b. rapid heat presentation -suadi
TRANSCRIPT
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Introduction to Induction Heating by
Rapid Heat Systems
In Partnership with PGWS
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Presentation Overview
R.H.S. Based in United Kingdom.
The Induction Process - How it works
Preheat/PWHT - Field Applications and
System Components
Economics
Related Applications
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Rapid Heat SystemsInduction Power Systems
For Specialized Heating ApplicationsAND
Construction Welding Applications
PreHeat
PWHT
Hydrogen Bake Out
Stress Relieving (Tempering)
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What Is Induction Heating?
Non-contact method of electrically heating
conductive materials.
High frequency, alternating current in coils creates
rapidly alternating magnetic field.
Magnetic field crosses the work-piece creating
current flow (eddy currents) within the part.
Heat is generated due to the resistance to eddycurrent flow within the material (IR losses).
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Induction Heating
Process / Transmission Pipe & Tubing
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Induction System orientations
Air-Cooled Systems- Up to 400F. Preheat Only
Water-Cooled Systems- Up to 1500F. Preheating
Hydrogen Bake-Out
Stress Relieving
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Water Cooled
Preheat andPost-weld HeatTreatment
Power Extension
Cable With Twist-lock
Connectors
Water Cooler
20 kW Power
Source
Insulation Blanket
and Water Cooled
Heating Coil
IHTS Temperature
Recorder and
Controller
Portable Cart
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Air-Cooled Induction Blankets
Induction Blanket
Flexible and lightweight
Several sizes - 10- 52 diameter
pipe.
400 F. (203 C.) capability
Protected by heat-resistantreplaceable KEVLARsleeve.
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Transmission Piping
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Pipeline Application
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Preheat Economics
Cost Savings:
Set up Take Down
Time Whole cycle time
reduced
Time to Temperature
Eliminate consumable Reduction in man-
hours
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Flexible Induction Coil and
Insulation for Preheating Reusable Insulation
1/2 Thick
Single Water CooledCable wrapped bothsides of joint.
Protective Coil Cover
Waiting around /finger pointing
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Resistance Old way versus Induc t ion
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Structural Applications
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Induction Heating
Structural Steel Preheat
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Alternatives for heating flat surfaces
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Induction Heating
RepairsFossil Plant Feedwater Heater
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Induction Heating
Flat Surfaces
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New Plant Construction
Stress Relieving
Diameter APE: 12
Wall Thickness: 1
Material Type: P22
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Induction Heating
Stress Relief
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Vertical Pipe Application
Weldolet - 16 Diameter - 2Wall
Stress Relieving Cycle Time - 5 1/2 Hours.
Soak Temperature 1350 F.
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Mossmoran Hot tap Shell FLNG
Mossmoran Hot Tap for Shell FLNG
14 inch pipe 10mm Wall 3500 ton gasoline per day
Preheat temperature 150c long seams welded same time
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Mossmoran Hot tap Shell FLNG
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Mossmoran Hot tap Shell FLNG
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Transco High Pressure 36Inch Transmission Line Hot Tap
Preheat 150 c Gas Flow not Given Pressure 55 bar
product Natural Gas
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Advantica 52 Inch x 1 Inch Vessel Preheat
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Steam Drain Valve
P22 Material
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Economics - Lower Consumable Costs
Reusable Insulation
Reduction in disposal cost
of potentially hazardous
insulation
Durable Hose - no fragile
wires or ceramic pads to
repair or purchase.
Induction system does not
melt connectors and wires.
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Post-Heat Application 2 Hr. 15 Min. to 1400 F. 12 inch wide heat zone
20" 2" WALL 25kw
0
200
400
600
800
1000
1200
1400
1600
013
26
39
52
65
78
91
104
117
130
143
156
169
182
195
208
221
234
247
260
273
286
299
312
325
338
351
364
377
390
403
416
429
442
455
TIME IN MINUTES
TEMPIN
DEGREESF
12oclk
east
12oclk
west
3oclk
east
3oclk
west
6oclk
east
6oclk
west
9oclk
east
9oclk
west
20" OD,2" WALL, 12 " WIDE HEAT ZONE (385 LBS), (1) 25KWPOWER SOURCE, 1 40' COIL OF 4 TURNS SPACED OVER THE 12" WIDE ZONE
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Temperature Results: ID - ODInduction
ID/OD Comparison
0
200
400
600
800
1000
1200
1400
1600
0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360 375 390 405 420
Time in Minutes
TempinDegreesF
2.5 hr soak
20 DIA. SCHD 160 Pipe
16 TCs, 12 Zone Apart, 3 IN Each Quadrant
4 ID 1 Each Quadrant
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Induction vs.. Resistance
0
200
400
600
800
1000
1200
1400
1600
0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360 375 390 405 420
Time in Minutes
TempinDegreesF
12
3
6
12L
3L
6L
9L
12ID
3ID
6ID
9ID
3R
6R
9R
16 TC's, 12 OD, 2" A PART, 3 IN EACH QUADRANT WORKING FROMCENTER OF 49" LONG 20" DIA . SCHD 160 PIPE; 4 ID 1 IN EACH QUADRANT WORKING
FROMCENTER OF 49" LONG 20" DIA. SCHD 160 PIPE; HEAT PROFILE: AMB TO 800 UNCONTROLLED, 800 - 1400 @ 400/ HR, 2.5HR SOAK, 1400 - 8 00 @
500/HR; FAULTY TC REMOVED
2.5 hr soak
RESISTANCE VS INDUCTION 3
0
200
400
600
800
1000
1200
1400
1600
015
30
45
60
75
90
105
120
135
150
165
180
195
210
225
240
255
270
285
300
315
330
345
364
379
394
409
424
443
458
473
488
503
523
538
553
568
583
603
618
633
648
663
678
697
712
TIMEIN MINUTES
TEMPINDEGREESF
12
3
6
9
12L
3L
6L
9L
12R
3R
6R
9R
12ID
3ID
6ID
9ID
AMB
FAULTY TC's
2.5HRSOAK
BAD TCCONTROLLING
THIS ZONE, HADTO
MOVETO THENEXT
NEAREST TC
16 TC's, 12 OD, 2" APART, 3 IN EACHQUADRANT WORKING FROMCENTEROF 49" LONG 20" DIA. SCHD160 PIPE; 4 ID1 IN EACHQUADRANT WORKING
FROMCENTEROF 49" LONG 20" DIA. SCHD 160 PIPE; HEAT PROFILE: AMB TO 800 UNCONTROLLED, 800 - 1400 @ 400/ HR, 2.5HRSOAK, 1400 - 800 @
500/HR; (8) 8 X 15" PADS, 4 ZONES
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Economics - Ease of Use Simple to wrap insulation
and install cable
Usually 15 minuteoperation versus up to 4
man hours Work performed by
welders and fitters -Maintain schedule andcontrol
Cabling consists of onecable to power source, onecable to work and TCs
Equipment is portable
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Economics - Flexibility
Can be used for pipe, valves, elbows, etc.
Can be used for preheat, hydrogen bake-out
and stress relieving
Coils can be adjusted in-process to
accommodate unique parts and heat sinks
Induction cables can be moved without
waiting for cooling after cycle
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Economics - Safety Welders and heat-treaters not
exposed to hot connectors and
pads. Less risk of fire hazard
Welders can work more
efficiently during preheat
No airborne insulation fiber to
inhale or get on skin
Insulation not exposed to
temperatures above 1800 F.
creating higher concentrations
of insulation dust
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Economics - Reliability
No burned connectors or wire to interrupt
heat cycle
No contactors cycling at max. current,causing failure
Digital Recorder does not require pens or
paper
Less rework and less cost
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Induction Heating
Self Perform Preheat and StressRelief
We Train Your Men On Site
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Thanks for allowing us to join you!
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CONTRACTINGSome Definitions
Sub-Contractor =a gambler who never gets to shuffle, cut or deal.
Tender Submission= a poker game in which the losing hand wins.
Tender Sum= a wild guess carried out to two decimal places.
Successful Tenderer= a contractor who is wondering what he left
out.
Architects Estimate= the cost of construction in heaven.
Management Contract= the technique for losing your shirt under
perfect control.
Completion Date= the point which liquidation damages begin.
Liquidation Damages= a penalty for failing to achieve the
impossible.
Lawyers= people who go in after the Quantity Surveyors and strip
the bodies.