Catalytic Heater Replacement

This client began by wanting a quote for 16 heaters that did not achieve the temperature ranges needed. JDI Industrial Services partnered with RL Kunz to determine that the gas heaters need replacement, proper tuning, and placing.

We then coordinate a two-day shutdown with the client to remove the old heaters and replace them with the new ones. Two mechanical experts and one journeyman electrician perform lock-out-tag-out (LOTO) for both gas and electrical components, so that the work is done safely.

This part ensures not only that there is safety for our people, but also to completely stop any chance of an explosion. This facility has active natural gas and propane lines that if not properly shutoff during the work, can explode from the slightest static or sparks.

After safety, our mechanical team removes all access panels, disconnects the gas lines, while JDI’s electrician disconnects the electrical connections for the 16 units.

To ensure the maximum efficiency of a Cata‑Dyne™ catalytic heater, we install it with the heating surface positioned plus or minus 45° from the vertical plane at a height of no more than 8 ft.

JDI’s mechanical contractors prepare themselves for projects by studying product manuals and corresponding with the client and suppliers to overcome any installation challenges.

The team then works to remove the 16 heaters from the assembly, then we installed the new units, and reinstalled the access panels.

Prior to JDI installing these new units, the manufacturer had to rent an alternative heat source to raise the temperatures in the room to cure the products.

When installing or working with these catalytic heaters, you need to understand how they work. Infrared energy travels in straight lines from the face of the Thermon Cata‑Dyne™ heater covering approximately 160° of an arc and is inversely proportional to the square of the distance.

The heater should therefore be mounted as close as practical to the object requiring heat for maximum temperature rise. A minimum of 28″ (710 mm).

Our mechanical and electrical team then reconnected all the gas lines and power, then began testing the gas and electrical connections to make sure they were working.

Finally, the team tests the units to make sure that the new heating elements are reaching the necessary temperature.

• 16 Thermon Cata‑Dyne™ Catalytic Heaters Installed
• Electrical Terminations on 200 and 400 AMP Service Panels
• Gas Line Termination and Restart
• Reconnects for Electrical Service
• Industrial Mechanical Services for Start-Up & Testing
• Increased heating exchange temperature

The client said about JDI’s work that, “the room is now at the optimal temperature, and we are thankful to have JDI helping us manufacture what our customers need.”

This was JDI first project at the facility, and we are grateful that since performing exceptionally for them they have given us more project opportunities.

The client was originally unaware that we offer more than mechanical and electrical and are having us quote other facilities projects.