Flanged Immersion Heaters
Bucan manufactures high-quality flanged immersion heaters for use in extreme environments. Flanged immersion heaters can be installed inside pipes, pressure vessels, and tanks.
Flanged immersion heaters can boil a variety of fluids such as water, oil, heavy fuel thermal fluid, gas mixture, natural gas, etc. They are suitable for use with both corrosive and non-corrosive liquids.
Specifications
Bucan’s flanged immersion heaters consist of multiple tubular heaters formed into a hairpin. The heaters are welded or brazed to flanges. The heating element can be made of copper, Incoloy sheathing, steel, or stainless steel, depending on the application.
The standard flanges are made of carbon steel rated at 150 lbs.
Flanged Immersion Heaters for a Variety of Applications
The manufacturing material of the flanged immersion heater changes with every application.
By choosing the wrong material for an electric immersion heater, you run the risk of high maintenance costs, low efficiency, and eventual degradation and self-destruction of the heater.
Contact us today for advice on selecting the best material, wattage, and correct power density for your immersion element.
In brief, the most crucial factors to consider while selecting an immersion element include:
1.The liquid to be boiled
The fluid to be boiled and the heater sheath material must be correctly matched. If they are not, the boiling liquid will quickly damage the sheath.
Some materials will perform average, while other materials will be ideal for the fluid you are going to boil.
The same applies to the flange material.
2.Operating temperature and watt density
Bucan offers flanged heaters with Watt densities ranging from 4w/in2 to 80w/in2. The right power density will prevent the fluid from scorching and overheating. It also prevents excess heat build-up, thus reducing the need for maintenance.
3.Wattage
To calculate the required wattage, you need a lot of numbers, but our engineers can do the math for you. Based on the tank volume and size, the properties of the liquid to be boiled, wattage loss and other parameters, we can suggest the optimal wattage range for your electric immersion heating element.
For a complete list of criteria to be considered to select the best sheath material, refer to the table below. Do not hesitate to call us if you need assistance.
Accessories and Optional Features
Bucan also manufactures immersion heaters with thermostat and thermocouples. Our thermostat supports a variety of temperature ranges and has a max capacity of 25A and 600V.
The thermocouples can be attached to heating elements and used as high temperature limiting devices.
The optional features of our immersion heaters include:
- NEMA 4 TERMINAL BOX
- NEMA 7 TERMINAL BOX
- Flanges rated at 300 lbs
- Stainless steel flanges
- Special terminal box
- Passivation
- Baffles
Contact us
Bucan is one of Canada’s leading manufacturers of flanged immersion heaters. You can depend on our expertise to provide you with an optimally designed heating element that will perfectly complement the fluid you are going to boil.
Our wide selection of immersion element materials will ensure the longevity of your system by preventing overheating or underheating. Call us today!
Specification of Immersion Heaters
| 150 Lbs. Flange detail rating | 300 Lbs Flange detail rating | |||||||||||
| Size | Max # of elements | Standard cold end | O.D. | Flange thickness | # Holes | Holes diameter | B.C. | O.D. | Flange thickness | # Holes | Holes Ø | B.C. |
| 2.5" | 3 | 5 1/2" | 7" | 7/8" | 4 | 3/4" | 5 1/2" | 7 1/2" | 1" | 8 | 7/8" | 5 7/8 |
| 3" | 6 | 5 1/2" | 7 1/2" | 15/16" | 4 | 3/4" | 6" | 8 1/4" | 1 1/8" | 8 | 7/8" | 6 5/8" |
| 4" | 9 | 5 1/2" | 9" | 15/16" | 8 | 3/4" | 7 1/2" | 10" | 1 1/4" | 8 | 7/8" | 7 7/8" |
| 5" | 9 | 6 3/4" | 10" | 15/16" | 8 | 7/8" | 8 1/2" | 11" | 1 3/8" | 8 | 7/8" | 9 1/4" |
| 6" | 18 | 6 3/4" | 11" | 1" | 8 | 7/8" | 9 1/2" | 12 1/2" | 1 7/16" | 12 | 7/8" | 10 5/8' |
| 8" | 30 | 6 3/4" | 13 1/2" | 1 1/8" | 8 | 7/8" | 11 3/4" | 15" | 1 5/8" | 12 | 1" | 13" |
| 10" | 48 | 10" | 16" | 1 3/16 | 12 | 1" | 14 1/4" | 17 1/2" | 1 7/8" | 16 | 1 1/8" | 15 1/4" |
| 12" | 60 | 10" | 19" | 1 1/4" | 12 | 1" | 17" | 20 1/2" | 2" | 16 | 1 1/4" | 17 3/4" |
| Bundle diameter to suit sch. 80 pipe | ||||||||||||
Typical Heating Applications Immersion Water Heaters
- HOT WATER TANKS
- BOILER HEATERS
- ASPHALT, PARAFFIN, WAX HEATERS
- OIL PRODUCT HEATERS
- CORROSIVE AND NON-CORROSIVE SOLUTIONS
- AIR AND GAS HEATERS
- HEAT TRANSFER EQUIPMENT
Selection of Immersion Heaters
Flanged immersion heaters can be used in different applications. In order to meet the heating requirements of a specific application and have a safe operation in the environment within which a heater operates, several factors should be taken into consideration in the design of flanged immersion heaters. The following are a number of criteria that should be considered:
- The pressure rating and the material of a flange.
- The sheath material of the tubular elements. Table 3 provides recommended tubular element sheathe and flange materials for different mediums.
- Operating temperature and watt density of tubular elements that are adequate to the material heated. Tables 2 & 3 provide maximum operating temperatures and watt densities that are recommended for heating various materials.
- Design watt density, flow velocity and outlet temperature are factors that contribute to the temperature level that tubular elements will attain. The table below shows the maximum temperatures that different sheath materials could be subjected to:
- for high wattages, multiple circuits are recommended
| Sheath Material | Maximum Temperature |
| Copper | 360°F (180°C) |
| Stainless Steel | 1200°F (650°C) |
| Steel | 750°F (400°C) |
| Incoloy | 1500°F (815°C) |
- Taking the environment within which the heater will operate into account, safety issues should be taken into consideration.
- Utilization of adequate temperature controlling devices, temperature and pressure high limit switches, low liquid level and flow controllers and other control/safety devices that will control the heating process and protect the heater from excessive heat.
- The classification of the electrical terminal box required (NEMA 1, NEMA 4, NEMA 7, NEMA 12 etc…).
- The level of the contamination that a heater will be exposed to.
- Electrical safety codes should be considered.
- The possible requirement of baffles that force a gas or a liquid to circulate around heating elements when flanged immersion heaters are used inside circulation tanks.
For more information in selecting Flanged immersion Water heaters please contact our technical specialists
| Application | Sheath Material | Screw plug material | Typical Watt Density w/in2 |
| Clean water | Copper | brass | 55-80 |
| Process water/Weak solution | Stainless Steel | Stainless Steel | 25-55 |
| Oil light | Steel | Steel | 20-25 |
| Oil medium | Steel | Steel | 12-15 |
| Corrosive solutions (basic) | Incoloy | Stainless Steel | 20-25 |
| Corrosive solutions (acidic) | Stainless Steel | Stainless Steel | 20-25 |
| Vegetable oil | Stainless Steel | Stainless Steel | 30-40 |
| Asphalt, tar, wax | Steel | Steel | 4-10 |
| Air | Incoloy | Steel | 25-30 |
THERMOSTATS AND THERMOCOUPLES
The thermostats used in flanged immersion heaters are the bulb and capillary style. The standard thermostat has 25A max capacity and could operate up to 240V. This thermostat is single pole/single throw style with a temperature range of 10-120ºC. The table below shows other ranges of thermostats that are available.
| Thermostat | Contact Operation | Temperature Range | Volts / Amps |
| T0 | SPST | 10ºC to 120ºC | 125V - 30A / 250V - 30A / 277V - 25A |
| T1 | SPST | -15,5ºC to 40ºC | 125V - 30A / 250V - 30A / 277V - 25A |
| T2 | SPST | 70ºC to 280ºC | 125V - 30A / 250V - 30A / 277V - 25A |
| T3 | SPST | 149ºC to 370ºC | 125V - 30A / 250V - 30A / 277V - 25A |
| T4 | SPST | 0ºC to 120ºC | 125V - 30A / 250V - 30A / 277V - 25A |
| T5 | DPST | 10ºC to 120ºC | max. 277V - max. 25A |
| T6 | DPST | -15,5ºC to 40ºC | max. 277V - max. 25A |
| T7 | DPST | 25,5ºC to 204,5ºC | max. 277V - max. 25A |
| T8 | DPST | 10ºC to 120ºC | max. 600V - max. 15A |
It should be noted that thermostats are only temperature controllers and should not be used as fail-safe high limit switches.
Built-in thermocouples could be used inside flanged immersion heaters to give more accurate temperature indications. Thermocouples could also be attached to one of the heating elements and used as high-temperature limiting devices.
Terminations of Immersion Heater Element
| Terminal Box Size | ||||||
| Flange | Without Thermostat | With Thermostat | ||||
| Size | Fig. # | Dim.A | Dim.B | Dim.A | Dim.B | |
| NEMA1 | 2.5" | 1 | - | 3'' | - | 4.5'' |
| 3" | 1 | - | 3'' | - | 4.5'' | |
| 4" | 1 | - | 4.5'' | - | 4.5'' | |
| 5" | 1 | - | 4.5'' | - | 4.5'' | |
| 6" | 1 | - | 4.5'' | - | 4.5'' | |
| 8" | 1 | - | 4.5'' | - | 4.5'' | |
| 10" | 1 | - | 7.5'' | - | 7.5'' | |
| 12" | 1 | - | 7.5'' | - | 7.5'' | |
| NEMA4 | 2.5" | 2 | 5 5/8" | 4 1/2" | 5 5/8" | 7 1/4" |
| 3" | 3 | 5 5/8" | 4 1/2" | 5 5/8" | 7 1/4" | |
| 4" | 3 | 6 11/16" | 7 1/4" | 6 11/16" | 7 1/4" | |
| 5" | 3 | 7 3/4" | 7 1/4" | 7 3/4" | 7 1/4" | |
| 6" | 3 | 8 3/4" | 7 1/4" | 8 3/4" | 7 1/4" | |
| 8" | 3 | 10 3/4" | 7 1/4" | 10 3/4" | 7 1/4" | |
| 10" | 3 | 11 7/8" | 7 1/4" | 11 7/8" | 7 1/4" | |
| 12" | 3 | 15 1/4" | 8'' | 15 1/4" | 8'' |
| NEMA7 | 2.5" | 4 | 4" | 9 1/4" | 4" | 11" |
| 3" | 4 | 4 1/2" | 9 1/4" | 4 1/2" | 11" | |
| 4" | 4 | 5 9/16" | 10 1/4" | 5 9/16" | 11 1/2" | |
| 5" | 4 | 6 5/8" | 10 3/4" | 6 5/8" | 12" | |
| 6" | 4 | 7 5/8" | 11" | 7 5/8" | 12 1/4" | |
| 8" | 4 | 9 5/8" | 13" | 9 5/8" | 13" | |
| 10" | 4 | 10 3/4" | 13 1/2" | 10 3/4" | 13 1/2'' | |
| 12" | 4 | 12 3/4" | 14 1/2" | 12 3/4" | 14 1/2'' |
Optional Features of IMMERSION WATER HEATERS
- NEMA 4 TERMINAL BOX
- NEMA 7 TERMINAL BOX
- 300 LB RATED FLANGES
- STAINLESS STEEL FLANGES
- SPECIAL TERMINAL BOX (STILTED, VENTED, STAINLESS STEEL, ETC…)
- BUILT-IN THERMOCOUPLES
- PASSIVATION
- BAFFLES
- THERMOSTATS WITH VARIOUS TEMPERATURE RANGES
- HIGH LIMIT TEMPERATURE DEVICES
