How Are Hot Water Sets Used?

Hot water sets typically utilize boilers to create either steam or hot water to be used in different processes around your plant. This type of modular machine is used in a number of applications-anywhere from closed-loop utility water heating to continuous clean in place duties. The type, size, configuration of the valves and heat exchanger varies upon these applications. Hot water sets utilize a series of shutoff and modulating valves to feed a precise quantity of steam through shell & tube or plate style heat exchanger(stainless or carbon steel) to execute the process.

Hot Water Sets can be used in a vast variety of industries. Offered are two types of applications whether it be a closed-loop or a continuous duty. Within a closed-loop system, the water is recirculated through the hot water set to be used again and again as the heating media. In a closed-loop scenario, the water that is pulled through the heat exchanger will be claimed by a specific process and not return back through the system.

Thermaline hot water sets are designed to be freestanding with adjustable ball feet, or fixed mount with provisions to bolt to a frame. Most models have the ability to have provisions for lifting and transportation. Frames are constructed to a standard design but also can be built to customer specifications.

What Comes Standard with a Hot Water Set?

Close approach temperatures, precision control, and dependability all come standard on every Thermaline hot water set. Each hot water set is designed around your process, closely matching the steam characteristics with the thermal demand for optimal performance, but still providing the power needed for startups and cleaning processes. Thermaline hot sets can be modified to meet the needs of the end user. From full control panels, pumps, condensate traps and steam control valves; most components can be modified based on the process and customer preference.

Hot water sets are either closed loop, or a continuous flow design. Closed loop designs would be utilized for things such as HTST/UHT loop water, utility water or jacketed tanks. Whereas the continuous flow design would be for CIP, batch heating, hose stations or instant hot water. To view design options for hot water sets, access our Thermaline portal and request a quote.

Installing Hot Water Sets

When installing a hot water set, we urge clients to provide sufficient clearance to allow for servicing of the steam components, pumps, heat exchanger and valves. In addition to sufficient clearance, an adequate foundation for the unit (so it does not settle and impose excessive strains on either the frame or attached components) is very important. Foundation bolts must be set to allow for setting inaccuracies.

Further, as we look at foundations, the hot water set should be set up so that pipe connections can be made without forcing. While small forces may be inevitable, at least they can be accommodated for, if necessary. A user can also install additional valves, vents, or by-passes in the piping system to allow further inspection and repairs.

We advise that any water hammering and mechanical vibrations be eliminated, or minimized, as best as possible. For additional safety, most hot water sets come with pre-installed steam pressure relief valves, but the user will need to install any required safety devices not provided with the hot water set.

Hot Water Sets: Maintenance & Cleaning

Maintenance is a crucial part to ensuring the overall functionality of any hot water set. We recommend interior and exterior inspections of the unit at regular intervals, to avoid a decrease in performance.

Our Thermaline Cross Contamination Tester (CCT) can identify both internal and external leaks from the heat exchanger. For external leaks, we follow disassembly/assembly procedures required to repair or replace, as necessary. Internal leaks, which are more difficult to detect, can also cause intermixing of fluids.

Before starting any operations, we recommend the entire system be cleaned and inspected for foreign material.

In general, heat exchangers are subject to fouling or scaling, and should be periodically cleaned. Any scale coating or a light sludge on their surfaces can reduce thermal efficiency – whether from the product side, or the steam side. When does your unit need a cleaning? If you notice an increase in pressure drop and/or reduction in performance, we recommend a cleaning.

Prior to cleaning, any unit must be locked out, de-pressurized, at ambient temperature and drained. Heat exchangers are designed to be chemically cleaned in place.

Operating a Hot Water Set

When operating a hot water set, it’s important to take into account a few key factors related to its components. It is important to be aware that all surfaces can become extremely hot while in operation. Before operating a hot water set, it’s important to consider any build documentation for special operating instructions and be aware of all emergency shut-off valves along with emergency shut-off procedures. Local safety and health regulations must be considered before operating.

In addition to operating procedures, an improper start-up or shutdown sequence can cause potential leaking, so it’s something to be mindful of when operating these units. More specifically, during start-up, open all vent valves (and leave these open) until all passages are filled with fluid (purged of air). Fluid should be introduced in a way that minimizes expansion - this accounts for flow rate adjustments being made slowly to avoid any pressure surge, or water hammer. Water hammer can considerably damage equipment.

Just as with start-up, system shutdown operations should also minimize different expansions, so steam must be shut off to cool the loop.

Hot water sets should not be subjected to potential or abrupt temperature changes. For example, this might mean not suddenly introducing hot fluid into a cold unit, or vice versa.

A hot water set is pressure-tested before leaving the manufacturer’s shop in accordance with specific standards. While this is the case, some normal contracting of the gasketed joints can occur between testing in the manufacturer´s shop and installation at the job site. Therefore, all external joints may require retightening after installation and, if necessary, after the system has reached operating temperature.

How Thermaline Does it Differently

For nearly 30 years, our team of engineers has manufactured heat transfer solutions made in the USA, and distributed worldwide. We work with production plants all over the World: Spanning across multiple industries, from food processing, dairy, beverage, brewery, distilleries, and cannabis facilities. We work to tailor products for your specific needs, and take pride in building robust, and innovative, equipment.

Thermaline is the industry standard in heat exchanger engineering, and we are certified by 3-A and ASME. All of our products meet stringent consumer safety standards and energy consciousness.

Have questions for us? You can easily request service or testing or find a distributor, but please feel free to reach out to us directly to see how we can best help you.