RHS’ induction heat system is welder friendly

RHS’ induction heat system is welder friendly

Induction heating scores, says PGTS

01 July 2008

Pan Gulf Technical Services (PGTS), a specialist in induction heating applications for a range of industries, has currently around 50 units with 100 per cent utilisation on sites in Saudi Arabia, a company spokesman said.

PGTS, a division of the Saudi Pan Gulf Group, performs as a rental service provider in exclusive partnership with Rapid Heat Systems- UK (RHS).
The heat units are working successfully up to clients’ satisfaction, the spokesman said.
“PGTS’ intentions are to become a derived provider of technical services for industrial equipment and accessories and it has potential to grow further on other rental opportunities which will be related to Pan Gulf’s existing customer base.”
The spokesman further commented: “Our induction heating system for welding applications has proved its technology in the region having been used in projects undertaken by  Al Tawleed, J&P, AL Qahtani, Globetech, CCC, MIS and Cameron and entailing oil and gas pipelines, pipe coating, heavy equipment construction and maintenance and repair of mining equipment, among other things.”
RHS patented induction heating technology which the UK company introduced to Saudi Arabia offers massive cost savings and provides added safety to clients throughout the oil and gas industry and in the sectors of power plants, petrochemical and iron and steal for all heating requirements up to 815 deg C covering PWHT, pre-heat and shrink fitting among other types.

Induction heating explained
Induction heating is a non-contact process of heating a metal object by electromagnetic induction in which heat is introduced in a specific part by placing it in a high-frequency magnetic field. The magnetic field creates eddy currents inside the part, exciting the part’s molecules and generating heat. Because heating occurs slightly below the metal surface, no heat is wasted. As an analogy, induction heating acts more like a microwave oven – the appliance (heater coils) remains cool while the food (metal) cooks from within.
The depth of heating depends on the frequency. High-frequency (eg 50 kHz) heats close to the surface, while low-frequency (eg 60 Hz) penetrates deeper into the part, placing the heat source up to 3 mm deep, which allows heating of thicker parts. The induction coil does not heat up because the conductor is large for the current being carried. In other words, the coil does not need to heat up to heat up the work piece.
“It is a constant endeavor at Pan Gulf to introduce the most modern heating application in the region and to Saudi industry by using new concepts in the induction process,” the PGTS spokesman said.
The PGTS team comprises operations manager Mohammed A Hilal, sales and marketing manager Asif Aghai and technical supervisors Saleh A Qarishah and Ahmed Makki. The operations manager for RHS, UK, is John Adams.
The PGTS team works under the leadership of Khalid Hamdan, managing director, Pan Gulf Holding; Paul Graham, managing director, RHS, and Andy Leigh, general manager, PGTS and PGWS.

Comparisons to resistance heating
The biggest difference between resistance heating and rapid heat system is time to temperature. The rapid heat system is so much faster – up to 20 times faster and there is uniform heat throughout the component.
Welders and heat-treaters are not exposed to hot connectors and ceramic pads; there is less reflected heat allowing for better productivity and happier weld.
Welders can work more efficiently during preheat as up to 75 per cent less heat is reflected back from the job.
The risk of fire hazard is less compared to the other method where rock wool or connectors could be burning or catching fire.
There is a durable hose; no fragile wires or ceramic pads to repair or purchase.
There is no airborne insulation fibre to inhale or get on to the skin.  Insulation is not exposed to temperatures above 1,800 deg F which can create higher concen-trations of insulation dust
Insulation is reusable leading to a reduction in the disposal cost of potentially hazardous insulation and making the process environmentally friendly.
Power consumption is far less as typical preheat power requirements would be 30 amps as opposed to a minimum 63 amps on a 50 Kva resistance transformer.
The rapid heat system will run off a 30-kva generator as opposed to a 100 kva generator required for a resistance transformer.
QA Documents can be downloaded from an on-board computer and handled very easily at the end of each shift saving many man-hours looking through charts and having to identify them and also copy them.
There are no failures in the stress cycle due to burned out connectors which is common with resistance machines.
The stress cycle can be set up in minutes and taken down in minutes saving many man hours and, with your own men performing, costs are reduced even more.
PGTS’ induction heating systems apply to many applications which need heat. They included but are not limited to the following: preheat, PWHT, hydrogen bake out, stress relieving (tempering), shrink fitting and any other heat applications such as unfreezing pipelines, trace heating and coating.

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