storage calorifier high quality with · pdf filerecovery period is the time it takes to heat...

HEAT TRANSFER

STORAGE

• EC SERIES

• SC SERIES

• BT SERIES

CALORIFIERS

Type of BuildingStorage/Person

(Litres)Recovery Period

(H )

Hotel 45 2

School/College 5 3

Boarding School 25 2

35 3

Houses/Apartments 45 2

Factories/Offices 5 3

Hospital Wards 30 1

INTRODUCTION

DESIGN AND MANUFACTURING STANDARDS

WHY HRSFUNKE?

STORAGE VOLUME AND RECOVERY PERIOD

Student Apartments

The design and manufacture of Calorifiers is generally carried out in accordance with BS853 1996 Part 1 Grade A.

However, where the scope of BS853 Part 1 is deemed insufficient or specified site requirements need a higher specification and design manufacturing code, calorifiers are manufactured in accordance with BS853 Part 2 with PD5500:2009 being offered as an alternative design code. Other design standards are also available should it be required.

HRSFUNKE has many years experience in the design and manufacturing of storage calorifiers. By using only the highest quality materials and components, we can guarantee the long life of our calorifiers removing the inconvenience of unit failure.

All our calorifiers are manufactured in accordance with the European Pressure Equipment Directive 97/23/EC. The standard units fall within the Group 2 Liquids category, Chart 4, thereby having a PED Category of SEP (full details are available from our technical office). All wiring and electrical assemblies conform to the latest IEE regulations.

The HRSFUNKE Storage Calorifiers offer a high qualitysolution for domestic hot water (DHW) heating. The standardrange is manufactured from either stainless steel, copper,copper lined steel, galvanised steel or glass lined steel. Theheater battery is manufactured from either copper or AISI316L stainless steel AISI 316L with the electrical heatersmade from from Nicalloy 825 ensuring an hygienic, reliablelong life. The heaters are removable for cleaning andinspection purposes.

These storage calorifiers are also designed to be used withelectricity as the primary heat input. This is ideal for applications where there are no boilers or other water generating equipment available. Although electricity is associated with high running costs, it is also a very efficient means of DHW heating since all of the power used is converted into heat. The use of electricity also negates the need for extra space within the plant room to cover the duty, so boilers can be smaller, thus freeing up space for other applications.

Of a high quality design and manufacture, the HRSFUNKEStorage Calorifiers offer an excellent product bothaesthetically and technically. The units are bespoke, and can therefore be designed around constraints within the plant room, with special attention being paid to where the terminat-ing connections need to be on the unit to ensure that they match up with existing pipework. This helps to reduce on site costs due to labour and material savings.

The storage volume of the cylinder (capacity) and THErecovery period (heat up period) determine the primary powerinput required (kW) and therefore the output (litres/hour). Therecovery period is the time it takes to heat the water up fromcold (usually 10°C to 25°C) to the working temperature(usually 60°C to 65°C) in minutes or hours. Long recoverytimes require low primary power input whereas short recoverytimes require high primary power input.

The actual storage volume requirements can be roughlycalculated using the table below which should give goodresults. A study of the application should be made todetermine actual requirements, taking space, weight loadingsand power supply into account when selecting a volume.

HEA T TRANSFER

QUALITY WITHOUT COMPROMISE

HEA T TRANSFER


The material specification of a calorifier is generally carried out to suit site requirements, the calorifier pressure and also the physical dimensions of the cylinder. Due to the high build specification and quality of the materials used for our calorifiers they are guaranteed to last a lot longer than those manufactured from inferior materials, which are susceptible to corrosion.

Copper is virtually impervious to attack by corrosive or aggressive water. It is a popular material choice used throughout the world due to its durability and long life. Shells manufactured from copper gain a coating of copper oxide on the surface, which protects against corrosion. Where water is aggressive, an aluminium anode can be fitted into the shell, this then deposits an aluminium film onto the surface, which permanently protects the shell from corrosion. The anode does not need replacing throughout the life of the calorifier. Please note that copper shells should not be used in conjunction with galvanised steel pipe work or fittings due to the incompatibility of the two materials.

Galvanised steel shells are also available. The shells are manufactured from carbon steel and then hot dipped in a galvanising tank. This deposits a layer of zinc onto the surface. Galvanised shells offer excellent corrosion protection in hard water areas, but should not be used in soft water areas. Soft water prevents the protective layer forming on the surface of the shell. Magnesium anodes should be fitted to galvanised cylinders to give the shell a protective coating. Anodes should be replaced annually to ensure the long life of the calorifier. Copper pipe work or fittings should not be used in conjunction with galvanised shells.

Due to low material design strengths, solid copper may become uneconomical to use on cylinders with larger diameters and high pressures. For where a copper shell is impractical we offer a copper lined steel shell calorifier. This material option combines the high strength of carbon steel with the corrosion resistant properties of copper. The process involves manufacturing a carbon steel outer shell and then lining it with copper sheets that are welded togeth-er to form a waterproof surface. All wetted parts within the calorifier are manufactured from copper.

Anti vacuum valves are fitted as standard to copper lined cylinders to avoid the vessel collapsing under vacuum conditions when draining down without a suitable vent.

Stainless steel calorifiers are becoming more popular for DHW heating due to its high material strength and compat-ibility with potable water. However, calorifiers with stainless steel shells may be unsuitable for installation in systems with a high chloride content since the chloride can attack the welds.

The shell is manufactured from carbon steel and then inter-nally lined with glass or enamel. The lining is hygienic and resistant to corrosion and scale formation. These are sup-plied with a magnesium anode to provide additional cathodic protection. These can be easily checked and replaced.

SOLAR CHOICE STORAGE CALORIFIER

CALORIFIER MATERIAL SELECTION

COPPER

GALVANISED STEEL

COPPER LINED STEEL STAINLESS STEEL

GLASS LINED STEEL

HEA T TRANSFER


Flow rate will depend on the demand for hot water. It will be op-timum during peak demand. Heating load should be calculated to satisfy the maximum flow rate.

STORAGE SIZE AND HEATING LOAD

FLOW RATE

SELECTION AND SIZING OF CALORIFIER

SAMPLE HEATING LOAD CALCULATION

For a Hotel:Normal recovery time is two hours

General hot water demand = 45 Litres/Person

Maximum demand = 125 x 45= 5625

Acceptable peak Demand = 0.7 x 5625= 3940

Max. Flow rate required = 3940L / 2HRS= 0.55 L/S

Heating Duty Required = 0.55 x 4.2 x 45= 104 kW

• HRSFUNKE standard models. custom models are also available

J

CapacityLitres

Diamm

H.O/Emm

MaxHt.

Accesssize

C on nect i on s

C D E

230 500 1300 1525 DN 250 1.1 /2 " B SP 3/4" B SP 1.1 /2 " B SP

F G H

1/2" B SP 3/8" B SP 3/4" B SP 3/4 " B SP

300 600 1180 1405 DN 250 2" B SP 1" B SP 2" B SP 1/2 " B SP 3/8 " B SP 1" B SP 1" B SP









1500 1000 2125 2350 DN 450 DN 65 PN 16 1 .1 /2" B SP DN 65 PN 16 1 /2 " B SP 3/8 " B SP 1.1 /2" B SP 1.1 /2" B SP

1750 1000 2480 2705 DN 450 DN 65 PN 16 1 .1 /2" B SP DN 65 PN 16 1 /2 " B SP 3/8 " B SP 1.1 /2" B SP 1.1 /2 " B SP

2000 1100 2350 2575 DN 450 DN 80 PN 16 2" B SP DN 80 PN 16 1 /2 " B SP 3/8 " B SP 2" B SP 2" B SP

2250 1200 2220 2445 DN 450 DN 80 PN 16 2" B SP DN 80 PN 16 1 /2 " B SP 3/8 " B SP 2" B SP 2" B SP

2500 1200 2460 2685 DN 450 DN 100P N 16 2" B SP DN 10 0 PN 16 1 /2 " B SP 3/8 " B SP 2" B SP 2" B SP

3000 1200 2950 3175 DN 450 DN 10 0 PN 16 2" B SP DN 10 0 PN 16 1 /2 " B SP 3/8 " B SP 2" B SP 2" B SP












So a Calorifier with a capacity of 4000 L with a 105 kW duty heater will be sufficient for this application. The specified system can supply the maximum flow rate based on the peak demand.

We cannot make an exact calculation of hot water consumption in a public area since the demand will fluctuate throughout the day. It is therefore better to collect all the data available and calculate the peak load demand. Alternatively, we can make a general calculation based on the hot water requirement per person and the recovery period required.

In general calculations are made based on heating the waterfrom 20°C to 65°C. If the required temperature is below 65°Ceither the hot water demand has to increase or the heating loadshould decrease.

Key

L

J

X150-

A,B

H

CD,E ØX

,K G F

L

100

H C

G F

D

Y K

M

A

B E

75

Vertical Models

Y

C H G F

DK

M AB

J E

A. Primary InletB. Primary OutletC. Hot Water OutletD. Secondary ReturnE. Cold FeedF. ThermometerG. Pressure Gauge

H. Safety ValveJ. DrainK. Thermostats (1” BSP)L. Inspection OpeningM. Immersion HeaterN. Anti-Vacuum Valve

The StandardHRSFUNKE range Calorifiers have working pressure of 6 BarG and 10 BarG. Higher pressures are also available.

HEA T TRANSFER


HEA T TRANSFER


The rod element is made up of a resistance heating coil sur-rounded by compacted magnesium oxide powder enclosed in a tubular metal sheath. The element is brazed to the heater boss or flange. If an element fails the entire heater must be replaced. These heaters are generically screwed BSP.

Our standard element material is Nicalloy 825. This is a high alloy stainless steel and has excellent corrosion resisting properties. Generally this material can be used in hard and aggressive waters and, in a range of chemical solutions.

The rod element comprises a resistance heating coil sur-rounded by compacted magnesium oxide powder enclosed in a tubular metal sheath. The rod element is brazed to glands that are bolted to the element flange. If an element fails the individual element can be replaced, however, the vessel must be drained and the heater removed.

A removable core element made up of resistance wire wound inside ceramic formers. Removable core elements are inserted into element tubes, which are expanded, brazed or welded onto the heater flange. If an element fails the individual element can be replaced without draining or removing the heater from the vessel. Removable core elements operate at a much lower watts density than rod elements and have much heavier wall thicknesses so they can operate in a far wider range of conditions.

Our standard sheath material is copper, which is generally suitable for use in hard and aggressive water conditions, particularly water with a high concentration of chlorine, for example desalinated water.

Element watts density is defined as the amount of watts giv-en out per unit surface area of an element. A high element watts density reduces the life of an element and significantly increases the effect of corrosion on the element sheath. High element watts density causes water to boil around the ele-ment and produces a noise similar to that of a boiling kettle. Where an immersion heater has been fitted close to sleeping accommodation it has been known for this noise to keep peo-ple awake at night.

Due to their design, removable core elements work at a low watts density, which allows them to operate with significant-ly less corrosion problems than rod elements. Generally removable core element watts density is below 3.1W/cm2 (20 W/in2)

With the exception of domestic and some light industrial heaters the standard watts density for rod element heaters is 9.3W/cm2 (60W/in2) . The standard watts density on our flanged heaters is 7.4 W/cm2 . This is suitable for heating most types of water. Where water conditions are very hard or aggressive particularly in respect of desalinated wa-ter or where chemical solutions are being heated, please contact our technical department to obtain the correct element specification.

IMMERSION HEATERS

FIXED ROD ELEMENTS

GLANDED ROD ELEMENTS

REMOVABLE CORE ELEMENTS

ELEMENT WATTS DENSITY

Typical Electrical Specification

CONTROL PANEL

Typical Control Philosophy

The control panels are bespoke, specific to each project and are designed and manufactured with the highest quality components. The panels can be supplied with either temperature based, timed or thyristor control as standard. The panels are wired through a low water switch in the tank to ensure the heaters are not running dry.

Control PanelTypical Timed Control Type

• Isolator with compatible door interlocking handle.

• Relays are Finder Fl55340040-8230 or equivalent.

• Enclosure for the control panel is made from sheet steel with an IP rating of IP69X and is at least IP54 once assembled.

• MCB D type triple pole CE marked and independently ested and approved to EN60947 and EN60898 with a breaking capacity of 10 KA.

• Panel is to operate in multi stages through an independent timer control per stage.

• Once there is a demand for heat from the control thermostat within the immersion heater the first stage contactor will be energised to give power to the first stage.

• If the heat has not been satisfied after the given time the timer will bring in stage two.

• This continues until heat has been satisfied through timers two and three until all stages are energised and/or until heat has been satisfied.

• The low temperature relay will be controlled via a separate thermostat. This is to provide indication that the vessel is under temperature only.

• The low level switch will stop the immersion heaters from operating until the tank is sufficiently filled with water.

• The high temperature thermostat has a built in manual reset facility that will require manual intervention to reset.

• 2A C type single pole MCB for control supply CE marked and independently tested and approved to EN60947 and EN60898 with a breaking capacity of 10KA.

• Cable terminals are 10mm rated at –A for power.

• Cable terminals are 2.5mm rated at 24A for control.

• Cable terminals are 2.5mm rated at 24A for BMS signals.

• Pilot lamps are 230Vac LED bezel style 22mm with IP rated seal. Available in various colour options.

• Contactor details as per data sheet.

HEA T TRANSFER


HEA T TRANSFER


HEATER BATTERY

U-tubes are the most common heat exchangers used in calorifier manufacturing. Our U-tubes are made with high efficiency tubes, which are unaffected by thermal expansion to provide optimum levels of reliability. The tubes in the heater batteries are available in plain copper, making them suitable for both hard and soft water areas. Standard batteries are manufactured using copper integron tubes. The heater battery is also available in stainless steel AISI 316L offering an hygienic, reliable long life. The heater is removable for cleaning and inspection purposes. Enough space must be allowed to permit removal of the batteries. If the required space is not known, assume the distance to be equal to the diameter of the vessel. The standard range of battery duties are based on a one hour recovery period raising water from 10°C to 60°C with a primary medium of water at 82°C to 71ºC. Bespoke calorifier designs are available along with other duties, working pressures and primary mediums. Please contact our sales department for further details.

Instead of U-tube, spiral tube heat exchanger designs are also available, which offer an alternative cost effective solution.

• Based on HRSFUNKE standard, subject to change

kW m2 mm mm mm mm

20 1.20 20 20 125 410

30 1.80 25 25 150 565

40 2.40 25 25 150 715

50 3.00 32 32 150 870

60 3.60 32 32 200 725

70 4.20 40 40 200 825

80 4.80 40 40 200 925

90 5.40 40 40 250 695

100 6.00 40 40 250 760

125 7.50 50 50 250 910

150 9.00 50 50 250 1060

200 12.00 65 65 300 1065

250 15.00 65 65 300 1290

300 18.00 80 80 350 1185

400 24.00 80 80 400 1125

500 30.00 100 100 400 1350

HeadingDuty

Heat TransferArea

Inlet Size OutletSize

Flange Size Length

Primary Side Flow Rate Requirement

Heating load 100 kW.As per standard primary side temperatures:

Inlet = 820C

Outlet = 710C

Heating Duty = 100 kW

Flow rate = 100/(4.2 x 11)

The selected 'U'-tube will be capable to produce 100 kW heating duty if there is a primary flow of 2.17 L/s

VENTED SYSTEMS

UNVENTED SYSTEMS

DIFFERENT MODEL HRSFUNKE CALORIFIERS

Electrical Calorifiers - (EC Series) Storage Calorifier - SC Series Buffer Tank - (BT Series)

seireS CE :epyT

L0005 :emuloV egarotS

H

Type of Material: SS Type of Material: CL

eating Duty: 135 kW L0005 :emuloV egarotS

Type of Material: GL

Storage Volume: 5000L Wk 041 :ytuD gnitaeH yramirP

Back up Duty: 60 kW

seireS TB :epyT

Ex: EC/5000/135 - SS Ex: DDC/5000/120/40

SC/5000/140/60 - CLEx: ST/5000 - GL

Type: SC Series

HRSFUNKE Storage Calorifiers are suitable for both vented and unvented (pressurised) systems. HRSFUNKE offer calorifiers suitable for both types of systems together with equipment to ensure correct operation.

The calorifiers can either be vented from the secondary flow connection or from a dedicated vent connection to allow air to exit the calorifier, air to enter the calorifier during drain down, and also thermal expansion of the water when it is heating up. The vent connection or pipe should never be blocked or valved off. The exception being to vent/bypass valves on multi-calorifier installations.

Unvented systems also known as sealed or pressurised systems are more common in installations than vented systems due to building regulations. They are also used when it is not practical to fit a vent. For unvented systems additional equipment is required:

• The shell should be designed at a pressure calculated after thermal expansion of the cold water.

• Pressure/temperature safety valves should be fitted in case of control failure.

• An expansion vessel should be fitted to accommodate the thermal expansion.

• A cold feed kit comprising isolating valves, strainer and pressure reducing/regulating valves and check valves should be fitted to regulate the cold feed pressure and to stop backflow from the calorifier into the cold water system. A booster set may have a pressure reducing valve fitted as standard on fixed speed pump units.

HRSFUNKE calorifiers are available in a range of models dependent on the application. Options include electric calorifiers with electric heaters, single duty calorifiers with U-tube heat exchangers with either boiler or solar systems as the heating source and double duty calorifiers with electric back up heaters.

HEA T TRANSFER


ACCESSORIES

Thermometer

Safety Valve

Insulation

Anti-Vacuum Valve

Control Thermostat

Supports

Manhole

Anodes

High Limit Cut Out

Low Level Switch

All Electric calorifiers should be fitted with a low level switch above the heater to ensure that it is not running in dry condi-tions, which can damage it.

Manholes are supplied to allow for internal inspection of the tank and heater. The heater can be inspected by removing it from the outside, but the manhole allows inspection without removal.

The standard manholes take the form of a flanged neck piece extending away from the calorifier body.

Anodes can be provided based on the shell material or as per requirement. Normally anodes are supplied with glass lined calorifiers to protect the shell from corrosion.

Magnesium anodes are normally specified and the life time of the anode will depend on the quality of water and should be removed and replaced at regular intervals.

Electric calorifiers are fitted with a high limit cut out to monitor overheating and a manual reset button to restore to original condition after malfunctioning.

The thermometer measures the temperature inside the tank and is located near to the top to obtain the temperature of water reaching the outlet to get the secondary side flow temperature.

All hot water application tanks should be fitted with a safety valve to protect the calorifier against the occurance of high pressure due to control malfunction or incorrect operation. We are able to supply a combined pressure/temperature relief valve for total protection.

The calorifier shell requires thermal insulation to prevent unnecessary heat loss. The calorifier may be standing for hours with hot water and if the tank is inadequately insulated the stored water will cool down.

Our tanks are supplied with compressed 50mm thick CFC free polyurethane or mineral wool insulation encased in stucco aluminium cladding.

All copper lined calorifiers must be protected against partial vacuum and ours are fitted with an anti vacuum valve. This should only be removed during inspection

In electric calorifiers the control of the heating depends on the feedback from the control thermostat so the accuracy of control depends on the selection of control thermostat. In our electric calorifiers the control is either by a number of control switches located at different levels or by a single temperature switch which activates the heating process and is continued by timer control relay in different steps.

Expansion Vessel

Expansion vessels are used with closed hot water and DHW systems to absorb the excess water pressure caused by thermal expansion. The expansion vessel is a small tank, which is separated into two parts by a rubber diaphragm. One part is connected to the hot water line and contains water. The other part is the dry side and contains dry air or other gases under pressure. During typical operation with normal pressure the diaphragm will push against the water inlet, but when the line pressure is exceeded the force reverses and the diaphragm pushes against the dry side.

Our calorifiers are supplied with permanent legs/supports fixed to the shell.

Pressure Gauge

A pressure gauge is fitted near to the top of the tank. This is used to measure the pressure inside the tank during operation to ensure that it does not exceed the designed pressure.

HEA T TRANSFER


Expansion vessels are used with the closed hot water system and domestic hot water systems to absorb excess water pressure caused by the thermal expansion. The expansion vessel are small tanks having two parts isolated by a rubber diaphragm. One part a whole tank which is connected to the hot water line and so will contain water. The other part is the dry side which contains dry air or other gases under pressure. During normal working conditions with normal pressure the diaphragm will push against the water inlet but when the line pressure is exceeding the force it will reverse and the diaphragm will move comprising the air on its other side.

EXPANSION VESSEL

HEA T TRANSFER


HRSFUNKE TURNKEY SOLUTIONS

HRSFUNKE PRODUCT OF RANGE

PLATE HEAT EXCHANGERS

HOT WATERBOILERS

STORAGECALORIFIERS

FLAT PLATECOLLECTORS

STEAMBOILERS

STEAMGENERATORS

PISTONPUMPS

SHELL ANDTUBES

HOT WATER GENERATION PLANT

STEAMSYSTEM

SOLAR WATERHEATING SYSTEM

HEAT EXCHANGERSSKID PACKAGES

HRSFUNKE Heat Transfer LtdUnit 15, Hanson Lane Enterprise CentreHanson Lane, HX1 5PG, Halifax, UKTel +44 (0) 1422 363 065Email: [email protected]: www.hrsfunke.co.uk

UNITED KINDOM (UK)

HRSFUNKE Heat Transfer SL – C/ Magallanes,5 – Pol. Ind. La Estrella Molina de Segura30500 – Murcia – SpainTel: (+34) (0) 634310640Email: [email protected]: www.hrsfunke.es

SPAIN

Tel: +971 4 8865540 | Fax: +971 4 8865541E-mail: [email protected] | Web: www.hrsfunke.com

HRSFUNKE Heat Transfer LLC,P.O Box: 106292, Abu Dhabi UAE

MIDDLE EAST SALES & SERVICE OFFICE

HRSFUNKE Heat Transfer FZE, P.O Box: 262243, Dubai UAE

storage calorifier high quality with · pdf filerecovery period is the time it takes to heat...

Documents