Division of Catalytic Industrial Group, Inc.
713 N. 20th Street • P.O. Box 827
Independence, KS 67301
800.835.0557 • 620.331.0750 • Fax: 620.331.3402
E-Mail: sales@bruestcatalyticheaters.com

HotCat spacesaver skid-mounted automatic models HC100 and HC125.

Automated Control Systems

The HotCat Pipeline Heater control package is available on units
beginning with the HotCat 50 model and upwards to the current
largest unit HotCat 2800. HotCat Super Freez-Fiter Models HC-28,
HC-30, HC-56 and HC-86 currently are not available with
automated control options.

All automated controls work in a similar fashion. They have heat
zones, which are added incrementally to satisfy the heating demand
of the gas flowing through the system. The smallest heaters typically
have four zones and the larger heaters range from 12 to 16 zones.
The zoning is somewhat dependant on the voltage power supply
source and application for the larger units.

Each automated unit will come with an integral control panel,
which contains an Allen-Bradley Compact Logix PLC with an
Ethernet interface. This controller can be linked to Owner Controls
with standard supply consumable tags. The HMI contained within
the unit is typically a 6” Allen Bradley Grayscale Panelview Plus
touch screen and contains all the necessary controls to field
configure this heater for most applications. It also provides
operator and maintenance control functions, which allow for
very flexible control capability. Alarm histories, temperature
trending and other helpful screens provide additional
operational information. This interface also provides password
protection to allow it to operate securely on remote locations.

The unit is designed to run in an automated, non-attended fashion
using inputs from RTD sensors installed in the gas stream and
provides, as standard, an input for temperature sensing downstream
of a pressure cut to allow more precise control than most competing
products. There are built in limits to provide for safe operation
and detection of fault conditions over a wide range of operating
situations. The unit can be remotely started and stopped with
standard I/O inputs. More elaborate control and monitoring
choices are available when interfaced with Ethernet capabilities
to Owner designed control systems.

These controls are designed to automatically restart on loss and
restoration of power, so no one has to be dispatched to resume
operation. They also have the ability to interface to Owner
provided UPS power to continue uninterrupted operation,
if this power source is available.

Only the required amount of heat is consumed to maintain the
loads required by the current flowing conditions. It does this
without noise, odor, or any environmental consequences associated
with open flame combustion and glycol, all without an operator
being present.

If an application requires customization, we have standard features,
which work with turbines and high demand loads. We can custom
design or configure the system to meet many client requirements,
if the standard software and hardware configuration does not fully
meet those needs. If wired Ethernet communication is not the
protocol or media required, we can provide customized options,
in many cases. CSA third party approval on the control package
is also available at an extra cost.

Bruest has chosen components for both automation options
that are widely used in SCADA systems worldwide,
particularly utility applications where robust performance
and accurate data acquisition is essential.

Automated HotCat vs. Manual HotCat

Here are the key differences between the automated and manual HotCat systems:

A fully automated unit operates without the need for an opertor to be continually on the premises. This unit has a PLC with A-B controls and software program, allowing unmanned operation of the HotCat heater. This unit can also be controlled remotely.

These are the accessories for fully automated units:

1. Inlet and outlet duel RTDs to monitor temperatures
2. Tube temperature RTD to monitor the skin temperature of the heating vessel
3. PLC, NEMA control panel with Allen Bradley components, operating system and designed software
4. Red Lion color HMI monitor
5. Ashcroft high and low safety pressure switches
6. Power disconnect
7. Inlet and outlet Bimetal thermometers
   

A manual unit requires an operator on site. Controls are limited; heaters are turned on manually, one at a time. Station operator has to be on site to add or remove heaters to control heat output. Power to the heaters is supplied from off site disconnect or a 120V mobile generator to terminal power box on the HotCat Unit.

These are the accessories for manual units:

1. Spirax Temperature Controller
2. Mechanical or electrical high temp safety switch
3. Baso safety valve and thermocouple for each heater, which allows individual zones to be turned on or off as needed.
4. Bimetal thermometer for outlet temperature viewing

HotCat Application Questionnaire

Bruest HotCat gas heaters are protected by
US and Canadian patents.
© 2012. Bruest Catalytic Heaters