Information & Resources

Please browse through our archive of selected articles, industry news and expert opinions

Resources & Information (41)

One of Thermal Products offering is a line are API Basco Aftercoolers.  Aftercoolers are heat exchangers, in this case shell and tube heat exchangers, for cooling the discharge air from an air compressor. Typically with shell and tube exchangers, we try to design the shell and tube aftercooler to have the plant air go through the tube side of the heat exchanger.  We do this for ease of piping and reduced pressure drop.  We can also mount the shell and tube aftercooler on your skid or wall and run air and water piping to the aftercooler.  Thermal products can design the heat exchanger to still have a minimal pressure drop on your air side.
 
Basco E Shell Mounted on Wall
 
Water cooled aftercoolersare an effective means of removing moisture from compressed air, as we designed in this case.  If you don't have water available, Thermal Products can design an air cooled aftercooler for you to use your ambient air within your plant.
 
Compressed air systems require clean dry air for long term operation, so Aftercoolers reduce the amount of water vapor in a compressed air system by condensing the water vapor into liquid form, by dropping the air temperature below the dewpoint. Aftercoolers combined with a separator and trap are an excellent way to reduce moisture in a compressed air system. A separator with a float and trap allow the separator to further remove moisture using a cyclone effect.  Moisture is removed and gathered at the bottom of the separator where the float will open a trap to allow water out and to drain.
 
Basco Float and Trap                     Basco Separator and Trap
 
An aftercooler is necessary to ensure the proper functionality of pneumatic or air handling devices that are a part of process manufacturing systems. Again, Aftercoolers can use either air-cooled or water-cooled mechanisms.
 
Learn more about aftercoolers and how they work with your compressed air system. If you have questions about how to find an aftercooler to fit your air compressor, call your local Thermal Products office at 518-877-0231 or email us at This email address is being protected from spambots. You need JavaScript enabled to view it.

indeeco sig A red rgb pos

Our partner, Indeeco Electric Heating, now supports CSA listed explosion-proof flange heaters!  The sales team at Thermal Products can design and offer a quotation for your exacting explosion proof immersion heater needs with CSA listing. All products are fully customizable allowing Thermal Products to design a EXP Flange Heater solution to fully optimize your process. 

Some of the product highlights include power rating up to 3 megawatts with watt densities up to 100 watts per square inch.  We can offer a full range of voltages up to 600V.  The Indeeco EXP Flange Heater can be designed with a wide range of materials for our flange and elements with sheath temperatures up to 1,200 degrees Fahrenheit.

Optional Features

Extended terminal box, or ""Stand-off" can be provided when necessary to allow for cooler operation of the terminal box. This allows the heating elements to be sealed with epoxy or RTV and for the customer to provide incoming wire with a much lower insulation temperature rating.

ASME
The heater can be supplied in accordance with ASME section VIII Div. 1 U-Part stamped and certified.

Thermostats
Bulb and capillary pilot duty or load carrying thermostats can be provided to control the heater. The thermostat bulb can be installed in a thermowell to sense process or element sheath temperature.

Thermocouples
Type J or K thermocouples can be provided to monitor the process or element sheath temperatures. Thermocouples provided with a ceramic wafer head and screw terminals for ease of wiring. Alternate type E or T available.

Removable bussing

Allows troubleshooting and isolation of a failed heating element.

Cross-baffle
Construction utilizes alternating half baffles spaced closely to cause increased flow velocity across the heating elements to allow better heat transfer from the elements to the fluid.

Pickle and Passivate

A chemical treatment in nitric acid can be performed to remove free iron from the outer surface of stainless steel for applications sensitive to contaminants.

Electro-polish
Is a process similar to plating using cathode and anode reactions but material is removed rather than added to the heater surfaces in order to provide a clean and bright finish.  This is very common with the pharmaceutical, biotech and food industries.

To learn more, contact your a member of the Thermal Products sales team for details.  Also download the brochure below for more information.

 

At Thermal Products we carry a wide variety of direct replacement parts and complete Heat Exchangers for API Heat Transfer and many other heat exchanger manufacturers like Standard Xchange, Thermal Transfer, American Industrial and others. We carry all API Heat Transfer brands including Basco, Ketema and Schmidt Bretten heat exchangers.

Parts

Whether you need a single pass heads, 2 pass heads or 4 pass heads we can ship to you.

Gaskets, zinc anodes, nut and bolt kits can all be provided by our team at Thermal Products. Contact us today

Models include:

Basco Type 500 Heat Exchanger and Parts
Ketema HT Heat Exchanger and parts
Ketema AHT Heat Exchanger and parts
Basco Type OP Heat Exchanger and parts
SIGMA Plate Exchanger units and parts
Standard Xchange BCF
Standard Xchange HCF
Standard Xchange SSCF
Standard Xchange SSCF
Custom TEMA Desgined heat exchanger parts

Please contact us at This email address is being protected from spambots. You need JavaScript enabled to view it.
or (518) 877-0231 for all your heat transfer needs.

When speaking of Shell & Tube Exchangers, we tend to break them into "standard" and "custom" shell and tube exchangers. When we talk of tolerances of flow nozzles and support locations, those manufacturers that belong to TEMA (Tubular Exchanger Manufacturers Association) are expected to build each heat exchangers to within those accepted tolerance called out in TEMA.

See link below for TEMA Tolerances brochure.

Having published tolerances is most important for both the customer and the manufacturer, especially when speaking of "custom" heat exchangers as they are built to a fabrication drawing, without the use of a manufacturing "jig" or "fixture". Without the use of a jig or fixture, the skilled welder relies on measuring tools, which is fairly precise to the naked eye, but when measured exactly, the dimensions will not exact each time that part is manufactured. Building shell & tube exchangers with nozzle tolerances of +/- ¼” don’t tend to be an issue for process plant or system integrator customer’s as long as it is not more than the noted tolerance. In that instance it would need to be corrected, especially, for a TEMA Shop.

“Standard” heat exchangers tend to be built for OEM customers that rely on exacting dimensions for each delivery of the same shell & tube exchanger. In order to maintain quality assurance of each unit, the use of a jig or fixture to assist the skilled welder is a must. This will ensure each and every part, that is welded together, to make a shell & tube exchanger will have the very same dimension each time it is made. This allows customers to use a Thermal Products heat exchanger, with precision and speed in their product.

Having shell & tube exchanger's built to precise measurements is also import when looking to replace a heat exchanger in kind. In this case a Drop In Replacement tube bundle or complete heat exchanger is easiest for plant maintenance personal, hospital or school facility engineers, to install. It assures them that they will not need to make any required piping modifications on either the tube side or shell side.

Thermal Products offers Drop in Replacement heat exchanger and tube bundles for a wide range of heat exchanger manufactures. In most cases, Thermal Products will have the needed equipment to manufacturer a NEW heat exchanger or tube bundle that will fit right into place of the old heat exchanger you are removing. If we don’t, we will advise you during the quoting phase and include freight, in our proposal, for you to ship your old heat exchanger to us for duplicating.

If your heat exchanger is custom and can’t ship it to our facility for duplicating, but have a fabrication drawing, we can offer and build a NEW heat exchanger to your fabrication drawing. Please see our latest Drop In Replacement heat exchanger shipment below.

BEM Replacement Heat Exchanger

A New England Food company approached Thermal Products, Scott Robinson and our partner Advantage Engineering to assist them in designing a new process cooling system to cool a new low protein food being manufactured and then packaged.

At first review the (3) process cooling loads were deemed to be in the neighborhood of 100 tons total, depending on product batch temperatures. The initial design fell well above the customers budget for this project and forced us to review other avenues.

During the site visit, Thermal Product’s Scott Robinson, noted that the incoming city water temperature was within a temperature range to handle two of the three processes and recommended using the city water to send to the existing Plate and Frame heat exchangers that were isolating the cooling water from the process food, affording Thermal Products and Advantage Engineering to offer a revised proposal to handle 80% less cooling load. This not only reduces the capital costs of the chiller, substantially, but also lowered the operating costs significantly from what was originally thought.

Scott determined the remaining third process, did require 6.5 gpm of 36°F cooling water to be supplied prompting a revised proposal for a 20 Ton Advantage Engineering Air Cooled Chiller Model OACS-20 with a close approach Plate and Frame exchanger, again to isolate a 30% Propylene Glycol and Water mixture from water heading to an existing heat exchanger with process food on the other side. Scott needed to “de-rate” the chiller to the 9.75 ton load thereby needing 20 tons. The industry design standard for chillers has been a base design of 50°F chilled water temperature @ 95°F ambient temperature. When a lower cooling temperature is required, as Scott did in this application, a higher nominal ton capacity is needed to reach 36°F. The final chiller included some of the equipment below.

• Air Cooled Condensed R407c refrigerant circuit
• Scroll compressors with hot gas bypass capacity control
• Crankcase heater for cold start-ups
• Discharge check valve
• Brazed Plate Heat Exchanger as the evaporator
• 3HP process pump
• NEMA 4 Control Cabinet
• Advantage Proprietary MI Microprocessor control instrument
• Plate and Frame Heat Exchanger, shipped loose for installation indoors

Thermal Products was able to further assist our customer’s tight delivery needs by doing a small customization of a stock chiller in order to have the chiller onsite in Massachusetts in 1 week from order.

The next step Scott says is to consider storing the approximately 10,000 gallons of elevated hot discharge water used daily by trimming those BTU’s off in one large insulated poly tank.
“I have a design in the works to recirculate and cool daily water by preventing it from costly one time use then down the drain”.
“Q3 and Q4 is the timeframe to look at this”

Please look for the follow-up article to wrap-up this application! Please contact Scott Robinson or any of the Thermal Products team to discuss your application

Scott has been with Thermal Products for over 7 years, but has more than 30 years’ experience in the HVAC and refrigeration industries, an easy shift to our line of heat transfer and related industrial products. Scott is an ASHRAE member and retains numerous state trade licenses. Scott is responsible for the New England trade areas.

Contact Us Today!

Titanium TEMA Type AET ready for Shipment

Thermal Products was approached by a chemical company to design an Acetic Acid heater using 450 Thermal Oil. Heating Acetic Acid to a precise process temperature is key in the manufacturing insulated boxes.

Thermal Products designed a TEMA Type AET with a titanium tube side, meaning titanium tubes, titanium baffles and bundle supports, titanium tube sheets, titanium channel head, titanium reversing bonnet and titanium tube side connections.

A TEMA Type AET, is designed with a front channel head with channel cover, which enables the tube side of the heat exchanger to be cleaned without breaking or removing any of the piping. See figure "A" below.

tema 

The backend or rear bonnet was designed with a pull through floating head. This design takes into account thermal expansion and the ability to have a straight tube design with a removeable tube bundle. See Figure "T" above.

If you have an application that would require higher alloy materials, contact Thermal Products via phone, email, website inquiry form or chat feature on our website.

Click here to be taken to our contact information page

A local distributor was looking for three replacement tube bundles for Thrush Heat Exchanger Model S1848(2).  Thermal Products offered our exact duplicate tube bundle Model TBU-18-48-2 with .049 wall copper tubes. 

Thermal Products manufacturers drop in repalcement tube bundles for many shell and tube heat exchanger manufacturers, such as Armstrong heat exchangers, Taco heat exchangers, Bell & Gossett heat exchangers, Yula heat exchangers, Patterson Kelly heat exchangers, Basco heat exchangers, ITT heat exchangers, Xylem heat exchangers, Standard Exchange heat exchangers, American Standard heat exchangers and many more.

All Thermal Products replacement tube bundles meet OEM specifications and in many cases, surpass.  Contact us today for your quote!

Above is a before and after picture of an old, tired heat exchanger and a new drop in replacement shell & tube exchanger that Thermal Products Inc designed and supplied as a drop in replacement heat exchanger to replace a modified Taco “E” BEU series heat exchanger. After meeting with the customer, a local state government, Thermal Products was able to offer one of our “Drop In Replacement” Heat Exchangers so piping changes would NOT be necessary. All critical center line dimensions were held.

Thermal Products offered a TPI-BEU-26-84-2, which is a 26” diameter shell, 84” tube length U-tube bundle, 2 pass tube side arrangement for steam to water application. We offered an all carbon steel constructed shell and head with ¾”, .049 wall copper tubes. The heat exchanger was built to ASME Code and stamped for 150 PSIG @ 375F. Higher temperature and pressure available upon request.

Although we supplied standard materials of carbon steel and copper tubing, Thermal Products, can readily supply Stainless steel shells and heads and stainless steel tubing, Cupro-Nickel tubing, admiralty tubing, Hastelloy, Titanium, AL-6XN among more.

If your shell and head or bonnet are in good condition, we can simply offer a replacement tube bundle instead.  Replacing your tube bundle only with one of Thermal Products quality Drop In Replacement Tube bundles would make your project far less difficult and time consuming.  In most cases, a Thermal Products replacement tube bundle comes with a .049 tube wall thickness, when most OEM tube bundles are supplied with .035 wall tubing, making your Thermal Products tube bundle more forgiving to tube side erosion from particulate in your water.  Simply call your local Thermal Products office with your heat exchanger model number or picture of your heat exchanger nameplate and we’ll provide a quote to you, in most cases, the same day.  All Thermal Products tube bundles come with gaskets.

All of our “Drop In Replacement” Heat Exchangers and Tube Bundles can fit identically to any of the heat exchangers made by Taco, Armstrong, Bell & Gossett, Thrush, ITT, Basco, Adamson, American Standard, Yula, Patterson-Kelly and many more, saving your company money and man hours.  Contact us today!

Visit our webpage for more information.

HC Heat Exchanger

The Basco Type 500 and HC Series shell & tube heat exchanger offers the widest variety of options for utilizing water or water/glycol for many cooling applications such as cooling compressor lube oil, cooling compressed air, engine lube oil cooling, blow mold cooling, extruder cooling and CNC cutting oil cooling to name a few. It remains the industry standard in ultimate value and long-term reliability. The proven fixed tubesheet design shell and tube heat exchanger offers the cost effectiveness that comes with having a highly standard design, while easily providing for various options to meet specific application requirements. Multiple material options are available as well. This series includes seventeen models with air flow capacities from 75-1500 SCFM (2.12-42.48 SCMM) or oil flow from 7-105 GPM (27-397 LPM) and heat rejection from 14-281 HP (10.4-209.5 KW).

Applications:
 
Compressor lube oil cooling
Compressed air cooling
Engine lube oil cooling
CNC cutting oil cooling
Blow mold cooling
Extruder cooling
Temperature control cooling
Process fluid cooling
 

Features

Preferred for new oil-water applications
Rugged steel construction
Low cost
NPT, SAE O-Ring, SAE flange, or BSPP shell side connections available
End bonnets removable for servicing
Mounting feet included (may be rotated in 90° increments)

Product Options

Optional material construction on tubes, tubesheets and end bonnets

Customer Focused and Driven

All catalog product is available with short lead-times
Expert application engineers are available to select and size the right product for your application
Custom designs are available

ASME Code Stamped available

Ratings

Maximum Operating Pressure - Shell Side 300 PSI*
Maximum Operating Pressure - Tube Side 150 PSI
Maximum Operating Temperature 300°F

Materials

Tubes - Copper
Tubesheet - Carbon steel
Shell - Carbon steel
Baffles - Carbon steel
End Bonnets - Cast iron
Mounting Brackets - Carbon steel
Gaskets - Nitrile rubber/cellulose fiber
Nameplate - Aluminum foil

Models

Old Model New Model
C-614-1.3-4-F HC-614-1.3-4-F
C-614-3-4-F      HC-614-3-4-F
C-624-1.3-4-F HC-624-1.3-4-F
C-624-3-4-F    HC-624-3-4-F
C-814-1.7-4-F  HC-814-1.7-4-F
C-814-4-4-F HC-814-4-4-F
C-824-1.7-4-F  HC-824-1.7-4-F
C-824-4-4-F  HC-824-4-4-F
C-836-1.7-4-F HC-836-1.7-4-F
C-836-4-4-F   HC-836-4-4-F
C-1014-2-6-F      HC-1014-2-6-F
C-1014-5-6-F   HC-1014-5-6-F
C-1024-2-6-F   HC-1024-2-6-F
C-1024-5-6-F HC-1024-5-6-F
C-1036-2-6-F HC-1036-2-6-F
C-1036-5-6-F HC-1036-5-6-F
C-1224-2.5-6-F   HC-1224-2.5-6-F
C-1224-6-6-F HC-1224-6-6-F
C-1236-2.5-6-F    HC-1236-2.5-6-F
C-1236-6-6-F HC-1236-6-6-F
C-1248-2.5-6-F  HC-1248-2.5-6-F
C-1248-6-6-F HC-1248-6-6-F
C-1260-2.5-6-F   HC-1260-2.5-6-F
C-1260-6-6-F  HC-1260-6-6-F
C-1724-3.5-6-F HC-1724-3.5-6-F
C-1724-8.4-6-F  HC-1724-8.4-6-F
C-1736-3.5-6-F  HC-1736-3.5-6-F
C-1736-8.4-6-F    HC-1736-8.4-6-F
C-1748-3.5-6-F   HC-1748-3.5-6-F
C-1748-8.4-6-F  HC-1748-8.4-6-F
C-1760-3.5-6-F HC-1760-3.5-6-F
C-1760-8.4-6-F   HC-1760-8.4-6-F
C-1772-3.5-6-F   HC-1772-3.5-6-F
C-1772-8.4-6-F    HC-1772-8.4-6-F

Application Spotlight: Batch Process Water Heating

Thermal Products Inc was asked to design a Shell & Tube Heat Exchanger within a certain footprint as it needed to fit within our customer’s packaged heating system. We offered to design and build an all 316 Stainless Steel Shell & Tube Heat Exchanger, but our customer requested 304 Stainless Steel Shell & Tube Heat Exchanger instead. Our customer also requested the tube side connections of our shell & tube heat exchanger to be Tri Clamp connections for ease of cleaning the heat exchanger.

The design parameters for the project were to heat 300 gallons of process water from 60 degrees Celsius to 80 degrees Celsius in 15 minutes or less. Our customer’s control package needed to maintain tight temperature control with a +/- .5 degrees Celsius discharge temperature variance for their exacting process downstream. The circulating process water flow rate for each batch will be 120 gallons per minute (GPM)

The 304 Stainless Steel Shell & Tube Heat Exchanger was designed to be a 08024, Type BEU with 304 stainless steel tubes and a 2-pass tube side design. The thermal duty was achieved using 387 lb/hr of steam and was built to ASME Code Section 8, division 1 and TEMA C.

Thermal Products sales and design engineers can design a fully customized heat exchanger to your exacting specifications or an "off the shelf" design for quick shipment and installation.  Thermal Products can supply the heat exchanger alone or integrate it into a skidded package with controls, valves and pump(s) on a skid enabling a more "plug and play" design, significantly reducing our customers installation costs.

Contact us today to discuss your application!

Page 1 of 3

Contact Us

Fields marked with * are required