B. Rapid Heat Presentation -Suadi

7/22/2019 B. Rapid Heat Presentation -Suadi

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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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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.

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