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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. • Heat is generated due to the resistance to eddy current flow within the material (I²R losses). • Magnetic field crosses the work-piece creating current flow (eddy currents) within the part. alternating current in coils creates rapidly alternating magnetic field.

Induction Heating Process / Transmission Pipe & Tubing .

• Preheat Only • Water-Cooled Systems . • Preheating • Hydrogen Bake-Out • Stress Relieving .Up to 400°F.Induction System orientations • Air-Cooled Systems .Up to 1500°F.

“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 .

– 400º F. .52” diameter pipe.10”.) capability – Protected by heat-resistant replaceable KEVLAR sleeve.Air-Cooled Induction Blankets • Induction Blanket – Flexible and lightweight – Several sizes . (203º C.

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 .

• Protective Coil Cover • Waiting around / finger pointing .Flexible Induction Coil and Insulation for Preheating • Reusable Insulation 1/2” Thick • Single Water Cooled Cable wrapped both sides of joint.

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: 1½” Material Type: P22 .

Induction Heating Stress Relief .

Vertical Pipe Application • Weldolet . .16” Diameter .2”Wall • Stress Relieving Cycle Time . • Soak Temperature 1350° F.5 1/2 Hours.

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 .

• Induction system does not melt connectors and wires.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.Economics .

12 " WIDE HEAT ZONE (385 LBS). 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. (1) 25KW POWER SOURCE. 1 40' COIL OF 4 TURNS SPACED OVER THE 12" WIDE ZONE 455 .Post-Heat Application • 2 Hr. 15 Min.2" WALL.

12 OD. SCHD 160 PIPE.5 hr soak 400 9ID 3R 6R 200 0 0 15 30 • • • 45 60 20” DIA. FAULTY TC REMOVED . 800 . 12” Zone Apart. 2. 2" APART.1400 @ 400/HR.5HR SOAK.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. 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. 3 IN EACH QUADRANT WORKING FROM CENTER OF 49" LONG 20" DIA.Temperature Results: ID . HEAT PROFILE: AMB TO 800 UNCONTROLLED. 1400 . 4 ID 1 IN EACH QUADRANT WORKING FROM CENTER OF 49" LONG 20" DIA. SCHD 160 Pipe 16 TC’s. SCHD 160 PIPE.800 @ 500/HR.

800 @ 500/HR. SCHD 160 PIPE.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. 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.800 @ 500/HR.1400 @ 400/HR. 1400 . 2" APART. 4 ID 1 IN EACH QUADRANT WORKING FROM CENTER OF 49" LONG 20" DIA. SCHD 160 PIPE. Resistance RESISTANCE VS INDUCTION 3 1600 1600 BAD TC CONTROLLING THIS ZONE. 800 .5HR SOAK. SCHD 160 PIPE. HEAT PROFILE: AMB TO 800 UNCONTROLLED. 4 ZONES . 2" APART. 3 IN EACH QUADRANT WORKING FROM CENTER OF 49" LONG 20" DIA. 1400 . 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. 12 OD.5HR SOAK 600 FAULTY TC's 6L 9L 12R 3R 6R 9R 12ID 2. 3 IN EACH QUADRANT WORKING FROM CENTER OF 49" LONG 20" DIA. 2.5HR SOAK. (8) 8 X 15" PADS. 4 ID 1 IN EACH QUADRANT WORKING FROM CENTER OF 49" LONG 20" DIA. HEAT PROFILE: AMB TO 800 UNCONTROLLED.Induction vs.1400 @ 400/HR. 12 OD. 2.. 800 . SCHD 160 PIPE.

one cable to work and TC’s • Equipment is portable .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.Economics .

valves. • Can be used for preheat.Flexibility • Can be used for pipe.Economics . elbows. 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 . etc.

Economics . creating higher concentrations of insulation dust .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.

current.Economics .Reliability • No burned connectors or wire to interrupt heat cycle • No contactors cycling at max. 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! .

Liquidation Damages = a penalty for failing to achieve the impossible.CONTRACTING – Some Definitions Sub-Contractor = a gambler who never gets to shuffle. Architect’s Estimate = the cost of construction in heaven. Tender Submission = a poker game in which the losing hand wins. Successful Tenderer = a contractor who is wondering what he left out. cut or deal. Completion Date = the point which liquidation damages begin. Management Contract = the technique for losing your shirt under perfect control. Lawyers = people who go in after the Quantity Surveyors and strip the bodies. . Tender Sum = a wild guess carried out to two decimal places.