THERMINOL INFORMATION BULLETIN NO.

Solutia Inc.
® 4
Pub. No. 7239124B
P.O. Box 66760 (Supersedes 7239124A)
St. Louis, Missouri 63166-6760
(314) 674-1000

TM

HEAT TRANSFER SYSTEM EXPANSION TANK DESIGN

The design of the expansion tank in a liquid Purpose of the Expansion Tank
phase heat transfer system using Therminol® heat in a Heat Transfer System
transfer fluid or other organic fluids is an important
As the term implies, the main function of the
parameter in the total system’s successful operation.
expansion tank in a heat transfer system is to provide
An expansion tank correctly installed and maintained
for fluid expansion, which can be greater than 25%
can contribute to increased fluid life along with lower
of its original volume depending on the fluid used
maintenance associated with the various mechanical
and the operating temperature.
components of the system, such as pumps, gaskets,
seals and heaters. A properly designed expansion Since the tank is usually installed at the highest
tank can eliminate many problems from the initial point in the system, it also can serve as the main
startup through everyday operation of the heat venting point of the system for excess levels of low
transfer system. boilers and moisture which may accumulate in the
heat transfer fluid. The highest point installation also
The following discussion will explore generally
creates positive head pressure to the pump’s inlet,
the purpose and design of an expansion tank in a
providing flooded pump suction with uninterrupted
heat transfer system. However, a qualified engineering
flow of fluid to the user station. A simplified drawing
firm should be consulted in connection with the design
showing a suggested positioning of the expansion
of an actual heat transfer system, since considerations
tank in a heat transfer system is labeled Figure 1.
outside the scope of this bulletin may be critical.

Figure 1
The Basic System*

*NOTE: This information does not constitute an express or implied warranty. See NOTICE on the back of this bulletin.
Expansion Tank Design Parameters Under normal operating conditions, valves A
and C are open, and valves B, D, E and F are
There are several basic design parameters which
closed. To add make-up fluid to a system in opera-
should be considered part of every heat transfer
tion, valve D should be used. This provides minimum
system’s expansion tank so that the maximum benefit
upset to an operating system. Any time make-up
can be obtained from the tank relative to overall
fluid is added to an operating system, normal safety
system operation.
precautions should be observed because of the high
Sizing temperatures associated with an operating heat
The expansion tank should be sized so that it is transfer system.
25% full at ambient temperature and 75% full at
The initial fill of a system should be made through
normal operating temperature. This sizing should
valve E with valves B, C and F open. This is the most
cause positive fluid pressure to the pump’s suction
efficient way of forcing air out of the system.
side during system startup and should minimize the
The expansion tank should be the primary point
vapor space in the tank during normal operation.
in the system for venting moisture and low boiling
Fluid expansion between two temperatures can
degradation products from the system. New systems
be calculated by dividing the fluid’s density at the
almost always contain some water either from
lower temperature by the density of the fluid at the
hydrotesting or from atmospheric condensation
higher temperature — i.e., the density of Therminol®
during construction. This moisture must be removed
66 at 40˚F is 8.47 lb./gal. and changes to 6.72
during system startup or pump cavitation will occur.
lb./gal. at 600˚F. Thus the expansion of Therminol
In order to use the expansion tank as a vent, valves
66 is 8.47/6.72 = 126% of the original volume at
A, D and E should be closed, while valves B, C and
40˚F when heated to 600˚F. Therefore, an expan-
F should be open. System temperature should be
sion tank for a 1,000-gallon Therminol 66 system
gradually raised to 300˚F-350˚F. Once all evidence
operating between 40˚F and 600˚F should be sized
shows that venting has stopped (steam plume disap-
for 260 gallons of expansion. Since this expansion
pears), valve A should be opened, and then valves
represents 50% of the tank volume (the volume
B and F should be closed. If low boilers accumulate
between 25% and 75% full), the expansion tank
in the fluid, this procedure should be repeated;
should be 520 gallons in size.
however, in this case the expansion tank should
Double Drop Leg and Valving be allowed to reach full system temperature before
The expansion tank should be located at the highest opening valve A.
point in the system with a double drop leg piping
Instrumentation
arrangement as is shown in Figure 2. If the only
In general, a policy striving for “fail-safe” instru-
purpose of the expansion tank was to provide for
mentation in the designing of the expansion tank, as
fluid expansion, a single drop leg would be sufficient;
well as the other components of the heat transfer
however, the expansion tank also provides the best
system, is essential. The expansion tank should be
point for system venting. In order to properly vent a
equipped with both high and low level alarms along
heat transfer fluid system, the expansion tank must be
with a low level switch to automatically shut off the
capable of full system flow. The lines to and from the
heater and pump in the event of accidental fluid loss.
expansion tank should be sized to take full system
Pressure relief devices should be incorporated in the
flow at startup conditions.
expansion tank’s design with possible discharges
of fluid directed to areas away from personnel and
sources of ignition. A high temperature sight glass also
should be installed as a visual backup for level sensors.
 INFORMATION BULLETIN
Figure 2
Inert Gas Arrangement for Expansion Tank*

*NOTE: This information does not constitute an express or implied warranty. See NOTICE on the back of this bulletin.

Inert Gas Blanketing of the expansion tank, preventing the entrance of

air and moisture which can adversely affect fluid
All organic heat transfer fluids, including
life. An uninterrupted supply of inert gas, usually
Therminol fluids, undergo oxidation when exposed
nitrogen, controlled by pressure regulators for both
to air. This fluid oxidation causes the vast majority
inlet and outlet flow is necessary to obtain this pro-
of solids formation and fouling, which lessen heat
tection. A pressure relief valve also is required to
transfer efficiency and impair mechanical seal func-
protect the expansion tank from overpressure due
tion. The rate of insolubles formation is dependent
to regulator failure, fire and other causes. Pressures
on the amount of air exposure and temperature.
used should be kept as low as possible inside the
The usual source of air infiltration in a heat transfer
expansion tank to minimize inert gas usage.
system is through the expansion tank.
Maintaining a positive pressure slightly over atmos-
An effective method of minimizing fluid oxidation
pheric barometric pressure is all that is necessary
is to blanket the expansion tank with an inert gas,
to prevent air and moisture from entering the tank.
such as nitrogen or CO 2, or with natural gas. Figure
A manual vent valve also should be installed to
2 also details a suggested arrangement for inert gas
facilitate purging of the expansion tank’s vapor
blanketing of an expansion tank.
space if it becomes necessary.
The purpose of inert gas blanketing is to main-
tain a non-reactive atmosphere in the vapor space
Cold Seal Trap and moisture-containing air will be allowed to enter
the expansion tank during periods of fluid level fluctu-
Inert gas blanketing of the expansion tank is
ations. Low boilers and moisture can collect in the
generally the most effective way of minimizing fluid
cold seal trap, so the fluid in the trap should be
oxidation. But when this option is not possible, there
drained and discarded periodically.
is another, less reliable arrangement, utilizing a cold
seal trap. Figure 3 illustrates a typical cold seal trap The primary short fall of any cold seal system is
on an expansion tank. the turnover of fluid between the main system and the
cold seal tank during “in-breathing.” Care should be
Precautions should be taken to ensure that the
taken to minimize this effect by proper sizing of the
cold seal tank fluid level does not drop below the
cold seal tank and the vent lines.
dip tube. When this happens, the seal is broken,

Figure 3
Cold Seal Trap Arrangement for Expansion Tank*

*NOTE: This information does not constitute an express or implied warranty. See NOTICE below.

For more information: call toll free 800-433-6997

visit our Web site – www.therminol.com

NOTICE: Although the information and recommendations set forth herein (hereinafter “Information”) are presented in good faith
and believed to be correct as of the date hereof, Solutia Inc. makes no representations or warranties as to the completeness or
accuracy thereof. Information is supplied upon the condition that the persons receiving same will make their own determination
as to its suitability for their purposes prior to use. In no event will Solutia Inc. be responsible for damages of any nature what-
soever resulting from the use of or reliance upon Information or the product to which Information refers. Nothing contained here-
in is to be construed as a recommendation to use any product, process, equipment or formulation in conflict with any patent,
and Solutia Inc. makes no representation or warranty, express or implied, that the use thereof will not infringe any patent. NO
REPRESENTATIONS OR WARRANTIES, EITHER EXPRESS OR IMPLIED, OF MERCHANTABILITY, FITNESS FOR A PARTICULAR
PURPOSE OR OF ANY OTHER NATURE ARE MADE HEREUNDER WITH RESPECT TO INFORMATION OR THE PRODUCT TO
WHICH INFORMATION REFERS.

Solutia ® Therminol is a registered trademark of Solutia Inc.

P.O. Box 66760 © Solutia Inc., 1999. All rights reserved.
St. Louis, MO 63166-6760 Printed on recycled paper
Tel: (314) 674-1000 Litho in U.S.A.