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Calorifiers
As a specialist calorifier manufacturer Heatxforce offer great expertise in designing and manufacturing heating calorifiers to suit all circumstances. We provide new-build and installation, re-tubing and can reverse engineer an existing bundle replacement, carry out crop backs, and replace eroded carrier plates.
The calorifier heat exchangers can be bespoke and designed and built for a specific application. However, we also carry out extensive repair work and upgrades. For example; replacement tube bundles, re-tubing, shells and channel replacement, plugging and repairs. As well as insurance preparation and remedial works.
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Calorifiers Explained
What is a Calorifier?
A calorifier could be either storage calorifier, a hot water storage tank that heats water indirectly via a heating coil or a plate heat exchanger. Similarly, a non-storage calorifier on a heating system which heats water directly as the external primary heat source is used to heat the heating hot water on the way around the heating circuit.
What is a Calorifier used for?
A calorifier is used to heat water for either heating or DHW (Domestic Hot Water) system. They comprise of a vessel into which a tube bundle is bolted. Steam or hot water is circulated through the 'U' shaped tubes of the tube bundle, this gradually heats the water in the vessel. Calorifiers are used in buildings such as hospitals, schools, colleges, offices, public buildings etc.
What are Calorifiers made of?
The 'U' tubes are usually made from copper as it has a high thermal conductivity. The copper tubes often have an extended external surface, designed to increase the heat transfer surface. The tubes are joined to a tube plate, usually using a tube expanding tool.
Calorifiers versus Plate Heat Exchangers
Calorifiers are steadily being replaced by plate type heat exchangers due to the smaller footprint and because quite often there is no need for a vessel as in the case of instantaneous hot water skids. Nevertheless, there are still many Calorifiers in service.
At Heatxforce we are here to help, so don’t be afraid to ask questions. Please call us on 0121 711 1908 or email us at info@heatxforce.co.uk
Calorifier Services
Specification & Design
Bespoke Calorifier Manufacture
System Requirements
When designing a calorifier, it’s crucial to accurately determine the heat load and ensure precise temperature control. Mismatched sizes or poor temperature regulation can lead to inefficiencies.
Heatxforce takes the guesswork out by offering in-depth analysis of your system’s demands, ensuring the calorifier’s size and capacity perfectly align with your process. Our design also incorporates advanced temperature control features, preventing fluctuations that could disrupt your operations.
Steam Pressure and Quality
Operating at the correct pressure and using high-quality steam are essential for effective heat transfer. Poor steam quality can cause serious issues like water hammer or inefficiencies in heating.
Heatxforce designs calorifiers to withstand your system’s maximum operating pressure and optimises them for superior steam heat transfer, reducing risks and ensuring smooth performance.
Sizing and Capacity
An undersized calorifier could lead to delays in hot water supply, while an oversized one wastes energy. Whether your system requires hot water storage or instantaneous heating.
Heatxforce carefully sizes your calorifier based on peak demand, ensuring that hot water is always available when needed while minimising energy waste.
Heat Exchanger Design
Choosing the wrong materials or exchanger type can lead to premature wear or poor heat transfer.
Heatxforce selects only the highest quality, corrosion-resistant materials like stainless steel or copper for your calorifier’s heat exchanger. Whether your application requires a shell and tube, plate, or coil exchanger, we provide the ideal solution for long-term performance and efficiency.
Energy Efficiency
Heat loss is a common issue that can drive up energy costs. By integrating top-tier insulation and condensate recovery systems.
Heatxforce designs calorifiers that minimise energy waste and recover valuable steam condensate, resulting in a significant reduction in operational costs and an overall increase in system efficiency.
Water Quality Management
Scaling and corrosion can dramatically affect calorifier efficiency and lifespan.
Heatxforce addresses this with tailored water treatment solutions, ensuring your calorifier is protected against scaling from hard water and corrosion due to aggressive water chemistry. This results in reduced maintenance costs and longer equipment life.
Safety Features
Safety is paramount in any steam system. Overpressure conditions and the risk of Legionella are key concerns.
Heatxforce incorporates pressure relief valves and anti-Legionella designs into every calorifier system, keeping your operations safe by preventing overpressure scenarios and safeguarding water hygiene.
Maintenance and Accessibility
Ease of maintenance is often overlooked during design.
Heatxforce ensures that all critical components, including the heat exchanger and storage tank, are easily accessible for routine cleaning, inspection, and repairs. Our designs emphasise longevity and durability, meaning fewer breakdowns and extended system life.
Compliance
Regulatory compliance is non-negotiable. Whether you’re navigating BS EN, ASME, or PED standards.
Heatxforce ensures that every calorifier we design meets or exceeds local and national codes. Additionally, our designs are crafted with environmental regulations in mind, minimising emissions and maximising energy efficiency.
Custom/Specialist Applications
Industries like food processing, pharmaceuticals, and healthcare often require unique solutions tailored to their specific needs.
Heatxforce specialises in creating custom calorifiers for these industries, ensuring strict hygiene and temperature control. In high-pressure systems, our team ensures that your equipment is designed to handle even the most demanding conditions with precision and reliability.
Installation & Commissioning
Design and Sizing
Ensuring that the calorifier is properly sized to handle the specific heat load of your system and that the flow rates for both steam and water are compatible with the calorifier’s design is crucial. Incorrect sizing can lead to inefficiencies and operational issues.
Heatxforce's team conducts a thorough assessment of your system’s thermal energy requirements and calculates the appropriate size for the calorifier. We also verify that steam and water flow rates align with the calorifier’s specifications, ensuring optimal performance and efficiency in your system.
Material Compatibility
The materials used in the calorifier must be suitable for the steam conditions and water quality to prevent corrosion and ensure durability. Additionally, the components must be rated to withstand the system’s pressure and temperature.
We carefully select high-quality, corrosion-resistant materials tailored to your specific steam conditions and water quality. Heatxforce also ensures that all components meet the required pressure and temperature ratings, thus extending the lifespan of your calorifier and maintaining system integrity.
Installation Location
The chosen location for the calorifier installation should facilitate easy access for maintenance and provide sufficient space for both installation and future service needs. Inadequate space or difficult access can complicate maintenance and repairs.
Our experts assist you in selecting an optimal installation site that allows for easy access and meets space requirements. This careful planning ensures that maintenance and operation are straightforward, minimising potential operational
Piping and Connections
Proper integration of the piping system with the calorifier is essential to avoid issues such as misalignment or inadequate support. Additionally, installing isolation valves is important for facilitating maintenance and allowing for emergency shutdowns.
Heatxforce ensures precise alignment and secure support for all piping connections, integrating them seamlessly with the calorifier. We also install isolation valves to provide convenient access for maintenance and enable safe emergency shutdowns, enhancing overall system reliability.
Safety Considerations
Implementing effective safety measures such as pressure relief valves and temperature controls is critical to manage overpressure and prevent overheating, which can pose risks to the system and personnel.
We install pressure relief valves that are calibrated to handle potential overpressure situations, and we implement advanced temperature controls to regulate and prevent overheating. These measures ensure safe and stable operation of your calorifier system.
System Commissioning
Proper commissioning of the calorifier requires specialised knowledge to ensure correct setup, calibration, and testing. Inadequate commissioning can result in inefficient operation or system failures.
Our experienced technicians handle the complete installation and commissioning process, including detailed calibration and thorough testing. We verify that the calorifier operates as intended under various conditions, ensuring reliable and efficient performance.
Compliance and Standards
Adhering to local regulations and industry standards is essential for legal compliance and operational safety. Ensuring that equipment is certified to meet these standards is also important.
Heatxforce ensures that all installations comply with relevant local regulations and industry standards. We verify that your calorifier and associated equipment are properly certified, providing you with assurance of regulatory compliance and safety.
Commissioning and Testing
Effective commissioning and thorough testing are vital to ensure that the calorifier is properly set up and performs as expected. Inadequate commissioning can lead to system inefficiencies and potential failures.
Heatxforce provides comprehensive commissioning services, including detailed setup, calibration, and rigorous testing. We check the system under various conditions to confirm it operates efficiently and reliably. Our experts make any necessary adjustments to ensure optimal performance and long-term stability of the calorifier.
Maintenance and Support
Ongoing maintenance is crucial to ensure the long-term reliability of your system, and adequate training for personnel is necessary for effective operation and upkeep.
We offer comprehensive service agreements that include regular maintenance and support to keep your system running smoothly. Additionally, we provide training for your team to ensure they are well-equipped to operate and maintain the system effectively.
Overhaul & Repair
Limescale Build Up
Over time, mineral deposits like limescale build up inside the calorifier, reducing heating efficiency and potentially causing overheating or reduced hot water output.
Heatxforce’s Overhaul Service tackles limescale build-up by performing a thorough descaling process, restoring your calorifier to peak efficiency. By removing mineral deposits, we help you maintain optimal heating performance and prevent long-term damage.
Corrosion
Corrosion, particularly inside the heat exchanger or on the shell, can lead to leaks or system failure, compromising the overall structure of your calorifier.
Through our specialised Repair Service, Heatxforce identifies and rectifies corrosion issues with precision. We offer targeted repairs to address internal and external corrosion, using protective coatings and materials that extend the life of your calorifier, preventing leaks and costly system failures.
Leaks
A cracked or damaged heat exchanger can result in leaks, reducing efficiency and causing water damage or contamination within the steam system.
Heatxforce’s expert technicians are equipped to repair or replace leaking heat exchangers. Our Overhaul Service ensures that any compromised components are fixed or upgraded, safeguarding the integrity of your system and restoring its efficient operation.
Faulty Temperature Control
Malfunctioning temperature controls, such as faulty thermostatic valves or sensors, cause inconsistent water temperatures, leading to inefficient heating or potential system shutdowns.
Heatxforce offers precise diagnostics and swift repairs for faulty temperature control systems. We recalibrate or replace malfunctioning components to ensure consistent and safe temperature regulation, preventing scalding risks and enhancing overall system reliability.
Pressure Relief Valve Malfunction
A malfunctioning pressure relief valve can fail to release excess pressure, leading to dangerous pressure build-up that may damage the calorifier or, in extreme cases, cause an explosion.
Safety is a top priority at Heatxforce. Our Repair Service includes the testing and replacement of pressure relief valves to ensure proper functioning. We make sure your system operates safely, maintaining optimal pressure levels and preventing catastrophic failures.
Insufficient Steam Supply
Blockages, valve issues, or low steam pressure can hinder the calorifier’s ability to heat water effectively, leading to subpar performance.
Our expert technicians at Heatxforce will assess and resolve any steam supply issues. Whether it’s a blocked valve or low-pressure problem, our Overhaul Service optimises your steam supply for uninterrupted and efficient water heating.
Condensate Issues
Poor condensate removal can result in water hammering, excess moisture, and inefficient heat transfer, all of which can damage the calorifier.
Heatxforce’s engineers specialise in resolving condensate issues through improved drainage systems and moisture control. Our Repair Service ensures efficient heat transfer, preventing moisture buildup and protecting your system from unnecessary wear.
Air Vent Blockages
Blocked or malfunctioning air vents prevent the release of trapped air, reducing heating efficiency and causing uneven temperature distribution.
Heatxforce’s Overhaul Service includes cleaning and repairing air vents, ensuring that trapped air is effectively released. This boosts your system’s heating efficiency and ensures an even temperature output throughout the calorifier.
Insulation Damage
Damaged or degraded insulation around the calorifier can lead to heat loss, decreasing energy efficiency and driving up operational costs.
Our comprehensive Overhaul Service includes insulation checks and repairs. Heatxforce replaces damaged insulation with high-quality materials to minimise heat loss, improve energy efficiency, and reduce your operational costs.
Maintenance & Service
Scale Buildup
Over time, hard water causes limescale buildup inside the calorifier, reducing heat transfer efficiency and forcing your system to work harder to meet temperature demands. This not only raises your energy consumption but can also shorten the lifespan of your equipment if left unchecked.
Our professional descaling and cleaning services ensure your calorifier continues to operate at peak efficiency. Heatxforce’s skilled technicians use advanced, non-invasive descaling techniques to remove limescale safely, restoring your system’s performance. With routine maintenance, we help you reduce energy costs and prolong the life of your equipment, avoiding expensive, premature replacements.
Corrosion / Erosion
Corrosion and erosion are silent killers in calorifiers and steam systems, gradually weakening tanks and pipes. Corrosion typically occurs due to water quality issues or material degradation, while high-velocity steam and water can cause erosion over time. These problems can go unnoticed until a serious breakdown occurs, leading to costly repairs or even full system failure.
Heatxforce employs cutting-edge techniques like ultrasonic thickness testing to detect early signs of corrosion and erosion. Our proactive inspection services catch these issues before they escalate, saving you from sudden failures and high repair costs. We provide targeted solutions to mitigate corrosion and erosion, keeping your system running smoothly for years to come.
Steam Trap Failures
Steam traps play a critical role in maintaining system efficiency, but when they fail—whether by staying open or closed—they can lead to significant energy loss or, worse, dangerous system conditions like water hammer. Diagnosing the problem is not always straightforward and often requires expertise to avoid a full system shutdown.
Heatxforce offers comprehensive steam trap testing and servicing. Our team uses advanced diagnostic tools to detect trap failures quickly, ensuring they’re functioning optimally. With our expert maintenance, we help you avoid steam wastage, prevent damage from water hammer, and maintain system efficiency, all while minimising downtime.
Thermostatic Controls and Calibration
Thermostatic controls and temperature sensors in your calorifier can lose accuracy over time, leading to poor temperature regulation. This can affect not only energy efficiency but also the safety and comfort of hot water systems.
Our specialists perform regular calibration and testing of thermostatic controls to ensure precise temperature management. Heatxforce’s services keep your system’s performance in check, ensuring it operates efficiently and safely at all times. This results in energy savings, better system reliability, and fewer temperature-related service disruptions.
Ventilation
In any pressurised steam system, safety relief valves are essential for preventing dangerous overpressure situations. If these valves malfunction due to blockages or wear, the system could experience uncontrolled pressure buildup, potentially leading to hazardous situations or equipment damage.
At Heatxforce, we provide detailed inspection and servicing of all safety relief valves, ensuring they remain fully operational under the most demanding conditions. Our technicians are trained to identify potential issues early, perform routine valve replacements, and ensure compliance with safety regulations, giving you peace of mind that your system is safeguarded against dangerous pressure surges.
Water Quality Management
Poor water quality is a hidden but major contributor to many steam system failures. High levels of hardness or improper pH balance can accelerate scaling, corrosion, and fouling, leading to inefficiency and damage over time.
We implement comprehensive water treatment programs designed to optimise water quality. Heatxforce monitors your system for pH, hardness, and other crucial factors, applying the correct chemical treatments to protect against scale and corrosion. This proactive approach extends the life of your equipment and keeps your calorifier running efficiently, helping you avoid costly repairs caused by water-related damage.
Insufficient Maintenance Schedules
A poorly coordinated maintenance schedule can lead to missed inspections, neglected components, and unplanned system failures. Steam traps, valves, and other essential parts may not receive the attention they need, resulting in inefficiencies and unexpected downtime.
Heatxforce works with you to develop a tailored maintenance schedule that ensures all parts of your steam system—boilers, calorifiers, steam traps, and valves—receive timely and thorough inspections. Our proactive maintenance planning helps reduce the risk of failures, keeps your system performing at its best, and minimises the impact on your operations.
Heat Exchanger Efficiency
Over time, fouling, scaling, or corrosion can reduce the efficiency of the heat exchanger inside the calorifier. This leads to higher energy consumption as the system struggles to maintain desired temperatures, and often requires intensive cleaning or disassembly to restore efficiency.
Heatxforce provides regular heat exchanger cleaning and maintenance services that improve energy transfer efficiency. Our technicians carefully disassemble, clean, and reassemble your heat exchanger to restore optimal performance. We focus on minimising downtime while ensuring your calorifier continues to operate at peak capacity.
Steam Pressure / Temp Control
Inconsistent pressure and temperature in a steam system can result in inefficient heat transfer and potential damage to equipment downstream from the calorifier. This is particularly challenging in older systems or those experiencing fluctuating demand.
Heatxforce utilises advanced diagnostics to maintain consistent steam pressure and temperature throughout your system. We fine-tune your system for optimal performance, reducing the risk of damage while improving overall efficiency, even during periods of fluctuating demand.
Regulatory Compliance/Certification
Calorifiers and steam systems must comply with a host of regulations related to pressure vessels, safety, and energy efficiency. Failure to stay up-to-date with certifications and compliance can lead to costly penalties and safety hazards.
Heatxforce offers full regulatory compliance services, from pressure vessel inspections to safety valve certifications. We stay on top of industry regulations and standards, ensuring your system is always compliant. Our certified technicians conduct the necessary testing and documentation to keep your operations running smoothly and safely.
Gasket and Seals
Over time, the gaskets and seals in your steam system can wear out, leading to leaks and reduced system efficiency. If not properly maintained, compromised seals can cause significant performance and safety issues.
Heatxforce’s maintenance team regularly inspects and replaces worn gaskets and seals to ensure your system’s pressure integrity. Our thorough checks and timely replacements prevent leaks, improve efficiency, and keep your steam system running smoothly.
Monitoring and Automation
Modern calorifiers often include automated monitoring and control systems that, if not maintained properly, can malfunction or provide inaccurate readings. This can lead to inefficiency or system failures.
Heatxforce provides expert servicing for your monitoring and automation systems, ensuring they work correctly and provide accurate data. Our technicians have the training and software tools necessary to maintain and update these systems, ensuring your steam system operates efficiently and with minimal downtime.
Energy Efficiency and Heat Recovery
An inefficient calorifier can lead to significant energy losses, increasing operational costs over time. Without regular energy audits and heat recovery solutions, your system could be wasting valuable resources.
Heatxforce offers comprehensive energy efficiency audits to identify where your system can save energy. Our heat recovery solutions help you capture and reuse wasted heat, reducing your overall energy consumption and operational costs, all while improving system performance.
Downtime Management
Unplanned system shutdowns due to failures are costly and disruptive to your operations. Predictive maintenance is key to minimising these unplanned events but requires advanced monitoring and skilled technicians to analyse system data effectively.
Heatxforce implements predictive maintenance strategies using cutting-edge monitoring technology. Our experienced team can analyse system data to identify potential issues before they cause breakdowns. With Heatxforce, you’ll minimise unplanned downtime, keeping your operations running smoothly and cost-effectively.
Codes, Standards & Certifications
Heatxforce build pressure equipment in accordance with PD5500 and ASME VIII Pressure vessel codes whilst conforming to the European Pressure Equipment Directive (PED) and UKCA Pressure Equipment Safety Regulations (PESR), which are mandatory inspection requirements applicable to pressure vessels and systems.
Our welding procedures are in accordance with ISO 15614-1 and ASME IX.
Welder qualifications are in accordance with ISO 9606-1 and ASME IX.
All of our welding related qualifications are certified by TUV Nord.
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