Secrets For Improving Electric Immersion Heater Lifespan

Immersion heaters are the beating heart of all sorts of industrial processes. As such, your heater is an important investment. Learn how to protect that investment with Wattco’s inside secrets on improving electric heater lifespans.

Electric immersion heaters are already built to last. They have simpler designs than fossil fuel heaters and avoid the wear and tear of a combustion engine.  Still, the right care and set up can significantly improve their longevity.

Using the Right Wattage

When it comes to watts, more isn’t always better. The important factor is getting the right wattage. In space heating, for example, heating a large room it takes a lot of energy. Maintaining that temperature, however, requires a much lower energy output. Choosing a high wattage may help during the heat up phase, but is an unnecessary waste for maintaining the temperature.

Raising the temperature too quickly can lead to warping over time, reducing the lifespan of a heater. Controlling the wattage and heat distribution to appropriate levels for the application results in a longer-lasting heater.

Tight Connections

For an immersion heater to operate efficiently and last longer, it’s important to maintain tight connections. Over time groove and bore integrity can deteriorate through erosion, compression or warping.

These faults make for a less efficient heat transfer. As a result, the heater works harder to achieve temperature, shortening its lifespan and increasing operational costs.

Preserving these connections starts with the installation. Making sure the initial fit is tight will reduce the damage over time to the grooves and bores. As well, regular maintenance should include cleaning and checking connections. Replace or repair damaged connections to ensure optimal heater efficiency.


One of the big advantages of purchasing heaters from manufacturers who custom-engineer their product is material selection. All Wattco heaters choose their materials to fit the specific use of the heater. The best material is not always the most expensive.

For heaters that don’t operate at too high of a temperature or deal with harsh chemicals, processes can use the more economical materials. For heating corrosive mediums something more resilient, like high-grade stainless steel, is a smarter option. The shaft and flange materials need to hold up to the conditions of operation and the medium.

Custom-matching the heater material to the process prevents premature deterioration. It’s an important aspect of keeping your heater efficient for years to come.


No piece of machinery will last without regular care. Proper immersion heater maintenance improves performance, efficiency, and lifespan. This maintenance includes regular cleaning and checks.

Wattco heaters are easy to clean, simply washing away sediment and grime with a damp cloth or power washer. Removable equipment, like over-the-side immersion heaters, allow for cleaning without having to drain the tank. As a result, maintenance is performed with no, or minimal, stoppages in production.

As part of maintenance, routine checks should include:

  • Checking coatings for corrosion.
  • Check terminal enclosure gasket for corrosion (if found, replace the gasket).
  • Check for sediment buildup on the heater. For rapid buildup, consider moving the heaters location.
  • Check fluid level (ensure elements are submerged)
  • Test safety equipment (ie. sensors and safety shutoff switch)

Heating Solutions That Last: Get An Electric Heater Quote Today

Wattco custom-engineers heating solutions for commercial and industrial use. They are built to last, from compatible design to their reliability and ease of maintenance. Contact Wattco today to get an electric heater quote or for more information.