STORAGE CALORIFIERS

GMS S T O R A G E C A L O R I F I E R S
Background Information

When domestic hot water is required in volume the GMS range of storage calorifiers offers an ideal solution Stored water is
heated indirectly by a primary medium (via an internal U-tube battery). Alternatively electric immersion heaters offer a clean
and efficient primary heat source.

Factors affecting the choice of storage calorifiers are:-

√ Cost - Storage calorifiers are often the most economical water heating solution.
√ Low Primary Power Requirement- The stored hot water meets high peak demands with
relatively low primary power, keeping the primary supply capital cost lower than in instantaneous
or semi-storage systems.
√ Economical Temperature Control - Simple on/off temperature control is often all that is re-
quired.
√ Reliability - Storage calorifiers are robust and uncomplicated, giving excellent reliability and
availability.
√ Space - An instantaneous water heater may be more compact than a storage calorifier, but
requires a larger primary heat source, negating some of the space saving.
√ Heat Loss - Correct insulation of the calorifier results in low heat loss. Compared to instanta-
neous heaters the low, steady primary heat requirement reduces inefficient boiler cycling. Primary
pipe-work is smaller and loses less heat. Electrically heated storage calorifiers, using off-peak
electricity, give savings in running costs.

Storage Heat-Up Storage Volume and Recovery Time

Type of Building Category Litres Period
Person (Hours) Storage calorifier volume and recovery time determine output.
“Recovery time” is the time the calorifier takes to heat up from cold
Hotel 5* 45 2
under zero demand. Long recovery times require low primary power
and vice versa.
3* 35 2 The tube battery (or immersion heater) is mounted low down in the
calorifier. The contents are heated almost uniformly by natural
School/College Boarding 25 2 convection. During draw-off the calorifier design minimises mixing of
incoming cold water with the hot water above. If draw-off is too high
Day 5 3 the hot water layer becomes exhausted and the water drawn will be
too cool. It is important to select an adequate storage volume to meet
Student Residence 35 3
anticipated demand.
Houses/Flats 45 2 The “CIBSE Guide” gives design curves for storage calorifiers for
various duties with worked examples. Also, as a quick guide, the
Factories/Offices 5 3 figures given in the table below will, in our experience, give good
results. Any sizing table should be used with a “common sense”
Hospital Wards In-Patient 30 1 estimate of the likely demand pattern. For example a business hotel
may have a sharper morning peak demand than a tourist hotel.
Table 1: Typical Hot Water Storage Requirements Available space or boiler power may also limit choice.

Standards
√ GMS Commercial Standard A GMS Commercial Standard calorifier is designed for minimum cost without loss of per-
formance or reliability, based on many years’ experience of calorifier design and construction.

√ BS853 For customers who require a calorifier constructed to an internationally recognised standard. GMS Thermal Prod-
ucts will produce calorifiers to BS853 if required, both BS853 Part 1 & BS853 Part 2. There is scope within BS853 for 3rd
party verification of design and construction. This adds to cost and delivery time, but can be arranged if required.

√ BS5500 For very high working pressures GMS Thermal Products can design and build calorifiers to BS5500. However
BS853 now includes higher pressures so it is not often necessary to resort to BS5500.

√ Other Standards GMS Thermal Products will consider production of calorifiers to other standards. Please contact us with
details.

All our buffer vessels comply fully with the European Pressure Equipment Directive 97/23/EC
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Primary Heat Source: Calculating Average Primary Power:

Steam, Water and other fluids. Assuming a well insulated calorifier and ignoring any heat
losses from primary pipe-work,
√ Steam: Steam condenses in a tube bundle and the latent
Average Primary Power Required,
heat transfers to the stored water. The resultant conden-
sate is at the same temperature and pressure as the
Q = V x 4.18 x (T1-T2) kW
steam. This can cause noise in the condensate main, as
t x 3600
steam “flashes” off the hot condensate after a steam trap.
To cure this problem a “flash bundle” to condense the where: V = Storage Volume (litres)
flash steam can be included in the calorifier if required.
t = Recovery Time (hours)
√ Low Temperature Hot Water (LTHW): Typically 82oC T1 = Required Temperature (usually 65oC)
flow / 71oC return. A common source of primary heat. T2 = Cold Feed Temperature (usually taken
√ Medium Temperature Hot Water (MTHW): Maximum as 10oC)
flow temperature 120oC, maximum working pressure 10.0
BarG Example: Calculate average primary power for a 2000L
√ High Temperature Hot Water (HTHW): Flow tempera- storage calorifier, with a 2 hour recovery time, heating
water from 10oC to 65oC ?
ture above 120oC, maximum working pressure 17.5 BarG
√ Thermal Oils: These allow high temperatures at low pres- Average Power Required
sure. Primary connections should be flanged and have oil- Q =2000 x 4.18 x (65-10) = 64 W
resistant gaskets. Copper degrades some oils so the tube 2 x 3600
bundle may have cupro-nickel or stainless steel tubes.
√ Refrigerant: Superheated refrigerant can be cooled (and
condensed if required) to heat a calorifier between com- Calculating Peak Primary Power:
pressor and condenser. A back-up system should be pro-
vided for times when the calorifier is unavailable. Multiply Q by the correction factor F obtained from the
√ Waste Heat: If waste heat is only available at low tem- chart below.
peratures a separate top-up heat supply will be required.
We can advise on the best match of calorifier to waste E.G. for LTHW primary:
heat availability and hot water demand.
82oC Flow / 71oC Return,
Secondary cold feed 10oC, Flow 65oC.
Calculating the primary power requirement - Average primary temperature = (82 + 71)/2 = 76.5oC
fluid primaries. From the chart, F = 1.8
From the example above, average power Q = 64 kW,
Peak Primary Power Required = 64 x 1.8 = 115 kW
At the start of the heat up period, when the calorifier
contents are cold, heat transfer is higher than at the end. To
E.G. for Steam primary:
achieve design performance, primary power must match this.
When the primary fluid is water or thermal oil, flowrate and
Steam at 3 BarG (143.75oC) after control valve, Secon-
flow temperature remain constant while return temperature
dary cold feed 10oC, Flow 65oC.
starts low then rises during heat-up. For steam, temperature
Average primary temperature = 143.75oC
remains constant but flowrate starts high then decreases dur-
From the chart, F = 1.25
ing heat-up.
From the example above, average power Q = 64 kW,
Peak Primary Power Required = 64 x 1.25= 80 kW
Fig 1. Peak Power Correction Factor (F)

NOTE:
Standard U-Tube bundles are externally finned
for high performance. If requested, or for steam
primary fluid, or if told that the water is hard,
F plain U-tubes may be offered.

Space must be allowed for withdrawal of the

tube bundle for inspection. If withdrawal dis-
tance is not known assume full length. We will
be pleased to advise withdrawal distances for
specific units.

Average Primary Temperature oC

GMS S T O R A G E C A L O R I F I E R S

Materials of Construction Some System Considerations

√ Solid Copper - type CS. Copper is virtually impervious to Secondary Vent. Calorifiers can be supplied for open
attack by aggressive water. In the few areas where water is vented or unvented (sealed) systems. In open vented
known to attack copper the calorifier can be protected by a systems the vent pipe allows escape of air from the calo-
sacrificial aluminium anode. This leaves a protective coat- rifier, ingress of air during drain-down, thermal expan-
ing on the copper and does not need replacing. The copper sion of water and (in the event of control failure) escape
thickness required for a calorifier increases with pressure of steam from the calorifier. The vent pipe should never
and diameter. Above a certain size copper lined steel is be blocked. No valves should be fitted to it except,
more economical. where more than one calorifier share a common vent,
special 3-way vent/bypass valves. These ensure that the
√ Copper-Lined Steel - type CL. Carbon steel lined inter- calorifier is always open to atmosphere.
nally with copper. None of the steel is in contact with the Unvented systems. When it is not practical to fit a vent,
water. The steel gives great strength, the copper prevents an unvented system will be used. Certain additional pre-
corrosion. Special techniques have been developed to en- cautions and equipment are necessary to ensure that an
sure a close fit of copper to steel, to allow thermal expan- unvented system will be safe:
sion and contraction of the lining and to test the lining. Fit-
ted as standard with an anti-vacuum valve to prevent par- √ The calorifier must be designed for the maximum
tial vacuum damaging the lining. Even so care should be
working pressure - after thermal expansion of the
taken during drain-down to ensure adequate venting of the
water.
calorifier. The cold feed must never be restricted during
√ A Temperature (or combined Pressure/Temperature)
draw-off.
Relief Valve must be fitted in case of control failure.
√ Galvanised Steel - type GS. Hot dip galvanising deposits √ An automatic air vent.
a zinc layer which provides excellent protection against cor- √ An anti-vacuum valve
rosion if the water is hard. Galvanised calorifiers should not
√ An expansion vessel.
be used with copper pipe-work or soft water. The copper
causes electrolytic action and releases particles of copper
A water booster set may be required to provide water at
which deposit in the calorifier, causing localised electrolytic
the required pressure and flowrates.
action and corrosion. Soft water prevents formation of a
Secondary Return. Most large systems circulate DHW
protective scale. The copper tube bundle rapidly gets a film
around a building and back to the calorifier. This ensures
of scale because of its higher temperature. This prevents
that all draw-off points have hot water available quickly.
electrolytic action and corrosion. For added protection a
The pipe-work should be lagged and the re-circulation
magnesium sacrificial anode can be fitted. This must be
rate minimised to reduce heat loss. The heat loss should
replaced when exhausted. Also the copper tube bundle can
be taken into account when selecting a calorifier.
be electro-tinned which reduces the electrochemical poten-
tial.
Thermal Insulation Options
√ Stainless Steel - type SS. Stainless steel calorifiers can
suffer chloride attack at welds. Most water supplies contain
enough chloride to cause problems. Heat treatment after all √ Type MA Consists of 50mm mineral wool with
welding is completed solves the problem but is expensive. dimpled aluminium cladding. This gives good
If the water supply is chloride free (e.g. de-ionised water) thermal insulation and a quality finish. For some
then stainless steel calorifiers will be acceptable. installations there will be a high risk of damage to
the factory fitted insulation. In these instances it is
√ Glass/Polymer Lined Steel - type PL. An alternative to preferable to insulate on site.
copper-lined steel. The lining was developed for arduous
conditions in industrial processes. It is generally more resis- √ Type UF For sizes up to 1000 litres or 250 kg dry
tant to abrasion, chemical attack and impact damage than weight (approximately) we can offer Type UF
traditional glass linings. If damage occurs the surrounding semi-rigid urethane foam insulation. This is
coating will not be affected and the damage can be re- sprayed on in a standard thickness of 25mm (up
paired. In the lining process minute glass flakes are com- to 60mm on request). Its ozone depletion poten-
bined with a special polymer, applied to the steel, cured tial (ODP) is zero, it does not support combustion
and electrically tested. The lining is WRC approved for use and it resists water penetration. Uniform thick-
with hot water. ness is not guaranteed.
Other materials available on request. Please contact our sales For a high quality appearance we recommend type
department with any enquiries you may have. MA insulation.

Materials

Type CS CL GS SS PL
Shell Copper Copper-Lined Galvanised Steel *2 Stainless Steel Glass-Lined
Battery Tubes Copper (Finned Copper (Finned Copper (Finned Stainless or Copper Stainless or Copper
or Plain) or Plain) or Plain, Tinned) (Finned or Plain) (Finned or Plain)
Tubeplate Brass Brass Galvanised Steel Stainless or Brass Stainless or Brass
Primary Header Mild Steel Mild Steel Mild Steel Mild Steel or Stainless Mild Steel or Stainless
Steel Steel
Insulation 50mm Mineral Wool Slabs & 0.9mm Stucco Aluminium Casing
W A T E R H E A T I N G M A D E E A S Y

Notes: Connections
*1 - Immersion Heater option (14) is for back-up
of primary (steam, water etc) heat source. Ref Description Size Ref Description Size
1 Primary Inlet Varies 9 Safety Valve Varies
*2 - Galvanised calorifiers are not suitable for
2 Primary Outlet Varies 10 Pressure Gauge ⅜”
use with soft or acidic water and is not to be
used in conjunction with copper pipework 3 Secondary Flow Varies 11 Vent (Optional) Varies
4 Secondary Return Varies 12 Pressure Gauge (Steam Only) ⅜”
*3 - Connections in boxes are flanged,
otherwise connections are screwed 5 Cold Feed Varies 13 Anti-Vacuum Valve (Optional) Varies
6 Drain Varies 14 Immersion Heater (Optional) *1 Varies
7 Control Thermostat 1” 15 Bursting Disc (If Specified) Varies
8 Thermometer ¾” 16 High Limit Thermostat (Optional) 1”

Size D L C Main Connection Sizes

Litres (mm) (mm) (mm)
3 4 5 6 11 13
230 508 1270 200 1¼” 1” 1¼” ¾” 1” ¾”
270 508 1473 200 1¼” 1” 1¼” ¾” 1” ¾”
360 610 1372 200 1¼” 1” 1¼” ¾” 1” ¾”
450 610 1753 200 1½” 1” 1½” ¾” 1” ¾”
500 686 1473 250 1½” 1” 1½” ¾” 1” ¾”
550 686 1727 250 1½” 1” 1½” ¾” 1” ¾”
600 762 1448 300 1½” 1” 1½” ¾” 1” ¾”
700 762 1678 300 1½” 1” 1½” ¾” 1” ¾”
800 762 1930 300 1½” 1” 1½” ¾” 1” ¾”
900 813 1956 300 1½” 1½” 1½” ¾” 1¼” ¾”
1000 915 1753 300 2” 1½” 2” 1” 1¼” 1”
1200 915 2086 300 2” 1½” 2” 1” 1¼” 1”
1500 1067 1956 375 2” 1½” 2” 1” 1¼” 1”
1750 1067 2175 375 2” 1½” 2” 1” 1¼” 1”
2000 1067 2388 375 2” 1½” 2” 1” 1½” 1”
2250 1220 2133 450 65 2” 65 1” 1½” 1¼”
2500 1220 2388 450 65 2” 65 1” 1½” 1¼”
3000 1220 2845 450 80 2” 80 1” 1½” 1½”
3500 1372 2743 450 80 2” 80 1” 1½” 1½”
4000 1372 3081 450 80 2” 80 1” 1½” 1½”
4500 1524 2768 450 80 2” 80 1” 1½” 1½”
5000 1524 3048 450 80 2” 80 1” 2” 1½”

Vertical Orientation 5500 1524 3302 450 100 65 100 1” 2” 2”

6000 1600 3429 450 100 65 100 1” 65 2”
7000 1676 3302 450 100 65 100 1” 65 2”
8000 1676 3657 450 125 65 125 1½” 65 2x2”
9000 1676 3911 450 125 65 125 1½” 65 2x2”

Horizontal Orientation