| How to Design Tank Heating Coils . Now you can take the “art” out of tank heating coil + Dovid Stuhtbarg Tha Procter and Gorble Conpeny, Cinsonat DESIGN OF TANK HEATING COILS has remaized moro les an “art.” Here are fruls, backed up with / experimental data, for calulating heat ln, col are | nd dcanion of factors which affece call layout and incon. Tank col design falls naturally into two part: thermal and pha The forme, in tur, sbbdvies into deer- brining the proper dei bau, calling the eat load | nthe col, and finally, computing the clara, Physical’ design includes. selecting ae, computing length, deciding on type of coll and location fa the tak, jad ten making the detailed layout DESIGN BASIS Process requirements and properties of the stock dex termine in ange par the telecon of te proper din ‘Suatioos Ital be known wither the etl expected te recat a cole tank or merely matsin the hot tk temperstare, If the rock. does con, wil se pavlally solify or “makeup,” and if so, wil i form a fe inslating layer on the top, bostom and sides? Selection ofthe deem ese can sualy be made from one of the felling’ 1 Steady sate—icena oils ‘3. Stocs cool remain fig 18. Stocks conl—form selfiultion 5. Stocks col —soidetle 16. Stocs coor ested with xtrsal eis ) Bach of thse requics its own mathematical treatment, at all ae based om suming the ambient temperature (Ty) constant nd sing the average thermal properte ofthe soc, PLQURE | spe oie ave fr Cue IV wien the April, 1989—Persouruse Rerivex design by using these experience-proved data Case I_Steady State—intornal Cells. This case i ‘elatively simple tho loud on the coll is the same asthe heat los by radiation and convection. Te only neceuary fo take info account the fact tha diferent ouficens smay apply tothe top, Botom and sides. For tank on les, S=UATWASUAN THT) (1) Equation (1) an be simplified in form by using the Veale area” concept Let wa Bat Beata, @ ‘Then Equation (1) becomes ATT) o For an isothermal heating medism, the esl area ie Asterina by = TT tte Pe o Fora nonsethemmal heating medium, (Ty—T) would bereplaced bythe log mean temperature dflerence Steady tte requires les ceil than any of the other cases, therefore, i wie fo make doubly sre that some ther condidon mach ar = werkepd shutdown, storage ‘vithout beat over a holiday, or even an emergency shut "own, door not mote validly wet the deren bas, ‘Equation (8) applica a to dat betom tanks, and %9 odd configurations sich as tanks extending through the Wall of buildings, ete, but the equivalent area srl not be de same fortes cue, MeAdaus gives the hes lee ‘ma thin i bid ne ground as g=(—T) Whore R= py If the eas from a a bottom tank “iuing on de ground is assumed tobe one-half thi value (since only onesie touching the ground), he eat less FIGURE 2—Stow spel tent lve fer sch forming si MsHow to Design Tank Heating Coils fom the tank woud be WA TUA) (TT) +ODL)TATY (9) exuscting Us and (T—Ty) a above, she equivalent + ECR) © ae OT eee esate or eer i ice ie eee eee ede eID 0 Where Au and Ave are the equivalent area for the evo portion of the tank and "Py and U' ele o Au ‘The equivalent area concept wil considerabir imply ‘he more complicated case which follow N case steady Stato—txternal Cols. The prob Tem is tore complicated fexteral cole are rue ‘These cols are usualy atached vo either the des or the bot (or Both) and then covered with iaslaton. To ‘design them hemally, it convenient to assame hat {he heat flow is fr he ell to the dead sir space be- neath the inulaton, In order to replace ration Ios from she tank surfaces which ae not protected by the coil (for exutple, the top, when the eat & on the Sex Sd botom), the dead airspace must be at a higher femperatare than the tank, and he heat balance AIUD WHAT) — & apples. The beat load on the eal i A) TT) WY + AY (Fy Tu) = aay salar hater 0) where Ty is the average temperature of the hebtng! aim, 5 Tn designing external coil, as much ofthe tank surface ‘as pose shou be tren. "This wil keep the tempers {re ofthe dead airspace ata minim, which in tum Wil minnie both the toa eat loss and the coll area ‘This uaement can be. proven mathematically, From Equasion (2) Ax Seow ‘The cover the rato “© ig to ro, the closer the tem perature of the dead ait space, Tis to the tank tempera: fare, T the greatr (Ty) wil be and, therfore, ‘he amar the cal area, Ay wll be aso li—Unsteady State—siocks Remain Liquid. Frequent tanks are permit to cool before beat ib Applied. To design colt for auch tanks, ef neesay to ‘tein the heat which has bem lost in enaling. IE ee ‘contents remain ligula, he poblen isnot difieul Kern by jacket or intemal soi If we aenume hi equations spply eaualy well to nomagitned tals, we lave for caine: y Bot. ay from which‘, can be caeulated, ‘The tral eat lost in cling ie detrnined fees Q=M, (7) «2 {An allowance should be made for radiation and con- weston loner during elheating. If the average houely Jom dusing reheating asumed the same as duving cooling the required col area is etrmined by: (Ge)(etnonieme) ‘A more rigorous equation i derived Ifthe above as sumption i not made, The folowing difterental equation ‘etre, Yasin res. ys ar am | sx] am | sm | am | oo | oi | ose “Morse Sure, Fang Dower ys vs a0 | am | em | am | soo ae |e = RASS AT SE TSN are pa are mp nm a rm Pevsocus Rerisen—Vol, 38, No, 4oe T auA NWA TY fsuing and raging TAT AUAT) —(UAF AIT MG, UATE UAT) ASE ULAD as “The writer has fund tht Bouton (18) 8 suficently acurte for poral design work Equation (14) Bs ciety ‘jade intrest wi ie peacpal we the evaluation fhe arr inher: in Equation (13). I-A—txtended Storage—Stocks Remain Ii th cokng tne fr Cave I # gute ene rl were or Unger ak woul be very le ‘bove te unbint temperate. For gene, he ale | Seria Equa (1) fortdaon ie ring reheating | Ndoguue andthe we of Equton (15) ic eam ended Bquason (1) cul be aoe bt abou bo / Slepate 2 amume Ty=', and alow for relation | atone ks af a seage ank emperate, Ths ne[f read Case V—Unsteady Stare—stocks Form Self. Insulation. Ame’ ore complicated situation eit if socks partly solidify during cooling, The actal heat tes wil depend heavily upon the behavior af the made-up tr waliifed sock, Tf it sinks (0 the bottom, the loss ‘ould be gester than Groen Buide which do ot make-up Since the temperative diference i eld high If forme 2 layer on he top, Dot, and ids, this serves as “sel insltion” which reduces begat heat lam and Leepe ‘he stock in the enter fn igid form. "This ater ean snalyond mathe in Append 1. For the asumprions made, we Rnd that nant 09 Where Ty is the temperature at which slide fs tart to Beal gern (PTI Jn Ty, ‘These equatins simplify down to manageable propor: April, 1990 —Pernouscw Rertwes tions once the consints ae inserted, Tt ie ascouary ‘hough to fllow the snmpone made in the dvvaton, ‘wile sean tse constant forall tm except Q, Ty Sad Oc The way to we the equation 1. Seve for Ty 2-Touere Ty and mum constants for all tems ex ‘cape, Ty and Oy im Equations (18) aad (14). 3 Amume vere f values for Ty (greter than Ta), ‘and sole for Q and 0, Grapt Ty vs 0, and vs (8. (ee Figures 1 and 2) 4. Determine Ty and Som the graph 5.Goreet @ sod 0, for the iference between the Inisl tank temperature, T and Ty as ealcusted from Equation (16) a follows SUT, > T, add MC, (P—T,) © BIETY < Th, fad 0, for To='y on the graph ease 8y (corrected) from thi point onward. (eorcied) i the diference berween for ToT ad T= Ty 16 Tie low to T,, thee omens would be mall and can be safely omit. 6. Find A, fren Equation (13). ase V—Stocks Cool—Solids Settle. Thi case is tomevhas exter to hand, I he cooling hae propre fly to the point where some, but nt all. of the rock fa fed the hea I would cont of wo pars Qo, the senuble feat of te bg andy te att eat of fusion of the sled portion, Ths +0, ao (2) en ay SUA TT ay Qz cannot exceed MA Tf cooling buyond this pont cccurs, vl be asa sl If we again anime the average heat los dung re heating is the same as during cooing the coil are sppeoninated by ae (ees) ase en Case Vi—Stocks Cool—Reheated with External Cells, Tis ease can be Handled by an excension of Ca TE Q is determined by Case 1, IV o V, then the erm oy i added to the righthand side of Equation (8) Thaw Ms _How to Design Tank Heating Coils . a 7 We mn this heat balance, Ts and T are actually both variable with ime; bt it ould be adequate to we an average ale for T and then solve for'Te. Equation (9) en odie a= AT 2) UI FAT—T) WFLA C8) sod A; maybe found fom Equation (10). SAFETY FACTORS “The safety facton to be used in Equations (4), (10), (13) and (15 wil be langely matter of judgment, but {he comtrativenes af te design bas shouldbe cone fiderd. For example if Q is found by Cave TILA, i ‘alu would be eonered comervativ.Likewis, fess tre ave on fll tanks In extreme weather, which Sa Cindi which woud are extwely aldom, a large Safer; factor is unnecesay. However, the astumptions ‘ade is deriving Equations (17) and (18) are amert, {ll Herat, hence a ater factor shoul be applied ‘Also to be considered fe whether the preset reheat time, 24 does not already include fair safety factor. ‘corrncients ‘Method fr computing or detain coins for us inthe foresoing equations ae aly ell covered in ‘he Beruce For heat teananion ftom surfaces and {rough insulation, the ter har found Carve ® and Table I taken Som publied bulletin! quite wel "For catural convection at veal planes McAdams commends the equation [beset Ga) en ee ie nee tern 3 eof ed Saitama bcbeaas ofa to the dimen 1 agiatl nk, the value of would be suiclenly high so that he resisance hy would be nealgible; bow ter for desiga Case TH through VI, the altcoe would Somallybe turned of dving werlvend or abut Sn Pefied, hence Bawation (27) or (27) would apply “The overall beat los couiant, Uy, for the de of tans would be where based on Curve II for outdoors or taken hom Table for indoors Normal, the vsstance of the nk wal fy nelle, Fors bare tan of course, the ‘erm Tf ops out Tor stank on eg the bottom coin, Uy, may be taken conservatively the sae a Us Tora fat btm tank tng om the ground, thew of equivalent atea Tound fren Equation (6) i recom ended “The top coeficint, Uy is affected by the resiane of the conned air pace, bene ve[btbabates] wo soit pabcton Pace eats Oe a hse 1 a ns cere Pfam ae fe cece ae ae ee ya serena an srr oo]! eat tramfer to and frm the confined se space at exeral en canbe safely Based op vale ken rom Tabi 1. Thus a8 aefrbtnte]? on ‘TABLE 2—Coofhcionts Ca ee Secu Pernoueca Rernven—Tol, 38, Wo. 4Soe eS Siconona eel 4 | RED Tint aint en we | oP | SkYRtS mocmewsc| | gp | es, Sic | P| ae rooeeracmeimies| et | 4 | BRERA Where opiate Coil cooiient for atural convection can be most conveniently found from a nomogtaph prepared by CChiton, Cobuee, Generac and Vernon" which b based on de equation ‘This nomogeaph tae been rpublsbed in a number of sslerneer ickiding Mehdarte and. Ker? MeAdamt eonmmends, for ingle horizontal ylinder, values 10 ferent Mker than thow found by the nomogaph ot EEqeation (59). For banks of tubes, Kern wemaends ‘ub of these vases without cretion. A modified veron ofthe nomegraph whic includes the MeAdams eoree: Ton is published in Pemy' Handbook For natural convection a vertical bes, the coeficent ‘maybe talon th soe az a vertical plaee a etrnined by Equations (27) of (27). For ani agitated with top eteing tubines and wing ‘vertical tube stalls, Dunlap and Raton found tha YOY" (2) 1s the value for at enter oF ie, at ap (3) For helical eis in a bled tank agitated by a top catering agitator, Oldie and Greson® found that ey)" @™ ene eee April, 999—Peroveuxe Rersses sod a more pros equation developed, itis sugested fat the Oldshue and Greton equation fe wed fer cols ‘p tonis with se entering agitators wih cortecton Seto of 080, For low values of hy the overall coil coefficient will ‘be ale diferent from hy and may often be assured the seme, or te general oe = [mbm try be 0) wher yi the tubes concent refered tn the outide, SIMPLIFIED PROCEDURES. ‘To expedite daiga wor, fis pouibleto calculate heat tou conicents for common i and telctod weather atone te up i a table, end se them for many Widely diferent condidens. Some loss of accuracy. wil one bit if ease i taken in the aplication, of ate ‘eto are mad foe deviations foc te design constants ‘eed in etn up the table, he ero shouldbe nel Slay, coll coefficients canbe. predetrined for the same Bue for a tandardaed coil ae and tected dhealng media and set in table form for reference, Using the heat ler cowficent, siplifed equations for the fgulvalent area for commen tankydesgns can alo be ‘Sereoped im sdeance, and these, oo, wl ply eae ciltons “This technique i ustrated by Tables 2 and 8 which Ihave Been setup fortwo fis, water and edible oil in ‘erdcal elindseal tanks for the “stndardnl”™” cond tons given in the last column of Table 2. ‘Sina tables can be st for other Buds ote ean ‘be saved by moving the coefficients even in Table 2 {Bother Suis or cndidons, For example, fora il with 2 flim ysosty of 3 ep, oe) odor nt = (am Simiaty, fora conductivity of 0.08 inated of 0.9, c Similar correction canbe aplid for temperature dle ferene, thermal expansion, et Tt shouldbe ted, bow fey that ST ip Equations (23) and. (2ta) i the ‘ieyence across the film only and not (T—Ta) ‘Another shortcut iso assume the area of shallow cone oc dite head go be 20 pecene greater than & Sat bead Sih the sme diner, A lord) 120 (#70) Bs on WwHow to Design Tank Heating Coils... ‘A horizontal ln! tnk can be handed by reatng ane in contact withthe a as Ay coeicent-“Uy) and All aren above the liquid level at Ay (oofiient — Ur) PHYSICAL DESIGN ‘Once the amount of coil ned has been deermined, the othe factor fleting call desge, nach a8 an ne to, and configuration mote be ceed. Mater ele. tion for corrosion venstance alo isporant, but boutide the scope of this article ‘Cow considerations usually determine the sie pipe ud. Ifthe calls are shop fabricated, Dineh sad yee lnch are reportedly the most economia si, with Lite dlifence ip pace when compared on a niin sqeare foot bass; butt th cos are Bold fabezaed, the weet has reched reports whieh favor either Zineh oe 16+ ich. Asa rel and sine the designer rarely knows in sdvance whether 2 elt be flor hop fabricated, andariang deigos at 2” ie recommended uals som ther factor modifies the choice. For example water the heating medium, i may be necenary to sauce the sie in order to secute 8 atfactry waterside heat tracer cof Plate coils ac fed tube can heaters are umd at tines in feu of bare pipe and have some advantage Plate coils are esy 10 clean, and faned. tbe beaters cfr considerable best tcifer area. in 2 compact bundle that ean be Brough int a tank though 220 tach ante “Tank sition heaters are alto sed oceainaly ine stead of coll, Their function i somewhat diferent TABLE 4—Test Dota: Efect f Col Height On Coofctent at ny et lhe eam ing pumped i a 00 aa ee Pana Slay vey oor bps ila el Sone Fy Shara Naame me Lage at naples fed Sone hay alent heya aed Sr teas tnd ed's eal fifncemeeranus The rama af ton be ae they ec tal otra ace Ctl ee no ae ee ee i ea SE Tamaya ch haope he eae, eae eee eet any eae oop eae 1 nko relent i ofiguin id st Bac neg Ten te we red a for stk ich perl sane creagee A Se ones Tips tai? wpe re arty cl Oho ded ay See en ace nreess SES Se Se Teal esa ool eee eo | en meets | Soest cited neu tow deg Se caer ee oe ‘ioe ware oxen, vated wel te bad ee eee Hensel" caed a pe oe Sree ete ay es a ae ti re be bet at ae tee wh Soetnet Reece ented Sac Tisha eek nar Sv eal cae erat Stes tee tae en ae a a le ay") FB = cS oy) ml me) a] om | pee] Be meee] | gh) ae) gel ag | i oa e\e| | a) ai) S| S| ae) ee * cyl ela) a | a | ime gags | 18) fh | pe Ege us Pesaoceust Revixea—Pal 38, No.4el wich rind» small mount of unled alo oe Garake wat homey poate Sse tlre tnt is teh hs peal for fa wees aie To atv te clon saad Se wart up fore pe ef mea alg for 29 ‘Geletng col ing within © ches ofthe tank wal and Spent tor tovenge tat go pint on e bte Tino be more ha 1 chef et “fw ght of cle shore heft fare gen seat ates Atuney of Per 8 Canble fant ‘oes tar col"hoghs peo cher tne be | Sete tt para Cele srke col not be ‘ceil more thin inns Bins ino the cll {rine cy tw fund Gat parser tek eke I iat cad ore mae more han nhs Ske eal Some iar epnsed a prefs teres nt dniy oo te bet te int te Ini wire oer pred ee Oh ih mai cht tine Wie colt e mt Sie f."be tein ey a ase! oopealy Bc nl cng the Coton wil ue “Fa pron nandrdd eage pois ls eer cn te Nt x mpd che igh depending She sac shape of te tn nd fact secre “fs ae appeal o wry whut see so Tins appre stb omen tg SS ree af cal beg “fo dekmine wher ting otk ety on the sot impeded tet eae ae were ra on we “Sinden nie Inte he el ote on te bo Die tke were equiped i ening a Som and darken he bh on eo iiceaady Ceuta el aot peo roma the ot the sme aun of ld bod tne tee he oi gn in Tale 6 dee! that ‘Sita a pene aftr hh afer ie caer ong. may be newny eo alt i two or more Uhh fel a mrt nope don il Se hae mn Dine nr Sng fund the pessoa stam followed the modiied Fanning Equation-~ where V i computed fr stam the colin () APPENDIX 1 Doing ea Ent atch Tomy inertia qlee Actes Spo bak Sons Oe ike MPEe pymiage maine sh paraneree rece Neem ase ie ea April, 1989 —Pernousese Restsx = / j 200 de r = 9 g J | 3 ave GV °° To 300 305 400 t00 “rmperatreDiternce Surtce Te Ae Leng fo srfces ints manne ys nen om ex oT NAc Te Ty) ha Tay —Ted SHA, TT SE gen Waa Ea KO —ORI=B OT) OT) SK TTI [eT ERAT Ty nt Beane Ww