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Operating Bruest Catalytic Heater

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For 61 years, Kerr Engineered Sales has represented Bruest Catalytic Heaters, providing flameless, infrared catalytic heating solutions for the natural gas industry.

This article has a general overview of catalytic heater operations, applications and troubleshooting tips.

The safest, most efficient alternative wherever flameless heat is required, Bruest Catalytic Heaters are found in heating applications along the gas network starting from the well head to the end user. Bruest leads the industry in engineering and manufacturing reliable, cost-efficient, green systems to prevent freeze-ups in critical metering and regulating equipment. Manufactured in Independence, Kansas, the catalytic heaters are used to heat meter buildings, platforms and pipelines.  

KERR customers who have Bruest Catalytic Heaters count on our practical experience of how to start and operate the heaters. For operating new heaters, or ones that are decades old, our Application Specialists are on the ground to answer questions and provide support to ensure that the heaters are safe and working optimally.

Catalytic Heater Fundamentals

Bruest HOT CAT at a Town Border Station

Catalytic heaters produce flameless, infrared radiant heat. Bruest heaters cause natural gas to release its energy at a much lower temperature with a catalyst. The natural gas auto- ignition temperature is between 1200 - 1400 degrees Fahrenheit.

Bruest heaters operate at temperatures of around 900F-900F (426C to 483C.)

It’s not magic.. it’s an Exothermic chemical reaction.

bruest heaters are rated for hazardous locations

FREEZ-FITER with a Regulator

Bruest Catalytic Heaters are rated for operation by FM and CSA for operation in Class 1 Division 1 and 2 operation as well as ATEX for European applications. The catalytic heaters can be fueled with either Natural Gas or LPG.

  • CSA Class I Div 1 or FM Class I Div 2

  • Catalytic Pads require little to no maintenance

  • No moving parts

Thomas Kerr starting a Dual Coil Freez-FITER at a Compressor station

Freeze-FITER applied in front of an instrument preheats the gas

Cody Smith troubleshooting a HOTCAT at a regulator station in Virginia.

Daryl Smith diagnosed that the 11 yr old HOTCAT needed new heater pads.

BASIC BRUEST HEATER OPERATION START UP STEPS

  1. Apply electric power – do not remove until the final step

  2. Wait 15 minutes

  3. (a) Thermocouple senses the catalytic temperature.
    (b) Activate the safety valve to introduce fuel gas

  4. Wait an additional 15 minutes

  5. Remove the electric power

Maintenance and Trouble Shooting

There are no moving parts in a Bruest catalytic heater. Maintenance is minimal. The face of the heater (the catalyst) should be protected when cleaning in the area, as high pressure air or water can damage or destroy the catalyst.

When the heater is not in use, it should be stored where dirt and other materials will not collect on the catalyst surface. To prevent contamination or the possibility of insect or rodent damage to the catalyst during the summer or any long period out of service, heaters should be wrapped in plastic film or similar material.

Trouble Shooting CHECKS

  • HEATER POSITION - Check the gas supply. Is the pressure too high, or too low?

  • ELECTRIC START UP - Do you have the correct voltage? Are the cables too long? Are any of the cables cut?

  • PREHEATING - Did you preheat for 15-20 minutes as recommended? If it is the first time of the year running the heater, preheat a bit longer. An insufficiently preheated heater can shut off unexpectedly

  • THERMOCOUPLE CHECK - 10-15 mv. Do you have the correct Thermocouple?

  • VALVES - Check the Baso valve and check the Thermostatic Gas valve.

  • START UP COIL - Did you check the resistance on the start up coil?

  • FUEL GAS PRESSURE - Check that the Fuel gas pressure is sufficient. The heaters require 3.5” WC / 8.7mBar. A variance of +/- 0.5” wc / 1.2mBar are okay

  • TEMPERATURE CONTROLLERS - When using temperature controllers, make sure that the low fire bypass has sufficient fuel gas pressure. A Minimum of 1.5” WC / 4.4 mBar IS required.

  • SULFER CAUTION - If there is sulfur in the fuel gas, it can cause the heater to fail prematurely. The length of service will depend on the concentration and duration of operation. Bruest offers sulfur filters.

COMMON ISSUES & SOLUTIONS

CLEANING & PROTECTION

Bruest Heaters should be adequately protected from the weather and elements. Excessive moisture or wind can cause the heater to cease functioning. Check to see if the Pad is dirty.

  • Heaters should be cleaned only with soft, feather like devices to gently brush off any debris on the heater face.

  • Never use compressed air to clean the heaters.

Get Bruest Brochure

For additional Bruest Catalytic Heater support, training, maintenance or troubleshooting, contact us to speak with KERR’s Application Specialists.

Bruest Catalytic Heater Installation & Operation Guide

Kerr Engineered Sales Company has been representing leading pipeline repair and performance companies in Eastern US since the company was founded in 1952. Seventy two years later, the company is a third generation family run business serving customers with the highest quality service and support.


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