Power Sources & Heat Treatment Unit
Heating Elements
programmer / controller
thermo couple welding unit
heat treatment furnaces
combustion systems
our other activities
thermal insulation
radiant preheat gas burners
cables and connections
Products
 
Power Sources & Heat Treatment Unit :  
 
40 KVA, 50 KVA, 80 KVA, 100 KVA. Transformer / Heat Treatment Units.

Provides safe low voltage power of 60 / 65 V and 80 / 85V, to feed flexible heating elements for the purpose of preheating, post heating and postweld heat treatment.

The units are housed in rigid steel frame of heavy gauge sheet steel wheeled cabinet for mobility, well balanced and quality powder coated finish.

Insulated to Class "H" standards, the windings are air natural cooled.

The unit can be fitted with either 3 way or 6 way contractorised control modules. Energy regulators are fitted as a standard feature for control of Heat Treatment cycle. Miniature size temperature controllers can also be fitted on request.

A 50 KVA unit can feed eighteen 60V, 2.7 KW or fifteen 65 V, 3.25 KW heating elements.

Complete Heat Treatment units housing temperature recorder and micro processor based programmer can be supplied on request.

 
Standard Features :
  Primary input supply 3 phase 380V / 415V / 440V Neon indicators for each channel Three metres 4 core input cable Four lifting eye bolts 230V and 115V auxiliary supply for lighting or operating power tools.
   
Optional Features :
  Transformer rating of either 40 KVA, 50 KVA, 80 KVA or 100 KVA. Contactorised 3 or 6 way control module.

Control modules can be supplied with either energy regulators only, or energy regulators and temperature controllers.

Full automatic programmers can be connected to the unit for fully automatic heat treatment profiles.
   
 
     
Heating Elements :  
 
   
CERAMIC FLEXIBLE MAT HEATERS :
   
  Ceramic Flexible Heaters are manufactured from high grade materials and have a working temperature capability of 1050°C. They can be powered from Power source/Heat Treatment units or Welding machines.

Heating element consists of multi strand Nickel Chrome element wire, electrically insulated by interlocking sintered alumina beads, providing a flexible high heat transfer-Mat, complete with twistlock connectors.

Heaters are rated at low voltage of 30V, 32.5V, 40V, 42.5V, 60V, 65V, 80V and 85V., and available in wide range of sizes. Non-standard voltages of 220V & 240V are also available. Other sizes and rating can be supplied on request.

Heaters are rated at 45Amps for 30V, 60V and 80V and 50 Amps for 32.5V, 65V and 85V.

Heaters can be used for pre-heat, post-heat and post-weld Heat Treatment of welds.

Ceramic Flexible Mat Heaters
 
 
 
60 & 30V Elements
Stock No. X mm Y mm V kW
201 75 660 60 2.7
202 100 495 60 2.7
203 150 330 60 2.7
204 205 250 60 2.7
205 255 205 60 2.7
206 305 165 60 2.7
80 & 40V Elements
251 75 910 80 3.6
252 100 680 80 3.6
253 150 450 80 3.6
254 205 350 80 3.6
255 255 290 80 3.6
256 305 230 80 3.6
257 380 185 80 3.6
258 430 165 80 3.6
259 535 145 80 3.6
260 840 85 80 3.6
261 1675 45 80 3.6
262 45 760 40 1.8
 
220 & 240V Elements
Stock No. X mm Y mm V kW
271 330 610 220 9.9
272 330 660 240 10.8
65 & 32.5V Elements
301 305 170 65 3.25
302 180 300 65 3.25
303 635 85 65 3.25
304 1195 45 65 3.25
305 1190 25 65 3.25
306 280 85 32.5 1.62
307 525 45 32.5 1.62
308 845 25 32.5 1.62
85 & 42.5V Elements
351 405 170 85 4.25
352 180 405 85 4.25
353 865 85 85 4.25
354 1650 45 85 4.25
355 3000 25 85 4.25
356 380 85 42.5 2.12
357 1500 25 42.5 2.12
   

Ceramic Flexible Mat Heaters
 
INSULATED CERAMIC FLEXIBLE MAT HEATERS :
   
  Similar in construction to Ceramic Flexible Mat Heaters with additional ceramic fibre insulation encased in stainless steel mesh and protected by a stainless steel backing plate.

Particularly suitable for preheating pipework, vessels, and welded fabrications having either longitudinal or circumferential seams.
 
Robust and operate from a welding machine or Heat Treatment unit.
Gives protection to the Ceramic Beads from weld splatter.
Can be magnetically attached to work piece for fast application by use of two magnetic clamps.
   
 
Stock No. Width mm Length mm V kW Amps
401 102 762 60 2.7 45
402 711 108 60 2.7 45
403 127 597 60 2.7 45
404 102 1016 80 3.6 45
405 940 108 80 3.6 45
406 127 762 80 3.6 45
   

Insulated Ceramic Flexible Mat Heaters
 
   
FINGER ELEMENTS :
   
  Finger elements are well established pre and post weld heaters, suitable to be powered from AD/DC welding machines.

Ruggedly constructed, they require minimal maintainence capable of withstanding considerable On-Site maltreatment.

The element consists of two solid drawn Nickel Chrome element wires passed through sintered alumina beads providing electrical insulation and high heat transfer capability.

Standard element maximum working temperature is 1050°C each finger being rated at 120 Amps at 1.3 Volts.

For heat treatment of stainless steel, special solid drawn Kanthal wire is required to give a maximum operating temperature of 1250°C.

Steel connector blocks or twistlock connectors are provided for end termination.

NOTE : The stock number identify the size (Number of fingers) of each element.
   
 
Stock No.
Outside Dia. of Pipe
Min mm Max mm
4 15 20
5 20 30
6 30 35
7 35 40
8 40 50
9 50 60
10 60 70
11 70 80
12 80 90
13 90 100
14 100 110
15 110 122
16 122 132
17 132 142
18 142 152
19 152 162
20 162 172
21 172 182
22 182 192
23 192 204
24 204 214
Stock No.
Outside Dia. of Pipe
Min mm Max mm
25 214 224
26 224 234
27 234 244
28 244 254
29 254 264
30 264 274
31 274 284
32 284 294
33 294 304
34 304 314
35 314 326
36 326 336
37 336 346
38 346 356
39 356 366
40 366 376
41 376 386
42 386 396
43 396 406
44 406 416
45 416 426
   

Finger Elements
 
   
CHANNEL HEATERS :
   
  Channel Heaters are main voltage heating elements. The elements can be connected in 'STAR' or 'DELTA' and operated from 380 / 415 / 440V 3 phase supply.

They can be used to heat treat circumferential joints of large vessels using 'BULKHEAD' technique or can be used for building temporary furnaces for Heat Treatment at site.

Portable and easy to handle, they have a long on-site working life and are suitable for a variety of applications.

Heatwork Engineers can also supply the main voltage control units for these elements. Control of heat can be by energy regulators or temperature controllers.

Working temperatures of upto 800°C are permissable, but higher temperatures can be achieved using Kanthal wire as alternative element material.

Steel connector blocks or twistlock connectors are provided for tail terminations.

NOTE : Extension leads for tails can be provided and are priced per metre length required.
   
 
Channel Heaters
Stock No. Length mm Width mm V kW Amps
501 685 360 240 13.2 55
502 685 360 220 12.1 55
503 685 360 254 14 55
504 725 400 60 13.2 220
505 685 70 60 3.3 55
506 685 70 55 3.0 55
509 685 70 63.5 3.5 55
   

Channel Heaters
     
PID STRESS RELIEF PROGRAMMER / CONTROLLER :  
 
 
The PID Stress Relief Programmer Controller is used for controlling the rate of heating, soaking and rate of cooling during stress relieving operation. It can be used in conjunction with the power source unit or other contactorised units.
   
Features
Control Types PID with Pre-tune and RaPID fuzzy logic, or Manual Tuning. Heat or Heat / Cool, applications
Auto/Manual Selectable from front panel, with bumpless transfer
Output Configuration Up to 3 total. Max 2 for control (Heat & Cool), max 2 for Alarms, max 1 for retransmit PV or SP
Alarm 1 & 2 Types Process high, process low, setpoint deviation and band
Human Interface 4 buttons, 10mm & 8mm high LED’s, plus run-hold, tune, event & profile / control status LED’s
PC Configuration Off - line configuration & profile editing via config socket (comms option not required)
   
Profiles
Number of Programs 4, each with 16 free-form segments (Ramp/Dwell/End). Max segment length 99 hours 59 minutes
Delayed Start Max 99 hours 59mins delay from initiation to program start
Guaranteed Soak Holds program if PV is outside of specified hold band during dwell segments.
Program Cycles 1 to 9999 or infinite (continuously re-starts program at end)
Ramp Rate Definition Either ramp rate, or time to final setpoint
Power Loss Recovery Hot (continue profile from point of power fail) or Cold (end profile and return to controller mode)
   
Input
Thermocouple J, K, R, S, T, B, L, & N.
RTD 3 Wire PT100, 50W per lead maximum (balanced)
DC Linear 0-20/4-20mA, 0-50/10-50mV, 0-5/1-5/0-10/2-10V. Scaleable -1999 to 9999, dec point available
Impedance >100MΩ for Thermocouple and mV ranges, 47KW for V ranges and 4.7W for mA ranges
Accuracy +/- 0.25% of input span +/- 1 LSD (T/C CJC better than 0.7°C)
Sampling 4 per second, 14 bit resolution approximately
Sensor Break Detection <2 secs (except zero based DC ranges), control O/P’s turn off, *high alarms activate (*low for RTD)
   
Outputs & Options
Control/Alarm/Event Relay Contacts SPDT 2Amp resistive at 240V AC, >500,000 operations
DC for SSR Drive capability >4.2V DC in 1KΩ (10V 500Ω version available)
DC Control/Retransmit 0-20/4-20mA into 500Ω max, 0-10/0-5V into 500Ω min. Control OP +/- 0.5%, Retransmit +/- 0.25%
Solid State (Triac) 0.01 to 1 Amp AC 20 to 280V, 47 to 63Hz
Remote Run-Hold Volt free or TTL input (Hold = -0.6 to 0.8V or contact open, Run = 2 to 24V or contact close)
Communications 2 Wire RS485, 1200 to 9600 Baud, Modbus
   
Operating & Environmental
Temperature & RH 0 to 55°C (-20 to 80°C storage), 20% to 95%RH non-condensing
Power Supply 90 to 264V 50/60Hz (optional 20 to 55V AC/22 to 65V DC), approx 4 Watts
Front Panel Protection IEC IP66 (Behind panel protection is IP20)
Approvals and Certification CE, UL & Ulc
 
Programmer Controller
     
THERMO COUPLE WELDING UNIT :  
 
 
Thermocouple welding unit provides a positive attachment of the thermocouple wire to the work piece surface by capacitance discharge.

The operation is fast and reliable, giving accurate temperaure readings under conditions where other methods of attachment have registered error of upto 50°C at 650°C.

Lightweight and portable, it is supplied complete with rechargeable battery, housed within the carrying case.

The unit can be charged from 230V supply and is ideal for working in areas with restricted access.
 
Thermo Couple
 
THERMOCOUPLES AND ACCESSORIES
Stock No. Description
710 'K Type Heavy Duty Beaded Thermocouple 600 mm length
702 'K' Type Heavy Duty Beaded Thermocouple 1200 mm length
703 'K' Type Heavy Duty Beaded Thermocouple 1800 mm length
704 'K Type Heavy Duty Beaded Thermocouple 3600 mm length
705 'K' Type 16 SWG Beaded Thermocouple 600 mm length
706 'K' Type 16 SWG Beaded Thermocouple 3600 mm length
707 'K' Type 21/22 SWG insulated Thermocouple wire for use with Thermocouple welding unit.
708 'K' Type Stainless Steel sheeted 3 mm Dia. 600 mm length
709 'K' Type Stainless Steel Sheated 3 mm Dia. 1800 mm length
710 Compensating Cable for 'K' Type Thermocouples 25 metre length with plug and socket.
 
NOTE: Above Thermocouples are standard grade.
Special limits of error Thermocouples can be supplied on request.
Multi Thermocouple calibration tube furnace, can be supplied.
 
Cables and Connections
     
Heat Treatment Furnaces :  
 
   
Heat Treatment Furnaces :
   
  Heat Treatment Furnaces for Postweld Heat Treatment of Large Pressure vessels/Normalising or Solution Annealing of Dish Ends by Fuel Fired Oil/Gas Burner Systems or Electric Heated
   
Gas / Oil Heat Treatment Curing and Dryout
     
Combustion Systems :  
 
   
HIGH VELOCITY COMBUSTION SYSTEM and GAS/OIL HEAT TREATMENT CURING AND DRYing :
   
  Gas / Oil fired high velocity portable combusion system are used for Post weld Heat Treatment, Refractory Dryouts and curing.

The unit has a maximum output of 8 x 10 BTU / HR.

Having an exceptional turn down characteristic (air / fuel ratio) It can provide high volume low temperature conditions that are essential at the beginning of an operational cycle.

The unit is designed for manual operation. Automatic control can also be provided.

The system can also be used in the construction of an On-site temporary furnace where permanent furnaces are not available for carrying out Post-weld Heat Treatment of odd size vessels and fabrications.
   
Radiant Preheat Gas Burners

Radiant Preheat Gas Burners
     
OUR OTHER ACTIVITIES :  
 
 
Heatwork Engineers are also capable of the following activities:
  1. Supply of Electric / Oil / Gas Fired Furnaces up to 1200°C
  2. Preheat, Postheatand Postweld Heat Treatment of pipes, vessels and fabrications on contract basis by Electric, Oil / Gas firing.
  3. Modification of existing brick lined furnaces with ceramic fibre.
  4. Ceramic fibre relining.
  5. Ceramic fibre fixing systems.
  6. Insulating / Erosion resistant castable lining.
Due to constant development of our products, the design and specifications mentioned herein are subject to change.
 
Our Other Activities
     
THERMAL INSULATION :  
 
   
Stock No. Description
851 Ceramic Fibre 128 kG. / m3 density 25 mm thick, roll 7620 x 610 mm
852 SS Wire Mesh for Ceramic Fibre
Thermal Insulation
     
RADIANT PREHEAT GAS BURNERS :  
 
 
Economical to use, versatile in application and simple to operate.

Our gas burners provide infrared preheating for circumferential seams on large vessels which would be mounted on a rotating fixture during automatic welding operations. They can also be used singly, either vertical or horizontal, or in multiples up to four burners when connected in series.

Other features of the design specification are:
Workpiece surface temperatures up to 200°C can be achieved.
Single burner output to 50,000 BTU hr.
Natural, butane or propane gas (LPG) can be used.
Even distribution of heat with no 'hot spots'.
All connections are self-sealing and of quick release design.
 
Savings in gas is up to 30% compared to open flame burners.
Stock No. Description
Burner face dimensions
BTU/hr (max)
mm mm
1051 Burner 152 610 50000
1052 Burner 152 305 25000
 
Radiant Preheat Gas Burners
     
CABLES AND CONNECTIONS :  
 
 
Used for connecting heating elements to the Heat treatment Unit.
Stock No. Description
601 Feed cable 25 metres with plug and socket 150 Amps
602 Return cable 25 metres with plug and socket 300 Amps
603 2 way Splitter cable with plug and socket, feed side
604 3 way splitter cable with plug and socket, feed side
605 4 way Splitter cable with plug and socket, return side
606 6 way Splitter cable with plug and socket, return side
 
 
     
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