| First Thermal Heaters |
Forced Circulation Vaporizer:
Specifications
General
The vaporizer shall be a factory assembled, pre-piped and wired package designed to minimize field erection and utility connection costs and arranged to meet the owner's site requirements. The vaporizer package, including control wiring, interconnecting piping, and stack, shall be assembled and erected so as to ensure proper fit and electrical wiring completeness prior to shipment from the vendor's factory.Scope
The vaporizer vendor's scope shall include, as a minimum, the following:
The items listed above are to be considered the minimum requirement and the potential vendor is encouraged to add any items that would improve the operation, efficiency, and safety of the equipment proposed.
Owner Furnished
The owner shall furnish the following:
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Site preparation, diking, drainage, and equipment foundation and mounting pad. |
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Unloading, erection, and assembly. |
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Dowtherm and fuel piping to vendor's equipment package connections. |
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Insulation, including flash tank, and equipment package piping. |
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Wiring of 120/1/60 power to vendor's control cabinet. |
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Wiring from owner's MCC to vendor package motors. |
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Motor starters. |
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Fuel gas supply. |
Site Data
Codes
The vaporizer shall meet or exceed the following specifications:
Performance
The vaporizer package shall be capable of automatic, unattended, and continuous operation at the design capacity stated below. In addition, the vaporizer shall be capable of automatically reducing the vapor output to match the owner's batch minimum processing cycle requirements.
Vaporizer Specifications
Elements 1.0, 2.0, and 3.0 shall be fabricated, assembled, factory piped, wired, erected, and functionally tested in the vendor's facility prior to shipment. The purchaser and his authorized agents shall have the right to inspect, witness, and have unlimited access to the vendor's plant during the engineering, manufacturing, and assembly process.
The heater shall be designed for forced circulation of thermal fluid through a helical coil system fabricated from seamless pipe of sufficient heating surface to satisfy the heat input requirements. The heater shall be designed and constructed in accordance with the applicable ASME Boiler and Pressure Vessel Code Section VIII or Section I. The coil is to be enclosed in an insulated shell. Observation ports, manway, and connections for heater coil combustion air and burner shall be provided.
Items appearing in orange are vendor data that is required with proposal.
| Design Capacity | x 106 BTU/HR |
| Heater Output (Operating) Temperature | °F |
| Heater Return (Inlet) Temperature | °F |
| Liquid Flow Through the Heater | GPM |
| Maximum Pressure Drop Through the Heater | PSIG @ operating temperature |
| Minimum Heater LHV/Operating Efficiency (Net) (Not including the additional efficiency available from combustion air preheaters or other optional heat recovery devices as suggested by the heater manufacturer. If the manufacturer requires additional heat recovery devices to attain this efficiency, these shall be quoted as a separate option. No extended heat transfer surface shall be employed in either the base heater or auxiliary heat recovery device.) |
% |
| Maximum Fuel Input at Design Capacity | C.F.H. |
| Number of Liquid Circuits in Heater | * |
* Vendor data required with proposal.
The heat exchange coil shall be a tangentially wound, helical coil constructed of SA-106B, seamless Schedule 40 carbon steel pipe. The coil shall be designed, constructed, tested, and inspected in accordance with the applicable ASME Code. The heat exchange coil shall have an ASME Code rating of 300 PSIG @ 800°F. Rating calculations shall include a 0.100" corrosion allowance and a 0.001" fouling factor. The coil shall receive an authorized National Board inspection and a copy of the inspection report shall be furnished to the purchaser. All butt joints in the heat exchange coils and headers shall be 100% x-rayed. Hydrostatic test pressure shall not be less than 1.5 x MAWP.
The heat exchanger shall be constructed with expansion loops to allow for thermal expansion and contraction without transmitting stress to the heater shell. The heat exchange coil assembly shall include inlet and outlet manifolds with 300 PSIG, ANSI RFS flanged connections. The heater vendor shall manufacture, inspect, and hydrostatically test at his own plant. The purchaser or owner's agent shall be present for the hydrostatic test.
The heat exchanger shall be specifically designed for the ______ GPM flow rate. Operating under these nominal design conditions, the maximum film temperature (measured at the point of maximum radiant flux) shall not exceed ______ °F at the maximum rated heater output.
Minimum/Vendor proposed
: No extended surface (fins or studs) shall be permitted in either radiant or convection zones.The heat exchange coil shall be supported and positioned in the heater shell by stainless steel supports and wear plates. All coil supports shall be in the heater convection section to minimize their exposure to radiant zone temperatures. Coil supports shall allow unhindered thermal expansion and contraction of the heat exchange coil.
The thermal fluid heater shall contain a maximum of two (2) liquid coil circuits. Dual circuit coils shall be parallel rolled and designed to assure equal exposure to radiant and convection heat transfer in both circuits. Vendor shall not average dissimilar fluid temperatures in the outlet manifold. Where more than one (1) liquid circuit is employed in the heater, the manufacturer shall furnish headers designed to provide equalized flow through each circuit for both heater inlet and outlet.
The heat exchange coil shall be enclosed in an insulated shell constructed of SA-36 carbon steel plate. Shell construction shall employ full diameter end plates and all heater joints shall be welded or gasketed "gas tight" by high temperature ceramic fiber gaskets. The shell shall not contain castable, brick, or gunnite refractory. The inside of the shell (and bottom cap) shall be insulated with multiple overlapping layers of ceramic fiber blanket. The blanket shall be fixed to the shell by welded stainless steel pins and retention clips. The clips shall be located on 9" centers (maximum). To resist high temperature gas erosion, the pins and clips shall be covered with high temperature caulk and the entire blanket surface shall be coated with a high temperature rigidizer.
The heater shell shall have a full diameter removable top cap to allow access to the heater coil for inspection and maintenance. The top cover shall have three (3) 1-1/4", two-thirds union peepsights with replaceable Pyrex glass and slide gates with stainless steel slides for viewing the heater internal, burner flame, and heater radiant zone. The top cover shall be internally lined with 6" of ceramic fiber modular block held in place by stainless steel pins welded to the heater cover. The top cap flange joint shall be sealed with a ceramic fiber gasket. An 18" diameter, bolted manway shall be provided to permit access to the heater radiant zone and burner.
The heater bottom cap shall contain the burner block, coil support ring, stack and heater leg support structure. The bottom cap shall be insulated with multiple layers (6" total thickness) of ceramic fiber blanket. The hot face rating shall not be less than 2400°F.
The heater shall be equipped with a ______" I.D. carbon steel stack (10 gauge minimum) that shall extend 15 feet above the top of the heater. The stack shall be 100% supported either by grade mounting or by support leg. No guys shall be required. The stack shall be complete with a high velocity rain cap. All fittings and connections required to allow EPA (state and federal) emission testing. Stack and cap shall be painted to withstand 100 mph winds. Stack and cap shall be finished to manufacturer's standard.
The heater manufacturer shall factory-install a ladder, cage, intermediate landing, and top catwalk to allow access to the heater top in the event of vertical configuration. All equipment shall meet OSHA standards.
The inlet of the heater coil shall be equipped with a ______", 300 PSIG RFS flanged nozzle for mounting the spring-loaded pressure-relieving safety valves in accordance with the ASME Code and as described below:
The safety relief valve set shall include a full pipe size, reverse buckling, 316 stainless steel rupture disc to protect the valve orifice. Rupture disc set shall include companion 300 PSIG, RFS flanges, with safety head assembly, excess flow valve, nipple and tee, 0-300 PSIG safety pressure gauge, and alloy studs and nuts.
An industrial, forced-draft, packaged gas burner with integral combustion air blower
shall be supplied and installed as an integral part of the heater by the vaporizer
manufacturer. Burner shall be designed for Low NOx emissions.
Burner manufacturer shall be ______________, Model No. __________.
The complete burner package shall include the following equipment all furnished, piped, wired, assembled, and installed as an integral part of the automatic heater combustion system.
Items appearing in orange are vendor data that is required with proposal.
A local (NEMA ___) control cabinet shall be furnished and mounted on the heater and contains the following:
The flame safety programmer shall be Honeywell #RM7840L with "UV" amplifier. Flame programmer shall provide prepurge ignition, flame monitoring, and post purge as required by FM, IRI, and NFPA. Control shall also contain a combustion fault finder to electronically assist service and maintenance.
All temperature controllers shall be thermocouple, electronic solid state, PID type
with digital scale and set point.
The primary indicating vapor temperture controller shall be automatic, indicating, electric thermal liquid outlet temperature controller, installed in the heater control cabinet. The control shall be adjustable type set point and indication shall be digital readout type. Scale range shall be 0-800°F. NOTE: Temperature element with well shall be installed in the flash tank.
When the system heat load requirement falls below the burner modulating input turn-down range, a secondary temperature switch shall automatically take over burner control and operate the burner in an "On/Off" mode until system demand rises above the minimum firing level (low fire input position) of the burner. Sequencing from modulating mode to "on/off" mode and back shall be automatic, not requiring operator monitoring.
Mounted in the heater control cabinet shall be a high thermal liquid temperature limit switch. This limit shall be indicating, electric, with adjustable set point and 0-800°F scale range. The switch shall be wired to shut heater down (shut down the heater's burner) and energize the heater safety circuit should the thermal liquid outlet temperature exceed the preset limit. Set point and read out shall be digital.
Mounted in the heater control cabinet side facing the burner shall be an adjustable, indicating, high stack temperature limit switch. Switch shall be wired to shut down burner and energize heater alarm and shut down circuit should preset temperature limit be exceed. High stack temperature shall annunciate and shut down the heater. Control shall have both digital set point and readout dial with 0-1200°F scale.
(NEMA ______) The control cabinet shall be equipped with a "First Out" Fault Annunciator which shall detect which safety or operating interlocks are not closed during burner start-up as well as which interlock opens first to cause burner shutdown. If more than one interlock opens, the annunciator shall annunciate the first one, and when that fault is corrected, it shall annunciate the second, third, fourth, etc. Annunciator utilizes solid state electronics for reliability and optical couplers (LED type) for visual annunciation.
An alarm horn shall be provided, installed, and wired to sound on activation of the heater/combustion safety shutdown devices. These devices shall include:
A set of dry contacts common to all of the heater safety limit devices shall be provided on the cabinet terminal strip for use by the owner for remote indication of a heater safety problem.
A painted steel instrument board shall be mounted on the heater so as to provide a support for the following gauges and switches.
with isolating stop and bleed valve for liquid circuit shall be included to provide the operator with a visual check of the pressure drop through the heater (i.e., fluid flow).
One (1) differential pressure switch shall be installed, mounted, and wired as an integral part of the safety system. This switch shall monitor the flow of thermal liquid through the heater. Should the flow (differential pressure) drop below the set point, the heater shall be shutdown (burner turned off) and low flow alarm initiated.
The heater shall have not less than _____ ft2 of fireside heat transfer surface.
Heater liquid fill shall be less than ____ gallons U.S.
Vendor shall state unit dry and operating weights and overall dimensions in initial proposal.
The heater manufacturer shall submit a HEATER PERFORMANCE DATA SHEET with the initial equipment proposal. Performance data to be supplied shall include, but not limited to, the following:
Items appearing in orange are vendor data that is required with proposal.
The vaporizer manufacturer shall design, fabricate, and assemble a Dowtherm Vapor flash tank with sufficient volume to efficiently separate the system vapor requirement for the liquid stream received from the heater.
The flash tank shall be designed, manufactured, and tested in accordance with the applicable ASME Code, Section VIII or Section I, be inspected and approved by an authorized National Board inspector and display the ASME Code stamping. Thank design pressure shall be 135 PSIG at 750°F. All tank connections shall be 300 PSIG, ANSI, RFS flanged.
The tank shall be arranged vertically and be of sufficient size to prevent vapor entrainment in the liquid returning to the suction of the circulating pumps to avoid pump cavitation and to maintain a stable liquid level in the vessel.
The tank shall include welded insulation rings for 6" of insulation. Insulation of the tank shall be by the owner.
The tank shall be supported and elevated by structural steel legs. The support structure shall be designed to meet the jobsite wind loading and earthquake loading specified for the owner's jobsite.
The tank legs shall elevate the bottom of the flash tank above the circulating pump inlet center line so as to eliminate the danger of pump cavitation due to insufficient NPSH. The heater vendor shall submit to the owner NPSH calculations incorporating all losses from the bottom of the tank to the suction of the circulating pump.
All ladders, cages, catwalks, and landings required to reach and service the flash tank
instruments shall be furnished and installed by the vaporizer vendor and dis-assembled for
shipping purposes.
Armored reflex gauge with integral ball check gauge cocks to visually show the level for the full length of the straight section of the tank.
The flash tank is to be equipped with a level controller sensing the level for the full straight section of the tank utilizing a differential pressure transmitter. Pressure seals shall be used to isolate the transmitter from the heat medium. The signal from the transmitter shall operate a vendor-supplied control valve in the condensate return line to the flash tank. The control valve shall be pneumatically actuated and maintain the proper level in the flash tank.
Switch shall be an external cage-type wired to shut (heater) burner down and sound alarm upon low flash tank liquid level.
As per 2.8.2 above. Provides 100% redundancy for the primary LSL.
Gauge shall be stainless steel bourdon tube type, 4-1/2" diameter scale, vacuum/pressure type (30" Hg., 300 PSIG).
The vaporizer vendor shall furnish the following interconnecting piping manifolds and valves:
Items appearing in orange are vendor data that is required with proposal.
The vaporizer shall be equipped with a circulating pump set designed to provide the heater with the condensed thermal liquid returning from the owner's reactor system and the recirculating liquid from the vapor flash tank. The pumps shall be sized to overcome all of the vaporizer pressure losses and to ensure correct flow through the heating section. The pump set shall include one (1) primary and one (1) stand-by pump with inlet and outlet manifolds and instruments mounted and supported on a common fabricated base.
Duplex circulating pump set shall include two (2) Series R400, DEAN BROTHERS centrifugal center line, water-cooled pumps, each complete with pump base, flexible coupling, steel OSHA type coupling guard, mechanical seal, and electric motor. Pumps are to have a casing drain, inlet and outlet nozzles drilled and tapped, all with steel plugs.
Pump seal shall be ______, ______, Model No. ______, manufactured by ______.
Pump motors shall be ______, ______, ______ RPM, NEMA ______, with ______ enclosure, 460 volt, 3 phase, 60 Hz. Pump HP is to be calculated for non-overloading at full run out and maximum heater outlet temperature.
Pump capacity shall be ______ GPM at ______
ft. TDH (______ PSIG). NOTE: Vendor
shall submit a pump capacity curve marked with operating point and operating NPSH.
The vaporizer manufacturer shall furnish and assemble the suction and discharge thermal liquid pump manifolds and install these manifolds on the pumps mounted on a common fabricated steel base. All pump pipe and valve support shall be included as an integral part of the pump skid package. Manifold pipe shall be schedule 40, SA106B, seamless carbon steel, welded and pressure tested per ANSI B31.1. The use of flanged joints shall be held to a minimum. However, where necessary, 300 PSIG, ANSI, RFS flanges with spiral wound mineral fiber gaskets and alloy studs/nuts shall be used. Manifold connections larger the ½" shall be flanged. Connections ½" and smaller shall be threaded and seal welded.
Each pump discharge shall have one (1) flexible welded metal bellows hose with double stainless steel braid, one (1) check valve, one (1) cast steel gate valve, and one (1) pressure gauge (4½" dial x ½" npt gauge with stainless steel trim and bourdon tube and steel gauge block valve). The two (2) pump discharge trains shall be piped to one (1) common header. The common discharge header shall be factory piped to the heater inlet.
Each pump suction train shall include one (1) flexible welded metal bellows hose with
double stainless steel braid, one (1) strainer, and one (1) cast steel gate valve. Each
strainer shall have a differential pressure gauge (DPI) piped with a steel block valve in
each leg of the gauge. Gauge shall be piped to indicate the pressure drop across the
strainer.
The two (2) pump suction trains shall be connected to one (1) common inlet heater
containing a bimetallic type thermometer (5" diameter dial) as well as a flanged
______" connection with cast steel block valve for connection to the owner's
condensate return header (by others). The pump suction header is to be piped to the flash
tank liquid return connection by the vaporizer manufacturer.
Items appearing in orange are vendor data that is required with proposal.
A complete description of all items to be furnished, including:
Computer analysis of vaporizer operating at maximum design capacity. Analysis shall show gross fuel input, maximum calculated metal and fluid film temperature, calculated combustion loading, and radiant flux rates.
Proposal sketch showing overall dimensions (plan and side elevation) and weights of equipment proposed, as well as liquid fill required by system proposed.
P&I sketch, illustrating the major components and instrumentation proposed and clearly defining the battery limits of the equipment quoted.
Pump capacity curve / BHP calculations.
Factory service rate sheet.
All exceptions, or suggested alternatives to specifications, shall be clearly stated in
the vendor's initial equipment proposal. Where no exceptions or alternatives are stated,
the equipment will conform to this specification.
Items appearing in orange are vendor data that is required with proposal.
The successful bidder shall provide the purchaser with the following data and documents:
Three (3) copies of the following reproducible drawings and data:
All drawings shall be CAD generated and suitable for use in the owner's master file. Symbols shall be ISA standards. Weights and measures shall be shown in English units.
Copies of Manufacturer's Data Report for heater coil and flash tank.
Vendor shall provide purchaser with two (2) copies of a complete operating and general instruction manual for the vaporizer package.
Priced list of Recommended Spare Parts.
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First Thermal Heaters |
1100 Industrial Blvd. Louisville, KY 40219 Phone: (800)665-4251, (502)962-2883 Fax: (502)969-9028 email: mail@first-thermal.com |