1

10"

9 1/2"

7/8"

11 1/2"5 3/4"

2 3/4"

7 7/8"

CL

EDGE

EDG

E

40 3/4"

EDGE

EDG

E

10 1/4"

4" 4"

4"

1/4"

5/8" X 5/8" X 1 3/4"LONG SA36 C.S. SQUARE BAR

CONTROTRACE BUTTWELD DETAIL

UNIJACKET

FRONT VIEW

20 1/2"

3 7/8" R.

8"

2 1/2"

13 3/4"

13 1/2"

14"

SIDE VIEW

19"

12 1/2"

11 1/8"

3/4" SA105 150#RFSO FLANGE

3/4" SCH 40 X 6"LONG SA106 GR B PIPE

5/8" X 5/8" X 1 3/4"LONG SA36 C.S. SQUARE BARCONTROTRACE ELEMENT

TYPICAL CPLG. ATTACHMENTAND END CLOSURE DETAIL

MIN.5/16"

3/16"

PANEL 1A CL

TOP VIEW

6"

18 1/2"

3 7/8" R.

2 1/2"2

PART LINE

CSI Bolt-OnHeating Systems

Piping • Valves • Pumps • Meters • Instruments • Tanks • Vessels

CSI Bulletin CTCH -1

The CSI Bolt-On Heating System

I ntegrally jacketed piping systems and components have long been the preferred method used with processes that require

elevated temperatures for efficient in-planttransfer of prod-ucts such as sulfur,bitumens, phthalicanhydride, DMTand polymers.Pumpability, prod-uct quality, flowproperties and reliable equipmentoperation for manyof these processesdepend on viscosity rangescontrolled by temperature.

Integral jacketing offer theadvantages of unitconstruction, highrates of heattransfer from theheating medium tothe process, andthe ability to maintain process-ing temperatures within close tolerances.

The disadvantages of integrally jacketed systems are the limited selections available forjacketed components, relatively long deliveriesfor these components, and inconsistencies ofquality of the jacketed components due to thelack of industry-wide fabrication standards.

The CSI Bolt-On Heating System is comprised of products that respond positively

to the disadvantages cited for integral jacketing.The bolt-on system provides thermal perfor-mance necessary to meet narrow-envelopeprocessing. The product heating options are

versatile, rang-ing from the primary functionof temperaturemaintenance tomore thermallycomplex applications ofheat-up and melt-out, and,infrequently,heat exchangerduty of processheating or cooling.

The CSIBolt-On HeatingSystem consistsof two basicproduct groupswhich arediscussed inmore detail onsubsequent pages:

• ControHeat Bolt-On Jackets for valves,pumps, meters and other components.

• ControTrace Heating Elements for pip-ing, tanks and vessels.

This brochure outlines the products and services offered by CSI to help designers andengineers optimize performance and value forspecific bolt-on heating systems.

Benefits of the CSI Bolt-On Heating System

No Cross-Contamination. Defects in castings or cracks incore piping cause cross-contamination. The double-walldesign of the bolt-on heating system eliminates the possibility

of cross-contamination. The heating fluid can’t reach theprocess, and the process can’t flood the heating system.

Economical Temperature Control. Depending on the thermal requirements of the process, the CSI Bolt-On Heating System can offersignificant cost savings compared to a fully jacketed processing sys-tem. In general, the cost of the clamp-on system increases asthe required temperature of the process approaches thetemperature of the heating fluid. When the design temperature envelope is very narrow, say 2-4°F, designersmust carefully analyze potential chill spots to determine theoptimum heat coverage.

Low Maintenance Costs. Practically any piece of equipmentor process component can be economically heated with a bolt-on jacket. Because standard line-size components can be used throughout the system, the replacement of individual components like a valve can be made without concerns

for long lead times and “crises” expediting.

There are several benefits that accompany the CSI Bolt-On Heating System. The major ones are:

Component Selection Versatility.Because components of the systemmost often are line-size components,project engineers can select from avery broad range of standard products. The basecomponent, of

course, must be able to operate at elevateddesign temperatures. More than 3500

typical processing components arerepresented in the ControHeat

Jacket pattern inventory. Several newpatterns are added to this inventory

each week.

Process

Heating Fluid

1

Here’s How TheControHeat Jacket Works:

ControHeat Jackets Cover Valves

1. Pressurized heating fluid enters thepressure chamber embedded in thealuminum casting.The pressure cham-ber may be either carbon steel or stain-less steel.

2. The pressure chamber is designed,manufactured and tested in accor-dance with the ASME Boiler andPressure Vessel Code, Sec. VIII, Div.1.

3. The aluminum casting, which never contacts the pressurized heating fluid,rapidly transfers heat from the pressure chamber to the external surface of the valve.

4. Normally, heat transfer cement is usedwith the jacket to minimize any air gapbetween the casting and the valvebody. The cement promotes efficientheat transfer.

2

CSI makes ControHeat Bolt-On Jackets for virtually any valve. Generally, there are twotypes of jacket construction offered: One-

piece jackets, called UniJackets, for valvessizes 3-inch and smaller; and two-piecejackets for valves sizes 4-inch and larger.Very large valves like 20-inch gate valvesmay utilize more than two pieces toaccommodate ease of installation.

1

2

3

Typical Two-PieceControHeat Valve Jacket

4

Control valves withintegral jackets oftenrequire very long lead times fordeliveries. Sometimes the long delivery times force instrument engineers to sacrifice performance for availability. ControHeat Jackets allow you to selectthe optimum valve for the process without concernfor the jacket.

This UniJacket on an off-the-shelf sampling valve keeps the valve plug-free, ready to operate at all times.

Three-way ball valves are easily heated withControHeat Jackets. Various styles of actuator brackets can be accommodated.

Designed for hot-oilvapor service, thistwo-pieceControHeat jacketwith flanged connections andextended coverage formating flanges is used in650°F service on a 20-inch ball valve in a polymer reactor operation.

UniJacket installed onball valve. CSI insulatedflexible jumpovers connectthe jacket to ControTraceElements heating adjacent piping.

Any ControHeat Valve Jacket can be designed toheat mating pipe flanges as shown on these plugvalve jackets used in BPA service.

3

ControHeat Jackets for Pumps

ControHeat Bolt-On Jackets are widely usedthroughout the processing industry to improvepump efficiencies, prevent motorburnout and promote uniform process-ing temperatures. Somecritical metering pumpapplications require jack-eting to assure accuratethroughput. Certain gearpump applications requirejacketing to minimizedegradation of polymersand other products that areshear sensitive. The barrels of progressive cavity pumps may need to be

heated for foodstuffs such as chocolate,syrups and dairy products. In some batch-type

operations, pumpjacketing may beneeded during

start-up only. Inpumping applications

like sulfur, phthalicanhydride, or DMT, not

only does the pump cas-ing need to be heated at all

times, the backplate also may needheating. When pump manufacturers do not

offer jacketed backplates, CSI offers both fabricated bolt-on heating jackets as well as ControHeat Jackets.

Two MeteringDiaphragm Pumpswith ControHeatJackets. The jacketscover fourpump headsas well as checkvalve assemblies.

High-PressurePiston Pump with 3-phase electricControHeat Jacket.

Progressive Cavity Pump for use in CIP service forfoodstuffs.

4

Gear Pump with Mag Driveand External Relief Valve totally jacketed for hot-oil application. ControHeatJacket on mag drive used for heating.

Condensables in gas streams can collect andchoke the flow in flame arrestor passages.ControHeat Jackets keep the passages clear.

ControHeat Jackets for Meters & Instruments

Accurate process dataand process perfor-mance often dependon instruments, metersand safety devices operat-ing at elevated processtemperatures. CSI makes jack-ets for many types of meters,instruments and related equipment:DP cells, vortex shedding meters,rupture discs, coriolis flow meters,viscometers, tank vents, level indicators

and chemical tees. Few of these componentsare available with integral jackets. The

ControHeat Jacket has a history ofsuccessful service with these

components. In fact, severalmanufacturers of these

products have standardized on the

ControHeat Jacketto complementtheir product lines.

Coriolis Meter used in high tem-perature service of pre-polymerprocess. Jacket is hot-oil heatedand maintains meter at 600° F.

Liquid LevelIndicator used in palm oil storage application. Jacket completely covers all process-wetted surfaces.

Pulsation Dampeners with ControHeat Jackets in high-temperature applications providecritical service for downstreaminstruments and meters. The jacketkeeps the stagnent process fluidunder the dampener’s gas pad

ControHeat Jacket on a Brookfield Viscometer increases the instrument’s operating range and longevi-ty, as well as improving accuracy of data collected.

5

molten.

ControTrace Elements Heat Pipe

ControTrace Heating Elements have performedvery well in diverse applications from chocolateto polyester resin. Numerous plants havedrastically curtailed their use of jacketedpipe, preferring to use ControTrace onprocess piping for DMT, rosins,sulfur, cyanuric chloride, acrylicacid, hot melts and numerousbottoms recirculating lines.Some of these plants fabricatethe elements in the field. Othersdepend on CSI for the completeservice of design, fabrication andinstallation of the bolt-on heatingsystem.

ControTrace Elements areformed from carbon steel, SA178Gr. A boiler tubing. The elementsare pressure rated in accordancewith the ASME Boiler andPressure Vessel Code, Section VIII, Div.1.

The most popular size of ControTrace is a 1”x 2” rectangular

shape with the pipe-side surface formed to

match the outside diame-ter of the pipe on which it

will be placed. Normally, anon-drying heat-transfercement is used to promoteheat transfer between the

element and the pipe wall.For nominal pipe sizes of 11/2”

and less, a smaller size ofControTrace(3/4”x11/2”) is avail-able. Other elementsizes may beordered on a

custom basis. Stainless steelControTrace is also offered for very

aggressive environments.

3. CSI provides individual components that own-ers use to fabricate on site their own bolt-on heating systems.

2. Based on isometric drawings provided by the customer, CSI spools the elementsand, with the customer’s approval, fabricates finished ControTrace pieces, tests them, and shipsthem to the field, ready for installation on the pipe by others.

1. CSI can turnkey the complete heated piping system. CSI provides the front-end engineering and drawings, fabricates the pipe and ControTrace (securing the ControTrace onthe pipe), and installs the system in your plant. Another frequently used option is production byCSI of both the piping and ControTrace Elements, installing the elements on the pipe, insulating thefinished assemblies, and shipping the system to the field for installation by others. We have the flexibility, of course, to provideonly specified portions of the project.

Custom Fabrication Options: Customers may opt for one of three methods to use when installing a heated piping system thatutilizes ControTrace Elements.

Process Piping

ControTraceHeating Element

Heating Medium

Process

HeatTransferCement

6

ControTrace coverage of elbows,even in smaller pipe diameters,as shown here, can be accom-plished on both the throat andthe heel. Side coverage of elbowsalso is frequently used.

ControTrace Elements can befabricated to uniformly heatcomplex piping shapes likethe cross, reducer and lateral shown here.

ControTrace is used successfully on piping in refineries, terminals, barges and acid plants.Combined with ControHeat jackets, as on the balljoints in this application, uniform heat can be provided to the the entire system very economically.

The design of the ControTrace coverage on a particularpiping run depends on the process thermal require-ments, pipe schedules, and the type and thickness ofinsulation used. In this application CSI designers deter-mined that heating elements placed normal to theprocess flow would provide the most uniform coverage.

In the application depicted in the accompanyingphoto, ControTrace Elements proved to be a costsaving alternative to all-stainless steel jacketedpipe. With no external pressure, core piping wasselected based on internal process requirements.This allowed a thinner pipe wall and saved money.

7

ControTrace Heating Elements for Tanks & Vessels

Storage tanks and vesselsup to 25 feet in diameter arein service with ControTrace elements providing uniformheat over their entire surfaces.

The ControTrace Elementconfiguration can bedesigned for liquid or vaporheating media. A key benefitof ControTrace is that elements can be dispersedevenly around the vessel,assuring the uniform heatcoverage. Jackets can be

fabricated for conic headsas well as elliptical heads.Generally, systems that utilize a liquid heating medium are designed in a serpentine configuration.Systems that use a vaporheating medium are usuallyconstructed for parallelmedium flow. When parallelflow must be used on a liquid system, flow diverterscan be placed inside theControTrace assemblies tochannel the liquid.

ControTrace Elements wereutilized in this phthalic anhydride storage facilitybecause the product could provide economical, uniform temperature maintenance in critical service.

CSI has developed special fabrication techniques to achieve uniform heat coverage of vessel heads,allowing for varioussizes of nozzle penetrations.

When liquid heatingmedia are used, jacketelements are fabricated in a serpentine design toprovide even heat distribution. Wherenon-condensablesmay cause vaporlocks, bleed vents areadded at strategicjacket locations.

Conical vessel bottom withControTrace.

8

Engineering Support for Bolt-On Heating Systems

A major segment of CSI’s totalbusiness is the design and fabri-cation of jacketed pipingsystems. The continu-ing evolution of CSIBolt-On HeatingSystems is linkeddirectly to theknowledge andexperience we gainin jacketed piping,because the same

engineers and designers who managejacketed piping projects also design and

manage projects for bolt-onheating systems. The

singular focus of thiscumulative experi-

ence, from initialquotations through

process start-up, is asatisfied customerthat likes doing business with CSI.

1. To assist customers in determining the right amount of bolt-on heatcoverage, CSI has developed a computer program that allows inputs ofup to five process variables. These variables are type and thickness ofinsulation, process temperature, heating medium temperature, ambientdesign temperature, and nominal pipe or tank sizes. Several values maybe selected for each variable. The data produced from these variables isused to determine the optimum system. Results of the program telldesigners the number of ControTrace Elements to be used, the energyloss per hour per foot of pipe and the consumption of heating fluid usedper hour per foot of pipe.

2. The second computer program, more sophisticated than the first, usesfinite difference modeling to profile the crossectional thermal performanceof the bolt-on heating system. The results yield a detailed temperatureprofile of the piping system at equilibrium, the heat lost to the atmospherethrough the insulation, and the net heat input to the process. This pro-gram considers the thermal conductivities of the system components aswell as film coefficients of both the process and the heating fluid.

Two Computer Tools

Hot Melt reactorwith ControTraceelements on vessel andControHeatJackets on valves, pumps and instruments.

CSI-designedBolt-on HeatingSystem installed inSulfur RecoveryUnit of a large gasplant. Run-downand distributionpiping utilizeControTrace Elements. Fittingsare heated withControHeatJackets.

END VIEW

9 1/4" 9 1/4"

3 3/8"

15"

2 5/8" R

JACKETPART

TOP VIEW

3 5/8"

2 5/16" R.

4"

10 1/4"4"

EDGE

EDG

E 68" EDG

E

18 3/4

6 9/16 7 1/4

R2 1/8R3 3/4

13 1/8

11

6 1/8

38"

57 1/4"

15 3/4" 12 7/8" 12 7/8" 15 3/4"

12 1/8"

13"

12 1/2"

2 3/8

1/2 6 1/16 11 11/16 1/2

5/8

1 1/8

5/8

1 3/4

1

3 1/84 3/4

7 1/4

2 5/16

5/16" DIA. HOLES THRUTYP (4) PLACES

3/4"-3000# TH'D FULL CPLG'S(2) TWO EA. PER HALF

For additional information and quotations, please write or call:

Controls Southeast, Inc,P.O. Box 7500 Charlotte, NC 28241Phone: (704) 588-3030 Fax: (704) 588-3039web: www.csiheat.come-mail: sales@csiheat.com

Polymer additiveskid with 450°Fbolt-onheatingsystem.

ControTrace elements on this rail car solved a critical maintenance problem for a major producer ofcaprolactam.

CSI Headquarters, Charlotte, North Carolina

15M498R1