ABOUT
Introduction
The Over-the-Side Immersion Heaters provide an adaptable and cost-effective method of heating for those industries that can only install the heaters from above the tanks or containers. The heaters are manufactured to be suspended from the upper portion of the tank. The direct heating of Liquid, Oil and all other process fluids inside the tank can be accomplished quickly and efficiently. They position the heating elements directly inside of the tank, eliminating any possibility of the tank requiring cutting, drilling, or welding to install the heater. In addition, the Over-the-Side Immersion Heater offers an additional advantage of the ability to easily replace the heater without having to empty the tank.Over-the-Side Immersion Heaters are an excellent choice for retrofitting or modifying existing heaters. These are manufactured in a variety of designs to ensure proper heating distribution throughout the tank volume. The heating elements are made from stainless steel, INCOLOY, and Copper and are designed for use in a variety of industrial applications such as Chemical Processing, Manufacturing, and the Petroleum Industry.
About Over the Side Immersion Heater
The Over-The-Side Immersion Heaters are a type of heater that is mounted at the top of a tank with heating elements that have a variety of different shapes, including L-shaped and O-shaped. The purpose of these shapes is to distribute heat evenly throughout the tank. The heated portion of the element will be in contact with the liquid and the terminal enclosure and cold portion of the element are above the rim of the tank.The Over-The-Side Immersion Heaters function like electric resistance heaters, utilizing nichrome wire twisted in a helical pattern and insulated with magnesium oxide and encased in a corrosion resistant sheath (nickel/chromium), allowing the heaters to produce watt densities of 60 watts per square inch and voltages of 600 volts AC.
Benefits of Over the side Immersion heaters
- Maintain structural integrity – without tank modification or welding.
- Easily maintain and replace without needing to drain the entire tank.
- Customizable L-shape and O-shape configurations for maximum coverage.
- Element-to-fluid direct heat transfer.
- Element housing materials (stainless steel, INCOLOY, copper, titanium) provide compatibility with fluids.
- Scalable power output – up to 50 kW – for different thermal loads.
- Thermocouples, RTDs, or digital temperature controllers work with all element products.
- Installations save costs because they can eliminate the need for costly tank modifications.
- Adjustable immersion depth of the element accommodates for changes in the fluid level.
Applications of Over-the-Side Immersion Heaters
- Heating of crude oil, asphalt, and lubricating oil for the petroleum industry.
- Chemical processing of plating and degreasing in bath processes.
- Maintenance of tank temperatures in the large storage.
- Heating fluids (heat transfer oils) & thermal transfer fluid systems.
- Temperature regulation of paint and coating industries.
Key Factors to Think About When Selecting OTS Immersion Heaters
- Use of Sheath Material:304/316 Stainless Steel for corrosive fluids, Copper for water, Incoloy for extreme corrosion, and Titanium for highly corrosive environments—selected based on fluid compatibility.
- Watt Density:Watt density (up to 60 W/in²) should be determined based on the fluid’s viscosity and heat transfer characteristics to prevent element burnout.
- Designing Heated Length:The heated length must remain below the minimum fluid level to avoid overheating and potential heater failure.
- Total Power Requirement:Calculate the required wattage by multiplying the fluid mass by its specific heat and the desired temperature rise, then add estimated heat losses.
- Voltage Configuration:Select an appropriate AC voltage (120–600 VAC) that matches the available electrical supply infrastructure.
- Terminal Enclosure:Specify suitable enclosure standards such as IP23, IP66 (waterproof), or ATEX (explosion-proof) based on application and environmental conditions.
- Advanced temperature controls:Use thermocouples, RTDs, or thermostats along with compatible controllers for accurate temperature monitoring and heater control.
- Heater Configuration:Depending on tank geometry, heaters can be designed in “L” or “O” shapes.
- CTA: See our blog on immersion heater selection for additional information.
Why Tempsens for Over-the-Side Immersion Heaters?
Tempsens has been manufacturing high-quality Over-The-Side-Mount Immersion Heaters, with the highest standards set by ISO 9001:2015 and ISO 14001:2015, since our founding in . With NABL-accredited manufacturing facilities, equipped with NABL Accredited Testing Laboratories and Certification Experts, we are able to create custom-designed heating systems to meet customer requirements and comply with applicable International Standard Certifications such as ASME, IECEx, ATAEX, UL, BSI, and PESO standards.
Conclusion
Over the Side Immersion Heater is your best option if you require a top-mount design without having to modify your tank.The versatility of the heater has provided a solution for all types of industries requiring this type of heater for their viscous fluids, corrosive chemicals, and products that are temperature sensitive. Selecting the proper sheath material, watt density, and control system for your application allows you to achieve efficient and reliable heating in different industrial applications.
FAQ
Frequently Asked Questions
Find answers to frequently asked questions related to Over the Side Immersion Heater.
Common sheath materials include 304 and 316 stainless steel for corrosion resistance, INCOLOY for severe corrosive environments, copper for clean water applications, and titanium for highly corrosive chemical solutions. The heating element of the heat exchangers has nichrome (80/20) coils that utilize magnesium oxide insulation.
Over-the-side immersion heaters attach on top of tanks without requiring threaded openings, while screw plug heaters need threaded (NPT) fittings on tank walls. Over-the-side designs provide more heated length and coverage area, making them suitable for larger tanks.
Establish a schedule to routinely check for scale buildup on heating elements; ensure that the heating element is submerged sufficiently in the liquid; visually verify electrical connections; test the electrical insulation; and clean the outer surface of the heater sheath regularly to optimize heat transfer capability.
This unit is well suited for applications involving open-top tanks, vessels that have no access from the side walls, retrofitting existing systems, large container size, and processing systems operating at atmospheric pressure, storing petroleum products, handling chemicals and heating viscous fluids where draining the tank is not practical.
