Information & Resources

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

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

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

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!

Thermal Products was approached by a regional Paper Mill to design a Semi Instantaneous Process Water Heater utilizing excess steam to trim heat process water for a new product line which required a slightly higher water temperature than what existed already.

Thermal Products designed a skid package that included the following equipment:

  • Skid Assembly  
  • U-Tube Heat Exchanger ASME Code Stamped, Model TPI-06-048-2P to heat 62 GPM water from 35.5F to 68F using 50 psi steam 
  • 3" Steam Valve
  • 1-1/2" Steam Trap
  • 3" 150# Y-Strainer
  • Check Valve
  • 150# Class Butterfly Valves
  • High Temperature Limit Aquastat
  • Temperature Relief Valve
  • Temperature Controller from Johnson Controls
  • Spool pieces and piping
  • Painted

Skid package was then painted to custoemr specifications with a 2 part epoxy

Thermal Products can also offer the following equipment for a skid package to fit your specific application.

  • Pump
  • Shell & Tube Exchanger
  • Plate & Frame Exchanger
  • Electric Circulation Heater
  • Air Cooled Exchanger
  • Isolation Valves
  • Controls package
  • Control Panel
  • Various Materials of Construction

The use of a low finned tube within a shell and tube exchanger is an excellent solution for increasing efficiencies in the cooling or heating of gases and liquids.  When space on your lube oil console or fuel conditioning skid is at a premium, see how Thermal Products can offer a smaller shell and tube exchanger design, using low finned tubes reducing the heat exchanger overall footprint and offering considerable potential to save in terms of materials and heat exchanger fill volumes.

The wide range of dimensions offered by Thermal Products Inc makes these products perfect for a broad scope of applications for oil/gas coolers in consoles, machinery and plant processes.

Low finned tubes increase that outside surface area. By having a finned tube in place, it increases the overall heat transfer rate. This then decreases the total number of tubes required for a given application which then also reduces overall equipment size and can in the long-run decrease the cost of the project.  

Applications Thermal Products has designed low finned tubes within our shell and tube exchangers.

  • Power Generation
  • Oil and Gas Productions
  • LNG NGL LPG Plants
  • Refining
  • Petrochemical and Chemical Processing

Benefits of Low Finned Tubes:

  • Offers 2.5-3 times the external surface area of bare tube
  • Enhanced heat exchanger efficiency means less tube is required to accomplish the same heat transfer as a bare tube
  • Low finned tube can increase the performance of an existing exchanger without the difficult and expensive task of building new shells etc
  • Reduced space and weight can be extremely valuable in offshore production or high elevation distillation columns. Low finned technology can transform large shell and tube exchangers into compact heat exchangers

Contact our team today to discuss your application!

Thermal Products was asked to replace “In Kind” an older all 316L stainless steel Type BEM with vertical installation at a local food additives company. The existing unit was an 26” x 120” BEMV 316L/304L with 16 passes on the tube side.

Thermal Products was asked to provide an updated performance data sheet, ASME Code Calculations and engineering drawing. When the ASME Code Calculations were completed it was realized that the ASME Code requirements now required an expansion joint to be employed on the shell side. Because this was a “Drop in Replacement” project, meaning all pertinent dimensions needed to be held from the existing to the new installation, the addition of an expansion joint created a small challenge for us to maintain the critical dimensions. The Thermal Products team was not only able to incorporate the expansion joint while meeting ASME code requirements but also our customer need to maintain thermal performance and dimensional requirements.

The construction of the sanitary heat exchanger was as follows:

• 316L stainless steel tubes, tube sheets and heads
• 304L stainless steel balance
• Product surfaces were polished to 32u-inch Ra finish
• Exterior was polished to 40 Ra finish
• Tri-clamp product connection
• Hinged head cover for easy access to tube side for cleaning
• Garlock Gylon 3522 gaskets for food use
• Support legs for vertical installation
• Insulation jacket for outer shell
• Designed to TEMA C guidelines
• ASME Code Stamped

Thermal Products was also asked to provide the equipment dossier that included the following documents:

• Final Arrangement Drawing
• Design specification sheet
• ASME Code data report
• Weld Procedures (WPS, PQR, and WPQ)
• Weld log
• Welder qualification records
• Q350 R4 Visual Weld inspection
• Passivation certification
• Surface finish certification
• ElectroPolish certification
• Material Test Reports (MTR’s)
• Gasket certificate
• Insulation safety data sheet
• Hydro Test Certification
• ASME Code Calculations
• Unit ID plate

Whether your application is new or replacement, the Thermal Products team stands ready to assist you with your heat exchanger design from start to finish.

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Please contact us today to discuss your project!

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