organization Gas Exporting Countries Forum (GECF) has agreed on the need to attain NZE, but re-emphasizes its belief that natural gas has a central role to play in energy transition, especially as developing countries move away from coal-fired plants. We won’t completely say goodbye to fossil fuels immediately, but there are several steps oil and gas companies can take to clean up their own operations.

Decarbonizing fossil fuels processing

It is still an open question as to where in a process companies should start making changes. Process heating is one obvious area. However, there are factors to consider when switching to electric process heaters.

First, electric heaters need to be able to accommodate the larger wattage and amperage necessary to hit specific temperature requirements. Furthermore, adequate control of the heater is needed to ensure that processes can be performed safely. Another consideration is the potential for coking and fouling, which is often a result of hot spots in a process heater created by so-called ‘dead-zone’ areas with little flow.

But challenges can be overcome. Newer technologies incorporated into electric heat exchangers allow for designs that take advantage of increased heat flux — i.e. watt density — for a given gas composition and a set of application conditions. Higher watt densities can help make processes more efficient and less costly, while still meeting critical temperature requirements, reducing overall footprint and providing safer operation. To deliver better control, two separate control systems should be used: one for process temperature control and one for high limit control. PID-type process temperature controllers offer more stable control and faster response than on/off switching controls or thermostats.

To dimmish fouling rates, heaters with Continuous Helical Flow Technology™ do not have these dead zones, which delivers a more uniform temperature across the heating surface. Material is always in motion and does not have time to collect and degrade. The result is near-elimination of fouling. Heaters with this technology, like Watlow’s own HELIMAX™, boast a much smaller footprint, allowing for a more efficient use of space.

Electrification of thermal processes will play a key role in the decarbonization of the energy sector. Companies in this industry have been taking significant steps to reduce their overall carbon footprint by electrifying their processes. However, making the switch to modern electric process heaters is key to helping the industry achieve its goals.

To find out more about Watlow’s range of electric heating equipment, visit watlow.com.

About Watlow:

Watlow is a global industrial technology company that uses its world-class engineering expertise, advanced thermal systems and manufacturing excellence to enrich everyday life. Many of the world’s leading companies leverage our technology in vital applications such as semiconductor processing, environmentally-friendly energy solutions and lifesaving medical and clinical equipment, to name a few. Founded in 1922, Watlow’s culture is driven by our purpose of “Enriching Lives Through Inspired Innovation,” enabling us to deliver high-impact solutions that improve our customers’ competitive advantage.

Published in Oil & Gas
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