Liquid phase systems

design guide
A design, operating, and maintenance guide for
low-cost, low-pressure heat transfer systems
Contents
Introduction.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Applications of liquid phase Therminol® heat transfer fluids.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Advantages of liquid phase Therminol heat transfer fluids.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Therminol heat transfer fluid versus steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Therminol heat transfer fluid versus direct fired heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TLC Total Lifecycle Care® program .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Therminol technical literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Process design factors.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Advantages of proper design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fluid factors .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fluid sampling .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Mechanical design factors .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

The heater .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Effect of liquid velocity on film temperature during heating .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Heat transfer coefficients .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Filters .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Materials of construction .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Expansion tank and venting arrangements .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Expansion tank and cold seal trap .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Insulation .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09
Valves .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09
Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09
Fire protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09
Safety controls .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Typical liquid phase heat systems .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

System 1—The basic system .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
System 2—Heating multiple users .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
System 3—Heating several users at different temperatures .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
System 4—Heating and cooling of a single user.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Start-Up .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Suggested start-up procedure for new systems.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Operating instructions .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Suggested operating instructions for liquid phase heating systems using Therminol fluids.. . . . . . 16
Safe handling and disposal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Resistance of valves and fittings.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Steel pipe dimensions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Engineering conversion factors.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Average properties of tubes.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Introduction

Applications of liquid phase

Therminol heat transfer fluids
Virtually any process or manufacturing operation requiring
heat transfer between 400°C (750°F) and –115°C (–175 °F)
The Therminol team has more than 50 years of experience is a candidate for the application of Therminol heat transfer
in designing, producing, and marketing synthetic heat fluids. Applications which involve any of the following
transfer fluids. Therminol® heat transfer fluids by Eastman requirements are particularly well-suited for the use of liquid
have been developed for a range of applications—from phase heat transfer fluid:
chemical and petroleum processing to solar energy. • Carefully controlled high-temperature heating
Eastman markets an extensive line of Therminol heat • Multiple heat users within a single process or plant
transfer fluids to match the unique requirements of the • Heating of thermally sensitive materials
many applications and technologies utilizing heat transfer • Heating and cooling with the same system
fluids. No single fluid has the best properties for all • Cooling
applications. Therminol fluids are available for a wide • Operation where minimal operating supervision is available
operating range which extends to a high temperature
of 400°C (750°F), while other fluids are available for Advantages of liquid phase
operations down to –115°C (–175°F). Therminol heat transfer fluids
There are two general types of heat transfer fluid
Therminol heat transfer fluid versus steam
systems—liquid phase and vapor/liquid phase. Liquid Compared to steam, Therminol heat transfer fluids cost less
phase systems operate via transfer of sensible heat to install, operate, and maintain. Low-pressure thermal liquid
(a change in temperature). Vapor/liquid systems transfer systems utilizing Therminol fluids can significantly reduce capital
heat with the heat of vaporization via a boiling condensing costs. The savings in eliminating installation of larger diameter
vapor piping, special vent piping, flash drums, pressure control
cycle. Eastman produces and markets both fluid types in
devices, and boiler feedwater treatment equipment can amount
the Therminol line. This guide is for assisting in the design,
to 25%–50% of the system cost.
operation, and maintenance of liquid phase heat transfer
systems utilizing Therminol fluid. Information on vapor/ A second source of savings is in operation: thermal liquid
liquid phase heat transfer fluids is available through your systems require less maintenance, eliminate heat lost through
draining of steam condensate in supply lines, and do not usually
local Therminol specialist.
require licensed operating personnel when operated in a manner
consistent with the recommendations in this guide (however,
check local codes).

Therminol fluids have minimal potential for corrosion and fouling.

Cost of chemical treatment of boiler feedwater is eliminated, as
www.therminol.com well as the environmental cost of boiler blowdown water disposal.

1
Therminol heat transfer fluid versus TLC Total Lifecycle Care® program
direct fired heating Eastman offers a complete technical service program to assist the
Heat transfer systems utilizing Therminol heat transfer fluid designer and the operator of heat transfer fluid systems utilizing
eliminate the problems associated with direct fired heating. Therminol fluids. These services include:
Heat transfer fluid systems eliminate hot spots which can • Fluid selection guidance
overheat sensitive process material while providing close and • System design assistance
accurate process temperature control. Heat transfer fluid systems
• System commissioning and start-up assistance
also allow the major source of ignition (the heater) to be installed
• System monitoring and used fluids analysis
remotely from the process, reducing fire hazards and improving
plant safety. With heat transfer fluid systems using Therminol • Troubleshooting and operating support
fluids, one heater can provide heat to any number of users. • Technical specialists based around the world
• System audit and leak detection services
In summary, heat transfer fluid systems using liquid phase
• Fluid trade-in program (in some countries)
Therminol heat transfer fluids offer the designer and the
operator the following advantages: • System design/safety seminars

• Simple to design For further information about selection of products or evaluation

• Easy to operate of application, contact your Eastman Therminol heat transfer
• Low maintenance cost fluid specialist.
• Minimal capital cost
Our Technical Assistance toll-free number is 1-800-433-6997.
• Energy efficient
• Eliminates multiple ignition sources
Therminol technical literature
• Flexible operation (heats and cools)
Eastman offers a complete library of technical literature, including
technical data sheets, Safety Data Sheets, system design data, and
more. Much of the information is also accessible through our
website at www.therminol.com.

2
Process design factors
Advantages of proper design System factors
Every thermal fluid system is different. Operating temperatures, Liquid heat transfer is basically heating or cooling an adequate
flow rates, process equipment, system components, and a host of quantity of fluid to a practical working temperature and
other design details vary from system to system. But one thing circulating it to user stations at a rate to control the temperature
remains constant: properly designed and operated heat transfer of the user as required by the process. Thus, in designing a system,
fluid systems are exceptionally reliable and economical. the following requirements should be considered:
• Is the process a continuous or batch operation?
Well-designed systems are safer, start up faster, deliver better
• What is the energy demand and the temperature requirement
on-stream time, use less energy, and require less fluid.
of each energy user? The cooling requirement?
Especially important in selecting the proper Therminol fluid • How much heat transfer area will be practical or available at user
for a particular system are the temperature requirements of its stations, and what heat transfer coefficient can be expected
operation. In any range, the fluids are suited for systems that from the heat transfer fluid and the material being processed at
must deliver uniform heat, precise temperature control, and quick the user heat exchange surfaces?
response to heating or cooling demand.
• Will more than one energy user be on stream at the same time?

While there is nothing profoundly different or highly complicated At the same temperature? At different temperatures?

about a system utilizing Therminol fluid, certain design parameters • What heat losses will be expected in the physical layout of the
must be observed for the system to give good service life, to system? What is the pressure drop?
operate efficiently, and to return all the benefits of heating or • Can older equipment or less-efficient heating systems be
cooling with a nonpressurized liquid. eliminated?
• Are expanded heating requirements probable?
The basic engineering checkpoints of designing a system are
• To what ambient conditions will the system be exposed?
five-fold:
• Are personnel/property/environmental protection controls
1.  The heater—to control heat transfer rate to ensure consistent
adequate?
energy supply with minimal fluid degradation.
2.  The pumps and piping—to provide adequate system A basic starting point is to estimate the energy balances and to
circulation, maintain the heat flux at user stations and to determine the total energy demand of the system. This will guide
ensure proper handling of the fluid. selection of the heater capacity and pump size, determine the
3.  The expansion tank—to provide for fluid expansion, venting, fluid operating temperatures, and indicate the type of Therminol
and positive pump suction head. A properly designed expansion fluid the system will require.
tank reduces difficulties in start-up and contributes to trouble-
free system operation.
4.  The process/safety controls—to ensure safe operation and
effective use of the heating/cooling system.
5.  The materials and construction—to ensure compatibility,
proper layout, and design.

With sufficient heater capacity, good control of flow at user stations,

and compatible materials, a well-designed system can give reliable,
efficient, and precise delivery of heat. Proper selection of fluid and a
clean, moisture-free system allow minimum maintenance and
trouble-free operation.

3
Fluid factors The velocity and the associated turbulence of the circulating
fluid, therefore, is a critical determinant of how much fluid is
Therminol heat transfer fluids are chemically and thermally subjected to the higher temperatures and for how long. The
stable liquids. To achieve optimum fluid life, users should observe differential between the fluid bulk temperature and the film
the recommended bulk and film temperature limits for each temperature is dependent on the fluid velocity over the surface
fluid. These limits are specified for each Therminol fluid on the of the heat source and the physical properties of the fluid used.
individual product data sheet. When not subjected to The maximum recommended bulk fluid use temperature and
contamination, i.e., moisture, air, process materials, etc., or heat film temperature are given in each Therminol product bulletin.
stress beyond their limits, Therminol fluids can give years of Therminol fluids have high specific heat, high thermal
service without significant physical or chemical change. conductivity, high density, and low viscosity, which make them
efficient heat carriers.
Liquid phase Therminol fluids transfer heat by sensible mode
rather than by latent mode as with condensing vapor. Heated In selecting both the heater and the fluid, the maximum fluid
liquid, circulated at reasonable velocities over a heat-using temperature—rather than the average—should be considered
surface, can be a more efficient and more readily controlled and a reasonable safety margin allowed to enable the fluid to
method of heat transfer than pressure or temperature-controlled give the longest practical service life. Therminol synthetic heat
condensing vapor systems. transfer fluids are formulated to provide a strong and efficient
link for both heating and cooling demands.
Therminol heat transfer fluids are designed to have physical
properties that enhance their value in liquid phase heat transfer. Therminol fluids are available for use in a series of temperature
Low vapor pressure and high boiling ranges permit operation at ranges, with fluids capable of operating as low as –115°C
their maximum recommended temperatures without the need (–175°F) and up to 400°C (750°F).
to pressurize the system. The particular chemical compounds in
Therminol fluids have always been recognized as among the
most thermally stable. Fluid sampling
When operating Therminol fluids near their upper temperature
All heat transfer fluids have a time-temperature decomposition
limit, the system should be monitored yearly for fluid quality to
relationship. Decomposition of heat transfer fluid results in the
determine whether corrective actions are required. When
formation of components which are both lower boiling and
operating at temperatures 20°C (50°F) or more below the upper
higher boiling than new fluid. Low boilers should be periodically
operating limit, routine samples should be analyzed biannually.
vented from the system to a safe area (usually through a manual
Fluid samples should be analyzed whenever fluid-related system
vent) from a hot operating expansion tank (see page 8).
problems are suspected. Eastman will perform free sample
Therminol fluids are designed to produce ventable low boilers in
analysis and indicate necessary corrective action required should
the event of decomposition. High boilers are soluble in the fluid
results be outside acceptable values for the fluid.
up to a certain level, and before this level is reached, the fluid
charge should be replaced. The old fluid should be disposed in Special heat transfer fluid sampling kits can be requested
an approved manner or traded in to Eastman.1 through your Therminol fluid specialist by calling 800-433-6997,
or through our website, www.therminol.com.
As with any heat transfer fluid, the design of the system must
take into account the relationship between thermal energy from Note: Most fluid samples should be taken from a flowing line and
the source and the thermal properties of the fluid, fluid velocity, cooled below 93°C (200°F) before placing in a clean sample
and heat transfer surface geometry. The liquid film in immediate container (cooling fluids may require lower sampling temperatures).
contact with the heat source surface (whether electric or fuel
fired) is subjected to higher temperatures than the bulk
temperature of the fluid stream. Minimum film thicknesses are
achieved in fully developed turbulent flow.

1
Fluid trade-in program only available in North America

4
Mechanical design factors
The heater Effect of liquid velocity on film
The heater, either electrical or fuel fired, is a critical component temperature during heating
in designing a heat transfer system with Therminol fluid. With The following illustration shows the effect of fluid velocity on
the proper balance of heating capacity, temperatures, and fluid film temperature and indicates the importance of this heater
velocity, the service life of the heat transfer fluid is increased to design requirement.
the maximum. Again, good service life is only achieved in systems
protected from contamination with foreign material. In electrical heaters, all the heat delivered by the elements
passes into the fluid. The maximum heat flux at the surface of
the heat source and the fluid velocity over it should be in proper
balance to avoid excessive film temperature. As with fired heaters,
careful attention must be paid to achieving turbulent flow
(without stagnation zones) around the heat transfer surfaces to
eliminate hot spots and localized fluid boiling.

In general, Therminol heat transfer fluids can give long service .

life if the maximum bulk and the maximum film temperatures
of the system do not exceed the recommended maximum limits
for the particular fluid and if no contamination or exposure to
oxygen occurs.

Two basic fired heater designs for Therminol heat transfer fluids
are available: the liquid tube and the fire tube types. In liquid High liquid velocity Low liquid velocity
tube heaters, Therminol fluid is pumped through the tubes as it is (Fully developed (Laminar or partially
turbulent flow) turbulent flow)
heated. The fire is outside the tubes. In fire tube heaters, Therminol
fluid flows through the heater “shell” around the outside of the Wall
temp.
fire tubes. Liquid tube heaters are preferred at all temperatures.
At temperatures below 260°C (500°F), fire tube heaters with
a special baffle design can be used to eliminate hot spots.
Heat Heat

Most Therminol fluids are liquid when transferring heat. To avoid

hot spots in the heater, the fluid should be pumped over the
heating surfaces at sufficient velocity so that no area of fluid
stagnation occurs. Since heating is not uniform in fired heaters,
the maximum heat stress conditions must be used to determine
what film temperatures will be encountered. Liquid
Wall film
temp. temp.
Fluid velocities over the heat transfer surfaces must be relatively
high to develop turbulent flow. This helps avoid excessive film
Bulk Bulk
temperatures that may be detrimental to heat transfer surfaces liquid liquid
temp. temp.
and to the fluid. The heater manufacturer should be consulted for
the required flow velocities.
Metallic wall
Liquid film
Bulk liquid

5
Heat transfer coefficients Sealless pumps (magnetically driven and canned motor) are
regularly employed in Therminol fluid systems. Because of
To determine overall heat transfer coefficients for the heating the operating temperatures and range of viscosities often
system, individual coefficients have to be calculated for the heat encountered in Therminol fluid systems, the pump manufacturer
source side and the fluid service side at each user station. For fully should be consulted.
developed turbulent flow through a circular tube with a constant
wall temperature, the average film coefficients for Therminol On pumps with a stuffing box, at least five rings of packing
fluids can be estimated by using a Seider & Tate2 type equation: should be provided, i.e., laminar graphite rings such as Grafoil.3
When a new system is first put into operation, a slight leakage
0.8 0.4 0.16 may be noticed at the pump packing. The pump gland should
hD ⎡ DG ⎤ ⎡ C p ìµ ⎤ ⎡ µ
ì bb ⎤
= 0.022 ⎢ ⎥ ⎢ ⎥ ⎢ ⎥ not be tightened, however, until the system has heated to near
k ⎣ µì ⎦ b ⎣ k ⎦ b ⎣ ìµww ⎦ the temperature of operation.

DG Reynolds number hD Nusselt number Regardless of the type of pump selected, the flow rate should
= = be checked regularly against the pump’s performance when new.
ìµ (dimensionless) k (dimensionless)
To prevent alignment problems and seal leakage, it is important
Cp µ
ì ìµbb to avoid pipe support stresses on the body of the pump. Each
= Prandtl number = Viscosity correction
k (dimensionless) ìµww factor pump should be fitted with a control device to switch off the
heat source in case of pump failure.
In this equation:
h = Film heat transfer coefficient If expansion loops are used in the pump suction piping, they
D = Internal pipe diameter or hydraulic diameter should be installed horizontally.
k = Fluid thermal conductivity at bulk temperature “b”
G = Mass velocity
Cp = Fluid specific heat at bulk temperature “b”
µ
µb
=
=
Fluid absolute viscosity
Fluid viscosity at bulk temperature “b”
Filters
µw = Fluid viscosity at wall (film) temperature “w”
Before starting up a new system, install a wire mesh strainer in
the pump section. These strainer baskets may be removed after
Pumps debris removal from start-up is completed.

Pumps must have sufficient capacity and pressure head to Piping systems should be designed with provisions for the
circulate the fluid at the rate required by the particular installation of a side-stream filter.
installation. For large flow rates, the pump should generally
Filters that have generally been employed for these applications
be of the centrifugal type. Pumps conforming to ANSI B73.1
are glass fiber string-wound cartridges or cleanable sintered metal
or to API Standard 610, for high-temperature service, will usually
filters in the 1-30 micron range.
be suitable. Fluid-cooled bearings and seals are recommended
to extend pump service life. Clean fluids prolong the life of system components, i.e., pump shaft
seals and valve stems. Filtration also reduces fouling and plugging.
For most systems, cast steel pumps are preferred. Pump
manufacturers usually specify that above 230°C (450°F)
a cooled, jacketed stuffing box or a cooled mechanical seal should Materials of construction
be used. Mechanical seals are widely used. Secondary sealing
(excluding heater coils)
with vent and drain glands is recommended to collect fluid
leakage and to provide space for inerting the outside of the seal. Process chemistry is normally used to determine materials of
Inert blanketing of the seal with steam or nitrogen eliminates construction. The majority of metals and alloys normally
oxidation deposit formation which can lead to seal leakage. encountered in high-temperature heating systems can be used
This secondary sealing provides additional safety in the case with Therminol heat transfer fluids.
of sudden seal failure.
Materials of construction are generally selected on the basis
of their suitability for operation throughout the system’s
A modification of the Seider & Tate equation for all liquids except water
2

Trademark of Union Carbide

3
6
temperature range. Mild steel is widely used, but it must be qualified with a high-pressure sight glass at the full range and with a
for low-temperature use (brittle/ductile transition temperature). minimum level switch to shut off the heater and the pump in
the event of accidental fluid loss.
While Therminol heat transfer fluids are compatible with aluminum,
bronze and brass alloys, etc., the use of these metals should be kept As is good design practice with all large components in a heat
to a minimum because of their loss of mechanical strength at transfer system, the expansion tank should be fitted with a
higher temperatures. pressure relief device, such as a relief valve, rupture disk, or vent
traps. These can relieve excessive pressures to prevent damage or
Due to their temperature limitations, nonmetallics (plastics and
rupture of the expansion tank. These devices should be sized to
elastomers) are not recommended for materials of construction in
vent the expansion tank vapor space in anticipation of the most
heat transfer systems.
severe venting condition. Industrial standards for relief devices
and sizing are covered in API Standards 520-527.
Expansion tank and
venting arrangements Pipework
Usually, the expansion tank is installed at the highest point in The piping layout for systems utilizing Therminol heat transfer
the system and is connected to the suction side of the pumps. fluids should be sized to provide the normal required flow rate at
It should serve as the main venting point of the system, as well an economical pressure drop. Because the system will undergo
as provide for system fluid expansion, which can be 25% or more temperature changes, adequate flexibility to relieve thermal
depending on fluid choice and on the operating temperature expansion and contraction stresses is essential. Schedule 40
range. All vent lines should be routed to a safe location. carbon steel pipe (ASTM A53 for welded and seamless or ASTM
A106 for seamless) should be used throughout the system. The
The double-drop leg expansion tank (see Figures A and B on
tendency to leak through joints and fittings is characteristic of
page 8) provides greater flexibility of operation than a single-leg
most organic heat transfer fluids (including Therminol fluids)
tank. From a single-leg expansion tank, venting of noncondensibles
unless these fittings are very tight. Control of piping leaks is
(water, etc.) is often difficult in heating systems as is purging of
especially important since fluid-soaked insulation poses a more
air/water on start-up. A double-leg expansion tank provides
serious hazard than the leaking fluid itself (see section on
uninterrupted flow on start-up and significantly improves the
insulation). The best way to prevent piping leakage is to weld all
venting capability of the system.
connections. Use of threaded fittings is strongly discouraged due
Experience indicates that systems with expansion tanks open to their tendency to leak. Where access is necessary, raised-face
to the atmosphere have fluid contamination problems related flanges with weld neck joint (ANSI B16.5 Class 300) or equivalent
to oxidation and excessive moisture. Therefore, open expansion raised-face flanges are recommended.
tanks should not be employed in systems using Therminol heat
Recommended flange gasketing for high-temperature heat
transfer fluids.
transfer fluid systems is the spiral-wound type conforming to
An effective way of minimizing fluid oxidation is to blanket ANSI B16.20. Standard materials for spiral-wound flange gaskets
the system with an inert gas (e.g., nitrogen) as shown in Figure A. are Type 304 stainless steel and flexible graphite filler. For
When using a nitrogen blanket, moisture should be driven off leak-free performance of spiral-wound gaskets, the following
from the fluid before the gas pressure is set. If this is not practical, points are important: use of raised-face flanges (125 RMS finish)
air contact can be minimized by a cold seal trap arrangement as and alloy steel bolting with copper- or nickel-based thread
shown in Figure B. Low boilers and moisture can collect in the cold lubricants, uniform compression of the gasket during bolt pull-up,
seal trap, so the fluid in the trap should be discarded periodically. and flange faces clear of imperfections and parallel.

The expansion tank should be sized so that it is one-fourth full Other requirements for safe design of piping are found in the
when the system is at ambient temperature and three-fourths full Chemical Plant and Petroleum Refining Piping Code, ANSI B31.3.
when the system is at operating temperature. It should be fitted

7
Expansion tank and cold seal trap For normal operation, valves B, C, and F are closed, and Valves A,
D, and E are open. This arrangement provides normal return flow
For start-up or venting operations, valves B, C, D, and F are opened. to pump suction with an open static head line from tank to
Valve A can be throttled to assure fluid flow through the pump. Bypass line through valve D minimizes thermal siphon to
expansion tank. Valve E should be throttled to limit the inert gas expansion tank.
flow through the expansion tank.

Figure A. Suggested inert gas arrangement for expansion tank

Relief valve
Low-pressure
regulator
Relief valve
Low-pressure Outlet
Inert regulator
gas regulator
E
Inert Outlet
gas F regulator
E HLA Vent to
safe area
LLA F
HLA Vent to
safe area
LLA
Approx. 1/3
full line size
D C B
Approx. 1/3
Catch
full line size pot
D C B
Catch
pot
A Fill line—initial (low point)
Pump
A FillFillline—operating
line—initial (low point)
Pump
Fill line—operating
HLA = High level alarm
LLA = Low level alarm
HLA = High level alarm
LLA = Low level alarm

Figure B. Suggested cold seal trap arrangement for expansion tank

Vent to
safe area
Vent to
Vent to F safe area
safe area
Vent to
F safe area
HLA Cold
seal
LLA tank
HLA Cold
seal
LLA tank

Approx. 1/3 Drain

full line size
D C B Drain
Approx. 1/3
full line size
D C B

A Fill line—initial (low point)

Pump
A FillFillline—operating
line—initial (low point)
Pump
Fill line—operating
HLA = High level alarm
LLA = Low level alarm
HLA = High level alarm
LLA = Low level alarm

8
Insulation Packing
Normal high-temperature insulation, such as calcium silicate, Various types of high-temperature packing have been used to seal
mineral wool, and cellular glass, can be used in Therminol fluid valve stems and pump shafts in high-temperature Therminol fluid
service. However, fluid-saturated insulation is a potential . service. Excellent service life has been achieved through the use
fire hazard at the temperatures often encountered while of graphite-based packing (as long as said packing contains no
operating a heat transfer fluid system. Heat transfer fluids soluble organic binders). Generally, a minimum of five rings of
can exhibit a slow oxidation reaction with air in the presence of packing is specified on valve stems to assure a reasonable seal.
porous insulating materials. Mechanical seals or ring-shaped flexible graphite packing gives the
best service for pumps.
This phenomenon can be minimized through the use of cellular
glass insulation which resists saturation by the heat transfer fluid
due to its closed cell nature. Controls
The following additional suggestions may help minimize the fire Controls for heating systems using Therminol heat transfer

hazard potential in insulation systems: fluids should be installed both on the heater itself and on the
energy-using units.
• Install and maintain a leak-free piping system.
• Reduce the number of flanges and other mechanical joints in Install heater controls to regulate the firing mechanism in
initial system design. direct proportion to the required output. These controls should
• Use suggested piping specifications. increase or decrease the heat input to maintain Therminol
• If a leak develops, remove the insulation and contain and control fluid at the operating temperature required by the energy
the fluid until the leak can be repaired. demand. Small units may be operated satisfactorily by relatively
simple “on-off” or “high-low” controllers. However, units of all
• On vertical runs of pipe where occasional leaks can develop at
sizes will operate more uniformly if equipped with modulating
flanges, install protective tight-fitting caps to divert any fluid
temperature controls.
leakage outside the insulation.
• Install valve stems horizontally or in a downward position so Install user controls to regulate the flow of the heat transfer fluid
that any stem leakage does not enter the insulation. in proportion to the energy consumption of the equipment. In a
• Always consult your insulation supplier and insurance company multiple-user system, separate controls should be installed on
for additional suggestions on reducing fire hazards in insulation. each consuming unit to assure the proper energy delivery.

Valves Fire protection

Cast or forged steel valves with 13-chrome trim are satisfactory Where fire protection is concerned, it is best to consult your
for systems utilizing Therminol fluids. Globe valves with an insurance company for guidance and counsel. Likewise, you will
outside screw (as a protection against high temperatures) should want to discuss your fire safety requirements with qualified
be used throughout the system when tight sealing of Therminol suppliers of fire protection equipment, as selection and sizing
fluids is desired. Gate valves are acceptable for Therminol fluid of this equipment is important to safeguard the installation.
service; however, they should not be relied on to provide reliable
Guidelines that may be followed to improve the overall safety of
positive shutoff.
the installation include the following:
The use of metal bellows valve stem seals is increasing and should 1. The fired heater and other equipment should adhere to the
minimize leakage. spacing guidelines noted in the NFPA 30. This document gives
guidelines for spacing from property lines and important buildings.

2. Where possible, heat transfer systems should be installed in

open structures. Closed structures should have explosion relief
construction and adequate ventilation to prevent vapor
concentration.

9
 3. The design should consider the benefits of a primary and 9. Insulation (in areas prone to leakage) should be of a type
secondary heating loop to isolate the heat transfer fluid. that cannot become saturated with heat transfer fluid. One
example would be cellular glass. Care must be taken to verify
4. Automatic, remotely operated (fail safe) valves and automatic
the insulation material is rated for the system temperature.
pump shutdown should be incorporated to prevent the
The piping system should be designed for combustible fluid
possibility of the system feeding the fire in the event of a tube
service at the rated temperature.
rupture. This shutdown could be triggered by a low-flow
interlock, a low-expansion tank level interlock, a high stack 10. Discharge lines on all heat transfer fluid relief devices should be:
temperature interlock, or other acceptable means. Provisions (a) Routed to a safe discharge to atmosphere (not inside a
should be provided for pressure relief as required. heater room) or routed to an adequate collection system.
(b) If necessary, protected with additional fire protection so
5. Automatic sprinklering is recommended. Considerations
that the fire hazard is minimized at the discharge point.
should include the burner front, relief device discharges,
control rooms, furnace openings, heat transfer fluid piping
systems and vessels, pump locations, escape routes, and Safety controls
operating areas.
In addition to activating controls, the system also must be fitted
Suggested guidelines for fire protection of new fired heater with the proper safety devices to meet local code requirements.
installations are as follows: Knowledgeable equipment manufacturers should be able to
(a) Automatic deluge protection on an area basis (0.3 gpm/ft2). provide guidance on proper safety controls. Safety controls
(b) Areas requiring the automatic deluge protection to should include, but not be limited to:
include grade level, burner firing level, the three external • High-temperature cutoff at the heater outlet­—to shut off
vaporizer walls (where vaporizers are closely spaced), and the burner in the event of an excessive temperature rise.
subsequent levels above the burner level. • Heater low-flow cutoff—to shut down the burner should
(c) Manual fire extinguishers available—Class B. flow rate drop below design rates or should a loss of flow occur
(d) Slope grade so runoff is routed away from equipment. due to pump malfunction or failure. Regular automatic ignition
(e) Supplement automatic systems with 500 gpm (single- controls and flame-failure controls should be included on all
fired unit)—1,000 gpm (multiple furnace) available burners. In wide-ranging firing, an overfire draft control will
capacity for hoses. save heat losses.
• Expansion tank low-level shutdown—to shut off the heater
6. Snuffing steam (or other acceptable media) should be and the pump(s) in the event of accidental fluid loss.
provided on the fire box side of any fired heater.
• Expansion tank high-level alarm—to alert plant operations
A commonly used method of preventing fire in the event of of system leakage into the fluid.
tube rupture in fired heaters is to supply steam or CO2 as a
• Safety relief valves—All safety relief devices in thermal liquid
snuffer into the combustion chamber of the heater. Steam
heat transfer systems should discharge at a point remote from
snuffer systems should employ a trap to avoid slugging the
possible ignition sources and away from areas where danger to
combustion chamber with water when the system activates
personnel exists. Pressure relief devices should be placed on the
or is activated manually. This snuffer system can be
heater outlet, on the expansion tank, and (where appropriate)
automated by the use of an exhaust stack temperature
on system users.
switch, which would energize a solenoid valve and an alarm
• Other safety controls—Electric power failure and instrument
on excessive temperature rise, thus automatically flooding
air failure safety controls also are desirable. In general, a policy
the chamber with a fire-extinguishing agent.
of “fail-safe” instrumentation and control in the designing is
7. Consider remote operation of key equipment/valving with essential, using quality indicating and recording gauges,
manual backup of automated controls. with accurate-reading scales calibrated for the specific limits
of operation.
8. Electrical equipment should be designed to prevent ingress
of heat transfer mists.

10
Typical liquid phase heat systems
System 1—The basic system System 1 is the basic system configuration with a single user
operating at heater outlet temperature. The temperature control
The transfer of process heat as a liquid offers these benefits to valve regulates flow of the hot Therminol fluid to meet the user’s
the installation: temperature requirements. The pressure control valve assures
• Precise heating levels that a minimum flow will be maintained through the heater at
• Closer temperature control at each user station all times. This system has maximum temperature flexibility.
• Minimum cost installations Note also the heater and the pump safety controls and their
connection to the heater flow, the heater outlet temperature,
• Greater operating safety
and the expansion tank low-liquid level sensors.
• Low maintenance costs
User temperature also may be controlled by regulating the fuel
Systems utilizing Therminol heat transfer fluids are characterized
supply to the heater. This method sometimes has a very limited
by their extreme flexibility. A single heater can serve multiple
turndown and should only be used with a continuous process with
“users” operating at the same or different temperature levels.
small load changes. An adequate flow of Therminol fluid must be
The systems can be designed to deliver and to remove heat.
maintained in the heater at all times to satisfy the energy balance
With thermal liquid heat transfer systems, there are few problems and to prevent exceeding the maximum bulk and maximum film
of condensation, pressure drop, and large heat surges associated temperatures of the Therminol heat transfer fluid.
with vapor systems. The four system diagrams on pages 11–14
illustrate a few of the many arrangements of heat users that can
be operated with Therminol fluids.

System 1

Vent to
safe area

Expansion HLA
tank LLA/S

User

Bypass
Vent to
safe area

TIC

TIC
Temperature
control
valve
Flow
meter TI
Safety
controls Pressure
P control
valve

Fuel Heater
Pump

TIC—Temperature indicating controller

TI—Temperature indicator
HLA—High level alarm
LLA/S—Low level alarm/shutdown
∆P—Differential pressure

11
System 2—Heating multiple users
This is the same system as System 1 except several heat users
are connected to the heater, all operating at the same
temperature. To control temperature, each user has a modulating
control valve. A single minimum flow bypass valve is used at the
end of the piping loop.

Note: Refer to System 1 diagram (page 11) for placement of safety

controls and fluid relief devices.

System 2

Expansion
tank

User
No. 2
User
No. 1

Temperature Temperature
control valve control valve

Pressure
control
valve

Pump
Heater

12
System 3—Heating several users This same principle can be used with System 1 when the user
has a very large fluid volume and a small heat load. The main
at different temperatures recirculating pump is sized for the heat load through the heaters
With this arrangement, several heat users at different while the zone pump is sized to recirculate a larger volume of
temperatures may be operated at one time. Each temperature blended Therminol fluid through the user.
zone has its own recirculating pump located at the user inlet with
Both of these arrangements will give excellent temperature
the temperature control valve located downstream of the user.
control, as well as a fast response to system change.
A bypass from the zone pump inlet is connected to the user
outlet. When the temperature control valve is opened, fresh Note: Refer to System 1 diagram (page 11) for placement of safety
high-temperature Therminol heat transfer fluid is admitted to controls and fluid relief devices.
the zone where it is mixed and recirculated.

This blending of hot and cold Therminol fluids gives precise

temperature control at some temperature below heater outlet
temperature.

System 3

User User
Zone Zone
Expansion 1 2
tank

Pump Pump

Temperature Temperature
control valve control valve

High-
temperature Low-temperature Pressure
supply return control
valve

Pump
Heater

13
System 4—Heating and cooling
of a single user
This is a dual system for heating and cooling, using two separate
circulating systems for a common user. The temperature
controller output is connected in a split-range manner to the
cold and hot Therminol fluid control valves. As the output
increases from 0%–55%, the cold valve closes (with a minimum
stop to prevent deadheading the cooling zone pump). As the
output increases from 45%–100%, the hot valve opens. The
pressure control valve maintains a minimum flow through the
heater under all conditions. Even with the slight overlap in the
cold and hot valve ranges, this design operates with a minimum
of interchange between the two circulating systems.

Note: Refer to System 1 diagram (page 11) for placement of safety

controls and fluid relief devices.

System 4

Heat exchanger Cooling

Expansion water
tank
Temperature
control valve—
cooling (with
minimum stop)

Pump

User

Temperature
control valve—
heating

Pressure
control
valve

Pump
Heater

14
Start-up
Suggested start-up procedure uggested start-up procedure
for new systems for new systems
For a new system or one that returns to service after draining, (c) Circulate the Therminol heat transfer fluid through the
the following checkpoints are recommended as guides. They system for about 3 to 4 hours to eliminate air pockets and
are supplemental to those of the heater manufacturers and the to assure complete system fill. Before firing the heater, .
recommendations of heat transfer equipment makers, and are be sure that the Therminol fluid is circulating freely
not intended to supersede or preclude those recommendations. through the entire system.
Generally, they apply to the care of the fluid in all sizes and types
5. Start the heater..
of systems.
(a) Bring the system up to temperature slowly—about 35°C
1. Check safety and control devices:. (63°F) per hour. This should prevent thermal shock to
For proper installation and functioning, be certain that the heater tubes, tube/heater joints, refractory materials, etc.,
range settings are proper for the operation. Manually activate and will allow operators to check the functioning of
the instruments and apply all tests necessary to assure proper instruments and controls. The slow heat-up also will allow
functioning. For protection of the system and for the expected moisture trapped in all sections of the system to escape
long service life of the fluid, it is vitally important that all as a vapor. Inert gas should sweep the expansion tank to
instruments and controls function properly. remove noncondensibles and residual moisture. Hold the
temperature above 100°C (212°F) until no signs of
2. Check for leakage.
moisture remain (e.g., knocking or rattling of pipes,

3. Remove moisture from the system, using dry compressed . moisture from vents, etc.).

air or other suitable means. (b) Bring the system to operating temperature, put the “users”
on the line, and place the expansion tank inerting system
4. Fill the system with Therminol heat transfer fluid. . into operation.
(a) Fill the system with Therminol fluid, with all vents to the
(c) The fluid should generally be analyzed with 24 hours of
expansion tank or atmosphere open for air removal. Fill
plant start-up and annually thereafter. Consult your
the expansion tank to the desired low level. Where needed,
Therminol fluid specialist for specific recommendations
have the steam tracing system operable.
for your system.
(b) Open all valves, then start the main circulating pump in
(d) Check the start-up strainers. If foreign material collects,
accordance with the manufacturer’s recommendations.
the strainer should be periodically removed and cleaned.
Observe the liquid level in the expansion tank, refilling
After several days of operation with no foreign material on
as necessary until the system has been filled. Allow for
the strainer, it may be permanently removed. If the start-up
thermal expansion of Therminol fluid in determining .
strainer is to remain permanently installed, it should be
the cold charge level. The expansion tank should be
tagged for easy identification.
adjusted to 70%–75% full when the hot operating
temperature is reached. Note: The system should be heated and cooled for at least two

S cycles with the screen in place since the resulting expansion and
contraction will loosen mill scale.

15
Operating instructions
Suggested operating instructions Suggested operating instructions
for liquid phase heating systems for liquid phase heating systems
using Therminol® fluids using Therminol® fluids
The following operating suggestions are not intended to 4. Procedure for start-up (hot fluid):.
supersede or preclude those operating instructions provided After an automatic shutdown by the safety controls, fluid
by a heater or a system supplier. should still be above 105°C (221°F).
(a) D
 etermine the cause of the shutdown and rectify the
1. Check safety controls:.
conditions that caused the shutdown.
In addition to activating controls, the heater also should be
(b) R
 un the circulating pump to turn the system volume over
fitted with the proper safety controls to meet local code
a number of times to eliminate any vapor pockets formed
requirements.
while the fluid has remained static in the heater.
2. Start-up temperature precautions:. (c) Start the burner at the low flame setting. When the flame
(a) T
 emperature of fluid at start-up is important; consult your is stabilized, the heater can be turned to full fire.
heater and pump supplier for the maximum recommended
start-up viscosity. This should correspond with the minimum 5. Procedure for shutdown:
permitted fluid temperature. Failure to comply with (a) S hut off burner completely with the circulating pump still
supplier recommendations may lead to equipment damage. operating. Continue to run the pump at full capacity to
(b) If start-up must be made at temperatures below the fluid dissipate residual heat in the heater.
pumpability limit, the fluid should be heated in a safe way, (b) W
 hen the heater has cooled to the manufacturer’s
i.e., with steam or electrical tracing. recommended low temperature, shut off the circulating
(c) O
 ne way of avoiding start-up temperature problems in pump and switch off all heater electrical controls.
cold weather is to keep the system idling at 105°C (c) C
 aution must be exercised during shutdown to ensure
(221°F)—especially for those fluids which can solidify that no area in the system is totally and completely
or become too thick to pump. isolated. This will prevent a vacuum from forming, which
could damage (implode) equipment.
3. Procedure for start-up (cold fluid):
(a) W
 hen the start-up temperature is correct, start the
circulating pump and check the expansion tank level to
see that the Therminol heat transfer fluid is at the proper
cold-start level (usually 25% full). Activate the inert gas
sweeping system at the expansion tank.
(b) S tart burner at the “low” flame setting and continue full
circulation until the bulk temperature of Therminol fluid
reaches 105°C (221°F).
(c) T
 urn heater to full or proceed with the heater manufacturer’s
heat-up schedule.

16
6. Planned maintenance:.
Safe handling and disposal
Regular maintenance inspection schedules should include
the manufacturer’s recommendations for the heater and the Animal toxicity studies and manufacturing experience indicate
components, as well as inspection of the Therminol heat that no special precautions are required in the handling of these
transfer fluid. The following maintenance suggestions are not products at ambient temperatures. Acute toxicity studies indicate
meant to supersede or preclude those maintenance instructions that most of the Therminol heat transfer fluids are practically
provided by the system designs or equipment manufacturers: nontoxic by ingestion of single doses. Although tests suggest
that these materials are probably not irritating to skin, it is good
(a) L ubricate moving parts.
practice to avoid repeated and prolonged skin contact with any
(b) C
 heck operating fidelity and the accuracy of the readings
industrial chemical, heat transfer fluid, or petroleum product.
of safety controls and temperature limit controls.
Vapors or spray mists of the material, on the other hand, while
(c) Inspect heater tubes, burner, and refractory linings.
not dangerously toxic, can give rise to discomfort, and thermal
(d) Periodically service the heater. decomposition caused by excessive heating may generate more
(e) Inspect the fluid cooling at the circulating pump. irritating fumes. Systems should be made as leak tight as possible
(f) R
 epack stuffing boxes according to the manufacturer’s and any spillage absorbed and/or removed. Repairs to leaks of
specification. hot fluid should be carried out under well-ventilated conditions.
(g) Inspect all sealed surfaces, i.e., flanges, valve packings, etc., Extra care is necessary when the system is at high temperature.
for evidence of leakage. Repair leaking areas to prevent more Most repairs and maintenance activities should be performed at
serious fluid loss and to reduce safety hazards. low temperatures.

(h) F luid samples for analysis should be taken within 24 hours More data are available for each product in the Safety Data
of plant start-up and annually thereafter. Consult your Sheets, which are available on request or directly from the
Therminol Fluid Specialist for specific recommendations for Therminol website. While it is believed that Therminol heat transfer
your system. Eastman will provide free sample analysis and fluids pose no serious problems with respect to the environment,
will then indicate the necessary corrective action required as a concerned supplier to the industry, Eastman urges the user
should results be outside the acceptable values for used to maintain a tight system, to correct leakage promptly, and to
fluid. Special heat transfer fluid sampling kits can be exercise care in the handling and disposal of this and all other such
requested through your Eastman Therminol Fluid Specialist products. A consistent maintenance program not only protects the
by calling Eastman technical service at (800) 433-6997 or environment but keeps employees comfortable, the working area
from our website at http://www.therminol.com. clean, and the system running smoothly.

Important warning
Heat transfer fluids are intended only for indirect heating purposes. Under no circumstances should
Therminol® heat transfer fluids contact or, in any way, contaminate food, animal feed, food products, food
packaging materials, pharmaceuticals, or any items which many directly or indirectly be ultimately
ingested by humans. Any fluid contact may contaminate these items or products to the extent that their
destruction may be required. Precautions against ignitions and fires also should be taken with these fluids.

17
Resistance of valves and fittings
A simple way to account for the resistance offered to flow by Example: The dotted line shows that the resistance of a 6-inch
valves and fittings is to add to the length of pipe in the line a standard elbow is equivalent to approximately 16 feet of 6-inch
length which will give a pressure drop equal to that which occurs standard steel pipe.
in the valves and fittings in the line.

Resistance of valves and fittings

Glove valve, open Gate valve 3,000

¾ closed
½ closed 2,000
¼ closed
Fully open
1,000
48 50
42
500
Standard tee 36
Angle valve, open
300 30 30
200 24
Square elbow 22
20 20
100 18
16
Equivalent length of straight pipe, feet

Swing check valve, 14

Nominal diameter of pipe, inches

fully open Borda entrance 50

12
Inside diameter, inches

10 10
30
9
20 8
Close valve bend Sudden
enlargement 7
d/D–¾ 6
d/D–½ 10
5 5
d/D–¼ 4½
Standard tee 4
through side outlet 5
3½
Ordinary 3 3 3
entrance
2 2½
Standard elbow or
run of tee reduced ½ 2 2
Sudden
contraction 1
1½
d/D–¾
1¼
d/D–½
0.5
Medium-sweep elbow d/D–¼
or run of tee reduced ¼ 1 1
0.3
¾
45º elbow
½
Long-sweep elbow 0.1
or run of standard tee 0

18
Steel pipe dimensions
Capacities and weights*
Cross- Circumference, ft,
sectional Inside or surface sq ft Capacity at 1 ft Weight
Nominal Outerside Wall Inside area sectional per ft of length per sec velocity of pipe
pipe diam., Schedule thickness, diam., metal, area, U.S. gal Lb per hr per ft,
size, in. in. no. in. in. sq ft sq ft Outside Inside per min water lb
40 0.068 0.269 0.072 0.00040 0.106 0.075 0.179 89.5 0.25
/8
1 0.405
80 0.095 0.215 0.093 0.00025 0.106 0.0563 0.112 56.0 0.32
40 0.088 0.364 0.125 0.00072 0.141 0.0954 0.323 161.5 0.43
/4
1 0.540
80 0.119 0.302 0.157 0.00050 0.141 0.0792 0.224 112.0 0.54
40 0.091 0.493 0.167 0.00133 0.177 0.1293 0.596 298.0 0.57
/8
3 0.675
80 0.126 0.423 0.217 0.00098 0.177 0.1110 0.440 220.0 0.74
40 0.109 0.622 0.250 0.00211 0.220 0.1630 0.945 472.5 0.85
/2
1 0.840 80 0.147 0.546 0.320 0.00163 0.220 0.1430 0.730 365.0 1.09
160 0.187 0.466 0.384 0.00118 0.220 0.1220 0.529 264.5 1.31
40 0.113 0.824 0.333 0.00371 0.275 0.2158 1.665 832.5 1.13
/4
3 1.050 80 0.154 0.742 0.433 0.00300 0.275 0.1942 1.345 672.5 1.48
160 0.218 0.614 0.570 0.00206 0.275 0.1610 0.924 462.0 1.94
40 0.133 1.049 0.494 0.00600 0.344 0.2745 2.690 1,345.0 1.68
1 1.315 80 0.179 0.957 0.639 0.00499 0.344 0.2505 2.240 1,120.0 2.17
160 0.250 0.815 0.837 0.00362 0.344 0.2135 1.625 812.5 2.85
40 0.140 1.380 0.669 0.01040 0.435 0.362 4.57 2,285.0 2.28
11/4 1.660 80 0.191 1.278 0.881 0.00891 0.435 0.335 3.99 1,995.0 3.00
160 0.250 1.160 1.107 0.00734 0.435 0.304 3.29 1,645.0 3.77
40 0.145 1.610 0.799 0.01414 0.498 0.422 6.34 3,170.0 2.72
11/2 1.900 80 0.200 1.500 1.068 0.01225 0.498 0.393 5.49 2,745.0 3.64
160 0.281 1.338 1.429 0.00976 0.498 0.350 4.38 2,190.0 4.86
40 0.154 2.067 1.075 0.02330 0.622 0.542 10.45 5,225.0 3.66
2 2.375 80 0.218 1.939 1.477 0.02050 0.622 0.508 9.20 4,600.0 5.03
160 0.343 1.689 2.190 0.01556 0.622 0.442 6.97 3,485.0 7.45
40 0.203 2.469 1.704 0.03322 0.753 0.647 14.92 7,460.0 5.80
21/2 2.875 80 0.276 2.323 2.254 0.02942 0.753 0.609 13.20 6,600.0 7.67
160 0.375 2.125 2.945 0.02463 0.753 0.557 11.07 5,535.0 10.0
40 0.216 3.068 2.228 0.05130 0.917 0.804 23.00 11,500.0 7.58
3 3.500 80 0.300 2.900 3.016 0.04587 0.917 0.760 20.55 10,275.0 10.3
160 0.437 2.626 4.205 0.03761 0.917 0.688 16.90 8,450.0 14.3
40 0.226 3.548 2.680 0.06870 1.047 0.930 30.80 15,400.0 9.11
31/2 4.000
80 0.318 3.364 3.678 0.06170 1.047 0.882 27.70 13,850.0 12.5
40 0.237 4.026 3.173 0.08840 1.178 1.055 39.6 19,800.0 10.8
80 0.337 3.826 4.407 0.07986 1.178 1.002 35.8 17,900.0 15.0
4 4.500
120 0.437 3.626 5.578 0.07170 1.178 0.950 32.2 16,100.0 19.0
160 0.531 3.438 6.621 0.06447 1.178 0.901 28.9 14,450.0 22.6
40 0.258 5.047 4.304 0.1390 1.456 1.322 62.3 31,150.0 14.7
80 0.375 4.813 6.112 0.1263 1.456 1.263 57.7 28,850.0 20.8
5 5.563
120 0.500 4.563 7.953 0.1136 1.456 1.197 51.0 25,500.0 27.1
160 0.625 4.313 9.696 0.1015 1.456 1.132 45.5 22,750.0 33.0
40 0.280 6.065 5.584 0.2006 1.734 1.590 90.0 45,000.0 19.0
80 0.432 5.761 8.405 0.1810 1.734 1.510 81.1 40,500.0 28.6
6 6.625
120 0.562 5.501 10.71 0.1650 1.734 1.445 73.9 36,950.0 36.4
160 0.718 5.189 13.32 0.1469 1.734 1.360 65.8 32,900.0 45.3
20 0.250 8.125 6.570 0.3601 2.258 2.130 161.5 80,750.0 22.4
30 0.277 8.071 7.260 0.3553 2.258 2.115 159.4 79,700.0 24.7
40 0.322 7.981 8.396 0.3474 2.258 2.090 155.7 77,850.0 28.6
60 0.406 7.813 10.48 0.3329 2.258 2.050 149.4 74,700.0 35.7
8 8.625 80 0.500 7.625 12.76 0.3171 2.258 2.000 142.3 71,150.0 43.4
100 0.593 7.439 14.96 0.3018 2.258 1.947 135.3 67,650.0 50.9
120 0.718 7.189 17.84 0.2819 2.258 1.883 126.5 63,250.0 60.7
140 0.812 7.001 19.93 0.2673 2.258 1.835 120.0 60,000.0 67.8
160 0.906 6.813 21.97 0.2532 2.258 1.787 113.5 56,750.0 74.7
*Pipe dimensions are taken from ANSI 836.10.
Engineering conversion factors
Multiply By To obtain Multiply By To obtain
atmospheres 14.70 lb/sq in. hp (boiler) 3.3479x104 Btu/hr
atmospheres 760 mm Hg hp (boiler) 9.804 kw
atmospheres 29.92 in. Hg hp hr 2.545x103 Btu
atmospheres 33.90 ft of water hp hr 0.7457 kw hr
British thermal units 3.93x10–4 hp hr inches 2.54 cm
British thermal units 2.930x10–4 kw hr in. Hg 0.03342 atm
Btu/hr 3.927x10–4 hp in. Hg 1.133 ft of water
Btu/(hr sq ft °F) 1.356x10–4 gram-cal/sec cm2°C in. Hg 0.4912 lb/sq in.
Btu/(hr sq ft °F) 2.035x10–3 watts/sq in. °F in. of water 2.458x10–3 atm
(Btu/hr sq ft)/(°F/in.) 3.445x10–4 (gram-cal/sec cm2)/(°C/cm) in. of water 0.07355 in. Hg
(Btu/hr sq ft)/(°F/ft) 0.0173 (watts/cm2)/(°C/cm) kg/cu m 0.06243 lb/cu ft
(Btu/hr sq ft)/(°F/ft) 14.88 (gram-cal/hr cm2)/(°C/cm) kilowatts 1.341 hp
Btu/lb °F 1.0 gram-cal/gram°C kw hr 3.413x103 Btu
Btu/sec 778.2 ft lb/sec kw hr 1.341 hp hr
Btu/sec 1.4147 hp L 0.2642 gal (U.S.)
Btu/sec 1.0549 kw L 1.057 qt (liq)
Btu/sec 107.6 kg-m/sec L/min 15.851 gal/hr
Btu/sq ft 0.2712 gram-cal/cm2 m 3.281 ft
Btu/sq ft 2.712 kg-cal/sq m m 39.37 in.
centimeters 0.3937 in. m/sec 196.8 ft/min
centimeters 0.0328 ft m/sec 2.237 mph
cm Hg 0.01316 atm ounces 28.35 grams
cm Hg 0.1934 lb/sq in. poises 1 gram/cm sec
cm Hg 27.85 lb/sq ft pounds 453.6 grams
cm Hg 136.0 kg/sq m lb of water 0.01602 cu ft
cm Hg 5.353 in. of water lb of water 0.1198 gal
cm Hg 0.4461 ft of water lb/ft hr 0.413 centipoises
cm/°C 0.2187 in./°F lb/gal 0.1198 grams/cm3
cm/sec 1.969 ft/min lb/sq ft 0.01602 ft of water
cm/sec 0.03281 ft/sec lb/sq ft 4.882 kg/sq m
cm/sec 0.036 km/hr lb/sq in. 0.06804 atm
cm/sec 0.60 m/min lb/sq in. 2.307 ft of water
cm/sec 0.02237 mph lb/sq in. 2.036 in. Hg
centipoises 2.42 lb/ft hr lb/sq in.5 1.7 mm Hg
cubic centimeters 0.06102 cu in. lb/sq in. 703.1 kg/sq m
cubic centimeters 3.531x10–5 cu ft refrigeration–std. ton 200 Btu/min
cubic centimeters 2.642x10–4 gal sq cm 1.076x10–3 sq ft
cm3/sec 2.119x10–3 cu ft/min sq cm 0.1550 sq in.
cm3/sec 0.0864 cu m/day sq ft 929 sq cm
cm3/sec 0.01585 gal/min sq ft 144 sq in.
cm3/sec 3.6 L/hr sq ft 0.0929 sq m
cm3/gram 0.01602 cu ft/lb sq in. 6.452 cm2
cm3/gram mol 0.01602 cu ft/lb mol sq in. 6.944x10–3 sq ft
cu ft 7.481 gal sq in. 6.452x10–4 sq m
cu ft 28.32 L sq m 10.76 sq ft
cu ft 62.43 lb of water temperature °C + 273 1.0 abs temp. K
ft of water 62.43 lb/sq ft temperature °C + 17.8 1.8 temp. °F
ft of water 0.4335 lb/sq in. temperature °F + 460 1.0 abs temp. R
ft/min 0.508 cm/sec temperature °F – 32.0 .5555 temp. °C
gallons (Imperial) 1.201 gal (U.S.) tons (long) 1.016x103 kg
gal (U.S.) 231 cu in. tons (long) 2.24x103 lb
gal (U.S.) 3785 cm3 tons (metric) 2.205x103 lb
gal (U.S.) 3.785 L tons (short) 907.2 kg
gal/hr 3.71x10–5 cu ft/sec tons (short) 2x103 lb
gal/min 2.228x10–3 cu ft/sec watts 0.05692 Btu/min
gal/min 0.227 cu m/hr watts 44.26 ft lb/min
gal/min 0.06309 L/sec watts 1.341x10–3 hp
gal/min of water 500.8 lb/hr of water watt hr 3.413 Btu
grams 2.205x10–3 lb week 168 hr
gram-cal 3.968x10–4 Btu week 1.008x104 min
gram-cal/gram 1.8 Btu/lb week 6.048x105 sec
gram-cal/gram mol 1.8 Btu/lb mol years (common) 8.76x103 hr
gram-cal/gram°C 1.0 Btu/lb°F
(gram-cal/sec cm2)/ 2.903x103 (Btu/hr sq ft)/(°F/in.)
(°C/cm)
Average properties of tubes
Diameter Thickness External Internal

Surface Lineal ft Volume or capacity

per of tube per lineal ft Length
lineal per sq ft Transverse Cubic ft United of tube
External Internal BWG NOM Circumference, ft of area Cubic also area States, containing
in. in. gauge wall in. sq ft surface sq in. in. in sq ft gal one cu ft
0.527 18 0.049 0.218 2.616 0.0015 0.011 661
5
/8 0.495 16 0.065 1.9635 0.1636 6.1115 0.193 2.316 0.0013 0.010 746
0.459 14 0.083 0.166 1.992 0.0011 0.009 867
0.652 18 0.049 0.334 4.008 0.0023 0.017 431
0.620 16 0.065 0.302 3.624 0.0021 0.016 477
3
/4 2.3562 0.1963 5.0930
0.584 14 0.083 0.268 3.216 0.0019 0.014 537
0.560 13 0.095 0.246 2.952 0.0017 0.013 585
0.902 18 0.049 0.639 7.668 0.0044 0.033 225
0.870 16 0.065 0.595 7.140 0.0041 0.031 242
1 3.1416 0.2618 3.8197
0.834 14 0.083 0.546 6.552 0.0038 0.028 264
0.810 13 0.095 0.515 6.180 0.0036 0.027 280
1.152 18 0.049 1.075 12.90 0.0075 0.056 134
1.120 16 0.065 0.985 11.82 0.0068 0.051 146
11
/4 1.084 14 0.083 3.9270 0.3272 3.0558 0.923 11.08 0.0064 0.048 156
1.060 13 0.095 0.882 10.58 0.0061 0.046 163
1.032 12 0.109 0.836 10.03 0.0058 0.043 172
1.402 18 0.049 1.544 18.53 0.0107 0.080 93
1.370 16 0.065 1.474 17.69 0.0102 0.076 98
11/2 1.334 14 0.083 4.7124 0.3927 2.5465 1.398 16.78 0.0097 0.073 103
1.310 13 0.095 1.343 16.12 0.0093 0.070 107
1.282 12 0.109 1.292 15.50 0.0090 0.067 111
1.620 16 0.065 2.061 24.73 0.0143 0.107 70
1.584 14 0.083 1.971 23.65 0.0137 0.102 73
1 /43
1.560 13 0.095 5.4978 0.4581 2.1827 1.911 22.94 0.0133 0.099 75
1.532 12 0.109 1.843 22.12 0.0128 0.096 78
1.490 11 0.120 1.744 20.92 0.0121 0.090 83
1.870 16 0.065 2.746 32.96 0.0191 0.143 52
1.834 14 0.083 2.642 31.70 0.0183 0.137 55
2 1.810 13 0.095 6.2832 0.5236 1.9099 2.573 30.88 0.0179 0.134 56
1.782 12 0.109 2.489 29.87 0.0173 0.129 58
1.760 11 0.120 2.433 29.20 0.0169 0.126 59

21
 For more information or to find the sales or technical contact nearest you, visit the “Contact us” page on our website:
www.therminol.com.

North America Latin America Europe/Middle East/Africa Asia Pacific

Solutia Inc. Solutia Brasil Ltda. Solutia Europe SPRL/BVBA Eastman (Shanghai) Chemical
A subsidiary of Eastman Chemical Company A subsidiary of Eastman Chemical Company A subsidiary of Eastman Chemical Company Commercial Company Ltd.
575 Maryville Centre Drive Rua Alexandre Dumas, 1711—Birmann 12— Corporate Village—Aramis Building Building 3, Yaxin Science & Technology Park
St. Louis, MO 63141 U.S.A. 7º Andar 04717-004 Leonardo Da Vincilaan 1 Lane 399 Shengxia Road
São Paulo, SP, Brazil 1935 Zaventem, Belgium Pudong New District
Telephone:
201210, Shanghai, P.R. China
Customer Service, 800-426-2463 Telephone: Telephone: +32 2 746 5000
Technical Service, 800-433-6997 Brazil, 0800 55 9989 Fax: +32 2 746 5700 Telephone: +86 21 6120 8700
Fax: Customer Service, (1) 314-674-7433 Other Locations, +55 11 3579 1800 Fax: +86 21 5027 9229
Fax: +55 11 3579 1833

Although the information and recommendations set forth herein are presented in good faith, Eastman Chemical
Company and its subsidiaries make no representations or warranties as to the completeness or accuracy thereof.
You must make your own determination of its suitability and completeness for your own use, for the protection
of the environment, and for the health and safety of your employees and purchasers of your products. Nothing
contained herein is to be construed as a recommendation to use any product, process, equipment, or formulation
in conflict with any patent, and we make no representations or warranties, express or implied, that the use thereof
will not infringe any patent. NO REPRESENTATIONS OR WARRANTIES, EITHER EXPRESS OR IMPLIED, OF
Eastman Chemical Company MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR OF ANY OTHER NATURE ARE MADE HEREUNDER
Corporate Headquarters WITH RESPECT TO INFORMATION OR THE PRODUCT TO WHICH INFORMATION REFERS AND NOTHING HEREIN
P.O. Box 431 WAIVES ANY OF THE SELLER’S CONDITIONS OF SALE.
Kingsport, TN 37662-5280 U.S.A.
Safety Data Sheets providing safety precautions that should be observed when handling and storing our products
U.S.A. and Canada, 800-EASTMAN (800-327-8626) are available online or by request. You should obtain and review available material safety information before
Other Locations, +(1) 423-229-2000 handling our products. If any materials mentioned are not our products, appropriate industrial hygiene and other
safety precautions recommended by their manufacturers should be observed.
www.eastman.com/locations
© 2016 Eastman Chemical Company. Eastman brands referenced herein are trademarks of Eastman Chemical
Company or one of its subsidiaries. The ® used on Eastman brands denotes registered trademark status in the U.S.;
marks may also be registered internationally. Non-Eastman brands referenced herein are trademarks of their
respective owners.

TF-04B 1/16