Introduction to Induction Heating by Rapid Heat Systems In Partnership with PGWS

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

Rapid Heat Systems

Induction Power Systems For Specialized Heating Applications AND Construction Welding Applications

PreHeat PWHT Hydrogen Bake Out Stress Relieving (Tempering)

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 eddy current flow within the material (IR losses).

Induction Heating Process / Transmission Pipe & Tubing

Induction System orientations

Air-Cooled Systems - Up to 400F.
Preheat Only

Water-Cooled Systems - Up to 1500F.

Preheating Hydrogen Bake-Out Stress Relieving

Water Cooled
Preheat and Post-weld Heat Treatment
IHTS Temperature Recorder and Controller Insulation Blanket and Water Cooled Heating Coil

20 kW Power Source Power Extension Cable With Twist-lock Connectors

Water Cooler

Portable Cart

Air-Cooled Induction Blankets

Induction Blanket
Flexible and lightweight Several sizes - 10- 52 diameter pipe. 400 F. (203 C.) capability Protected by heat-resistant replaceable KEVLAR sleeve.

Transmission Piping

Pipeline Application

Preheat Economics
Cost Savings: Set up Take Down Time Whole cycle time reduced Time to Temperature Eliminate consumable Reduction in manhours

Flexible Induction Coil and Insulation for Preheating

Reusable Insulation 1/2 Thick Single Water Cooled Cable wrapped both sides of joint. Protective Coil Cover Waiting around / finger pointing

Resistance Old way versus Induction

Structural Applications

Induction Heating
Structural Steel Preheat

Alternatives for heating flat surfaces

Induction Heating
Repairs Fossil Plant Feedwater Heater

Induction Heating Flat Surfaces

New Plant Construction Stress Relieving

Diameter APE: 12 Wall Thickness: 1 Material Type: P22

Induction Heating
Stress Relief

Vertical Pipe Application

Weldolet - 16 Diameter - 2Wall Stress Relieving Cycle Time - 5 1/2 Hours. Soak Temperature 1350 F.

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

Mossmoran Hot tap Shell FLNG

Mossmoran Hot tap Shell FLNG

Transco High Pressure 36Inch Transmission Line Hot Tap

Preheat 150 c Gas Flow not Given Pressure 55 bar product Natural Gas

Advantica 52 Inch x 1 Inch Vessel Preheat

Steam Drain Valve

P22 Material

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.

Post-Heat Application
2 Hr. 15 Min. to 1400 F. 12 inch wide heat zone
20" 2" WALL 25kw
1600

1400

1200

1000

800

600

12oclk east 12oclk west 3oclk east 3oclk west 6oclk east 6oclk west 9oclk east 9oclk west

TEMP IN DEGREES F

400

200

0
0 13 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

TIME IN MINUTES

20" OD,2" WALL, 12 " WIDE HEAT ZONE (385 LBS), (1) 25KW POWER SOURCE, 1 40' COIL OF 4 TURNS SPACED OVER THE 12" WIDE ZONE

455

Temperature Results: ID - OD
Induction ID/OD Comparison
1600 1400 12 1200 3 6 12L 1000
Tem p in Degrees F

3L 6L 800 9L 12ID 3ID 600 6ID

2.5 hr soak
400

9ID 3R 6R

200

0 0 15 30

45 60

20 DIA. SCHD 160 Pipe 16 TCs, 12 Zone Apart, 3 IN Each Quadrant 4 ID 1 Each Quadrant
75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360 375 390 405 420 Tim e in Minutes

9R

16 TC's, 12 OD, 2" APART, 3 IN EACH QUADRANT WORKING FROM CENTER OF 49" LONG 20" DIA. SCHD 160 PIPE; 4 ID 1 IN EACH QUADRANT WORKING FROM CENTER OF 49" LONG 20" DIA. SCHD 160 PIPE; HEAT PROFILE: AMB TO 800 UNCONTROLLED, 800 - 1400 @ 400/HR, 2.5HR SOAK, 1400 - 800 @ 500/HR; FAULTY TC REMOVED

Induction vs.. Resistance

RESISTANCE VS INDUCTION 3
1600
1600 BAD TC CONTROLLING THIS ZONE, HAD TO MOVE TO THE NEXT NEAREST TC

1400
1400

12 1200 3 6 12L 1000

Tem p in Degrees F

1200 12 3 1000
TEMP IN DEGREES F

6 9 12L 3L

3L 6L 800 9L 12ID 3ID 600

800 2.5HR SOAK 600 FAULTY TC's

6L 9L 12R 3R 6R 9R 12ID

2.5 hr soak

6ID 9ID 3R

400 6R 9R 200
200 400

3ID 6ID 9ID AMB

0 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 Tim e in Minutes 16 TC's, 12 OD, 2" APART, 3 IN EACH QUADRANT WORKING FROM CENTER OF 49" LONG 20" DIA. SCHD 160 PIPE; 4 ID 1 IN EACH QUADRANT WORKING FROM CENTER OF 49" LONG 20" DIA. SCHD 160 PIPE; HEAT PROFILE: AMB TO 800 UNCONTROLLED, 800 - 1400 @ 400/HR, 2.5HR SOAK, 1400 - 800 @ 500/HR; FAULTY TC REMOVED
0
0 15 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

TIME IN MINUTES 16 TC's, 12 OD, 2" APART, 3 IN EACH QUADRANT WORKING FROM CENTER OF 49" LONG 20" DIA. SCHD 160 PIPE; 4 ID 1 IN EACH QUADRANT WORKING FROM CENTER OF 49" LONG 20" DIA. SCHD 160 PIPE; HEAT PROFILE: AMB TO 800 UNCONTROLLED, 800 - 1400 @ 400/HR, 2.5HR SOAK, 1400 - 800 @ 500/HR; (8) 8 X 15" PADS, 4 ZONES

Economics - Ease of Use

Simple to wrap insulation and install cable Usually 15 minute operation versus up to 4 man hours Work performed by welders and fitters Maintain schedule and control Cabling consists of one cable to power source, one cable to work and TCs Equipment is portable

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

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

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

Induction Heating Self Perform Preheat and Stress Relief We Train Your Men On Site

Thanks for allowing us to join you!

CONTRACTING Some 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.