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Helical Coil Heaters

C E I E n t e r p r i s e s

TEMPERATURE CONTROLLERS & DIGITAL ANNUNCIATOR

HELICAL COIL

HC-SERIES HEATER WITH MANIFOLD FOR MULTIPLE CIRCUITS

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General Dimensions and Specifi cations

Heater Model Output Btu/hr

Max. Fuel Usage

Pump Motor HPVolume Flow Rate (gpm)

Expansion Tank (gallons)

Heat Transfer Fluid Required

(US Gal.)Length

AWidth

BHeight

CPipe Size

DApproximate Weight (lbs)No.2 (gph) Gas (cfph)

Single-Circuit HeatersHCS-100 1,200,000 11 1,560 10 100 175 95 12’-9” 5’-10” 8’-11” 2” 5,000

HCS-175 2,000,000 18 2,600 15 150 280 145 14’-9” 6’-4” 9’-9” 2-1/2” 6,500

HCS-250 3,000,000 27 3,900 15 150 280 165 15’11” 7’-4” 10’-6” 3” 9,300

HCS-350 4,000,000 36 5.200 15 200 400 250 18’-7” 8’-2” 11’-2” 3” 10,700

Multi-Circuit HeatersHC-120 1,200,000 11 1,560 10 100 175 95 12’-9” 6’-8” 8’-11” 2” 5,100

HC-200 2,000,000 18 2,600 15 150 280 145 14’-10” 6’-6” 9’-9” 2-1/2” 6,600

HC-300 3,000,000 27 3,900 15 150 280 165 15’-11” 7’-6” 10’-6” 3” 9,500

HC-400 4,000,000 36 5,200 15 200 400 250 18’-7” 8’-4” 11’-2” 3” 10.900

The amount of fuel used is for a thermal effi ciency of 85% and one hour of operation at maximum output. A properly sized heater normally runs for intermittent periods at lower outputs. No. 2 fuel usage is based on 132,000 Btu per gallon, its LHV (low heating value). Natural gas usage is based on 905 Btu per cubic foot, its LHV. Heights include the exhaust stack without a stack heat exchanger. The stack heat exchanger for the HCS-350 and HC-400 weighs 800 pounds and adds 2’-7” to their height. For all other models it weighs 460 pounds and adds 1’-9” to their height. NOTE: Specifi cations are subject to change without prior notice or obligation.

OPERATION & FEATURES

AB

C

Standard model without stack heat exchanger

HCS-series heater

FillOverflow PipeCo

ntro

l Pan

el

Expansion Tank

Low Level Control

Coil Outlet

Oil Return

Helical Coil

Coil Inlet

Stack Heat Exchanger (optional)

Full Modulation Burner

Circ

ulat

ing

Pum

p

D

Helical Coil Hot Oil HeatersHelical Coil Hot Oil Heaters

Helical Coil Heaters are available in two basic confi gurations: HCS-series for single hot oil circuits, and HC-series for multiple hot oil circuits. Four standard models are available in each series, with outputs from 1.2 million to 4 million Btu/hour. All heaters can be customized to meet your specifi c needs.

Single Circuit Systems: Small plants with only one or two liquid asphalt tanks usually need only one hot oil circuit with one pump. HCS-series heaters are well-suited for such plants. One circulating pump, mounted on the heater skid, circulates the heat transfer oil through the heater and through heated plant components.

Multiple Circuit Systems: Plants with storage silos, multiple asphalt tanks, and additional components can usually benefi t from using multiple hot oil circuits.

HC-series heaters are designed for such applications. They feature a manifold on the output connection that

supplies oil to multiple additional pumps. Each of these side pumps is dedicated to an independent hot oil circuit.

Using multiple circuits reduces the load on each pump, its motor, and its operating pressure. This system is much more fl exible than a single-circuit system because each circuit can be operated independently.

Helical Coil is designed and built to ASME code. It is designed to provide a large heat transfer surface area, low fl ux rates, and an ideal fl uid velocity of 7 to 11 feet per second. ASME stamp is available as an option.

Stack Heat Exchanger is an available option that can boost the heater’s thermal effi ciency by 5%. Hot burner gases exiting the heater pass around a densely packed set of serrated fi nned tubes inside the heat exchanger. Thermal oil fl owing inside the tubes is heated before entering the helical coil.

This option reduces fuel usage by reducing the output demand placed on the burner. This can reduce fuel consumption by 261 gallons of No.2 fuel oil or 345 therms of natural gas per month. A stack heat exchanger usually pays for itself in one year, or less.

UL-rated, NEMA 4 Control Panel is the nerve center of the heater’s temperature control and safety systems. Compliance to UL standards not only assures you of the quality of the electrical system, it also puts your insurance company at ease, potentially bringing you lower premiums. The NEMA 4 enclosure provides watertight protection against splashing water, hose-directed water, rain, sleet, snow, ice, dirt, and windblown dust.

Panels that meet CSA specifi cations, and other NEMA standard enclosures are available optionally.

Temperature Controllers: Two microprocessor-based controllers provide control over output temperatures. The Temperature Controller regulates the fl ow of fuel and combustion air to the burner to effi ciently maintain the temperature set point on the controller.

The High Media Controller is a safety control. It will shut down the burner if the heat transfer oil reaches the temperature limit set on this controller.

Flame Monitor is a microprocessor-based burner management control system. The monitor provides proper burner sequencing, ignition and fl ame monitoring protection. In conjunction with limit and operating controls it sequences the burner/blower motor, ignition, and fuel valves to provide for proper and safe burner operation. Other features include:

• Self-diagnostic for safety and reliability.• Non-volatile memory retains information even when

power is interrupted.• Microprocessor-based for accurate timing,

comprehensive diagnostics and precision control.

Centrifugal Circulating Pump, mounted on the heater skid, circulates heat transfer oil through the heater. Viton shaft seal rings provide a reliable seal with virtually no leakage.

If the heater is equipped with an optional stack heat exchanger, the oil fi rst enters the exchanger, where it is heated by hot exhaust gases. Oil then exits the stack heat exchanger and enters the helical coil, where it is heated by hot gases from the burner.

Full-Modulation Burner conserves fuel, reduces temperature overshooting and eliminates constant on-off burner recycling.

The burner fi res into the open center of the helical coil, creating the fi rst pass of hot burner gases. Burner gases then turn at the end of the coil, making a second pass along the coil’s outer surface.

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Efficiency Gallons / hour Gallons / Month Gallons / Life

50% 15.0 10,830 2,020,969

60% 12.5 9,008 1,680,806

70% 10.7 7,773 1,450,484

80% 9.5 6,815 1,271,661

85% 8.9 6,406 1,195,307

88% 8.6 6,198 1,156,565

These usages are based on a 1-million Btu/hr heat load, operating 24 hrs/day, 7 days/week, 40 weeks/yr, a 20 year heater life and No. 2 fuel oil with a heating value of 132,000 Btu/gallon (LHV).

Heat Transfer Fluid Specs

The heat transfer oil should be paraffi n base, solvent refi ned and recommended for operating temperature to 450° F.

WARNING: Do not mix paraffi n base oils with aromatic base oils. Mixing will clog and severely damage the heater and heating system.

Gravity API 28-30

Flash Point 420° F

Viscosity at 100° F 200 SSU

Viscosity at 210° F 50 SSU

Viscosity Index 95 Min.

Pour Point 5° F

Carbon Residue 0.10%

Neutralization No. 0.10%

Sulphur Content 0.5% Max.

HCS-SERIES HEATER FOR SINGLE HOT OIL CIRCUIT. SHOWN WITH OPTIONAL STACK HEAT EXCHANGER.

Available Options: • Low-NOx burners (30ppm).• Ultra low-NOx burners (less than 9ppm).• Stack heat exchangers for boosting fuel effi ciency.• Optional burner management system utilizes an

exhaust stack O2 sensor to maintain heater operation in adverse climates. Reduces fuel consumption and tunes burner automatically.

• Sock fi lters for longer fl uid and pump life.• 7-day time clock.• Non-standard voltage (525/60, 380/50)• ASME code stamp.• CSA approved panel• CRN stamped coils• Class I Div. I or Class I Div. II explosion-proof

components.• High-temperature (550°F) operation.

Helical Coil Hot Oil HeatersHelical Coil Hot Oil Heaters

Digital Annunciator visible on the front of the control panel displays heater status at all times. Any safety limit that is exceeded will immediately shut down the burner. The cause will be clearly displayed on the LCD screen, reducing down time and assisting CEI Service personnel diagnose any heater issues remotely, if necessary.

Wireless Monitoring Systems are optionally available for additional convenience and reduced down time. These systems communicate any heater shut-down issues to your cell phone, so you will know what’s happening with your heater, no matter where you are.

Fuels: The heaters operate on natural gas, LPG, or No. 2 commercial grade fuel oil, depending on the burner used. An optional combination burner allows switching between two different fuels.

Thermal Effi ciency: Aside from safety and reliability, thermal effi ciency is probably the most important aspect of any heater. CEI’s helical coil heater approaches the theoretical limits of thermal effi ciency possible in a fi red 2-pass heater. Even without the stack heat exchanger, its effi ciency is 85 percent.

Maintenance: The heaters are very easy to maintain. Components are easy to reach. Replacement parts are readily available from CEI’s large parts inventory. We back our products with worldwide parts & service support.

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ADDITIONAL CONFIGURATIONS

First Pass

Third Pass

Second Pass

VERTICAL HELICAL COIL HEATER ASPHALT BOOSTER HEATER

3-PASS HEATER ON A CEI ASPHALT RUBBER MIXING SYSTEM

OPERATION OF A 3-PASS HELICAL COIL HEATER

Vertical Helical Coil Heaters occupy a relatively small ground footprint, allowing placement of a higher-output heater in a confi ned space where a horizontal heater of the same output may be too large. Many options are available. All heaters can be customized to meet your specifi c needs.

Helical Coil HeatersHelical Coil Heaters

Three-Pass Helical Coil Heaters provide higher outputs than two-pass heaters of the same physical size. By elongating the path of burner gases to the exhaust, the three-pass design performs at high thermal effi ciency.

Three-pass heaters utilize two helical coils: a smaller inner helical coil fi ts inside a larger outer helical coil. The burner fi res down the center of the inner coil, creating the fi rst pass of hot burner gases. This pass exposes the inner coil to both radiant and convective heat.

At the end of the coil, the burner gases turn and pass through the space between the two coils, creating the second pass. This exposes both coils to convective heat.

At the end of the second pass, the hot burner gases turn and pass along the outer surface of the outer coil, creating the third pass and exposing the outer surface of the outer coil to convective heat.

Heat transfer oil fl owing through the two coils, either sequentially or in tandem, gains heat from the hot coils. Many options are available. All heaters can be customized to meet your specifi c needs.

Asphalt Booster Heaters are a variation of the vertical helical coil heater design. Liquid asphalt is pumped through the coil, where it is heated in the same manner as a two-pass hot oil heater.

Booster heaters are used at bulk storage terminals to boost the temperature of liquid asphalt as it is pumped into a tanker truck for delivery to end users. This allows the terminal to store liquid asphalt at lower temperatures, yet still provide delivery at or near usage temperatures.

CEI ENTERPRISES,INC. an Astec Industries Company

245 WOODWARD RD, SE • ALBUQUERQUE, NM 87102 USA • 800.545.4034 • FAX 505.243.1422 • ceienterprises.com

Equipment. Parts. Service. Rely on CEI. A legacy of innovation and quality since 1969.

© 2015 CEI Enterprises, Inc. Publication # 15-04-004