Peggy, Bad day at the office ???
Peggy,Nobody is questioning your knowledge in this area, but please read all the words in my post. As suggested in the title and first sentence, my entire discussion deals with an empty tank. You address the operation of a full tank. I am talking about the expansion of the element, which is what happens when it destroys itself, not the expansion of the tank. A thermal sensor and cut-off would prevent the element from burning out.The tank on my P42 (probably the original) is definitely not as well insulated as a household tank. The outer can on a typical Sears 40 is barely above ambient temperature. My boat tank when heated is uncomfortable to skin contact for more than a few seconds. Its not going to start a fire, but it definitely heats the surrounding air. This is simply a trade off of insulation efficiency vs making it fit in boat size spaces. Thus, one gallon in six hours would take slightly more energy in the real world than six gallons in one hour due to heat loss during the six hours.