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Specialist in the provision of

Heat Treatment Equipment, Servicesand Thermal Systems

THERMAL HIRE

www.thermalhire.com

P R O D U C T C ATA L O G U E

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THERMAL SYSTEMS www.thermalhire.com

Product Range Pages

100000 50 KVA LOW VOLTAGE HEATING UNIT (TRANSFORMER) ....................1 - 465 KVA LOW VOLTAGE HEATING UNIT (TRANSFORMER) ..................5 83 PHASE DISTRIBUTION/CONTROL UNIT ........................................9 10

200000 TEMPERATURE CONTROL SYSTEM (PROGRAMMER) ......................11 12

300000 TEMPERATURE MEASUREMENT (RECORDER) ..................................13 14THERMOCOUPLE WELDING UNIT ................................................15 16

400000 CERAMIC PAD HEATING ELEMENTS..............................................17 20CHANNEL HEATING ELEMENTS....................................................21 22PREHEATER ELEMENTS ..................................................................23 -24

500000 LOW VOLTAGE AND MAINS CABLES ..................................................25

600000 THERMAL INSULATION ............................................................26 -27 -29

700000 EQUIPMENT SPARES :LOW VOLTAGE HEATING UNIT (TRANSFORMER) ..................................28TEMPERATURE CONTROL SYSTEM (PROGRAMMER) ..............................29

TEMPERATURE MEASUREMENT (RECORDER)..........................................30CABLE CONNECTORS ........................................................................31CERAMIC PAD ELEMENT ......................................................................32TANK TRACK ELEMENT........................................................................33CHANNEL HEATING ELEMENT ............................................................33

800000 GENERAL SPARES................................................................................34

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65 KVA 6 CHANNEL LOW VOLTAGE HEATING UNITWITH SET POINT CONTROL

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65 KVA 6 CHANNEL LOW VOLTAGE HEATING UNIT WITHINTEGRATED PROGRAMMER UNIT

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6 CHANNEL 3-PHASE DISTRIBUTION/CONTROL UNIT

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TEMPERATURE CONTROL SYSTEM

PROGRAMMER SPECIFICATION P167

Overall dimensions 27cm W x 15cm H x 42cm L

Weight (cased) 8 kgNo. of control channels 6

Display LED, 7-segment Input Voltage 115 OR 230V A.C.., 50/60 Hz

Types of thermocouple Type K (standard)Units C: hours & minutes

Resolution 0.1C measurement, 1C displayProportional band 10C, 20C or 30C

Cycle time 25 seconds

Set point 0-1200C in 1C incrementsHeating rate 0-999C/hour in 1C increments

Soak temperature 0-1200C in 1C incrementsSoak time 1-100 hours in 0.1 hr increments

Cooling rate 0-999C/hour in 1C incrementsAmbient conditions 0C to +60C, 5-95% rel. humidity

Ref. No 200011

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INTRODUCTION

Thermal Hire offers a digital recorder as an

alternative to the analogue recorder overleaf.The digital recorder has a number of useful featuresto supplement the robust features of the analogueversion and these follow. The hybrid recorder is a180mm multi-point type having 12 channels andprovides a simultaneous display of multi-channel data,universal sensor input with alarm display and printingoptions. Packages for data processing for use withthe recorder are available.

TEMPERATURE RECORDERThe 12-channel digital Chino temperature recorderopposite has also been selected as ideal for therigours of site heat treatment. It has a number of useful features

Simultaneous display of multipoint data which isreadily available.

Its universal input permits 56 options 10 DCvoltage ranges, 35 thermocouple ranges and 11resistance thermometer ranges. These may beprogrammed for individual channels.

Clear trend and digital printing which uses acassette type wire-dotting 6-colour ink ribbon.

Chart illumination convenient for reading data atlow ambient light levels.

A supplementary software packages areavailable for data processing using a PC. Aseparate software package is also available thatallows inputs and printing through a PC.

An optional communications interface is available forconfiguration with a PC.

The recorder is housed within a rugged steel casingand is fitted with rear polarised socket connections forthe widely used Type K thermocouple to compensatinglead connections, to prevent reading errors. A flyinglead is also fitted to the rear of the case to for the 110VAC input power from the heat treatment transformer.

TEMPERATURE MEASUREMENT DIGITAL RECORDER

DIGITAL RECORDER SPECIFICATIONModel AH3725-N00. Ref No 300015

Overall dimensions 360mm W x 360mm H x 445mm L

Weight (cased) 18.5 kg

Scale length 180mm

Accuracy 0.1% input span

Balancing time 2 seconds

Input Voltage 100-240V A.C., 50/60 Hz

Types of thermocouple Selectable, set for Type K

Chart dimensions 200mm W x 20 m fanfold

Channels 12

Stamping interval 10 seconds

Stamping System Dot printing

Ambient temperature 0C to +40C

RECORDER SPARES Ref No 300015

Stock Ref Description

SPARES

700402 0/1200C Temperature chart

730601 Ink ribbon cassette

730602 Chart cassette

730603 Drive cord

730604 Door

ANCILLIARY EQUIPMENT

800159 Calibration unit

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THERMOCOUPLE ATTACHMENT

Accurate temperature measurement is ensured by

the attachment of thermocouple conductor wiresdirectly to the metal surface by a spark dischargewelding system. Accordingly, the metal surfacebecomes the hot junction of the thermocouple, soeliminating any inaccuracy associated with directheat transfer from the heating source. After thewires are removed from the metal surface, it isusually necessary only to lightly dress the localarea.

The standard unit is operated from a rechargeablebattery several hundred welds can be made

before a re-charge becomes necessary using the110V AC connection to the heat treatmenttransformer. The unit operates at a safe lowvoltage.

The Mini welding unit is significantly lighter andsmaller than the standard unit and therefore is moreportable. The unit is therefore particularly useful inlocations where access is poor.

The unit may be worn on a belt so permitting theoperator freedom for access and manipulation inconfined spaces.

Unlike the standard unit the smaller mini unit ispowered by AA batteries and therefore has a lowernumber of applications before recharge.

THERMOCOUPLE WELDING UNITS

Standard Unit Mini Unit

Dimensions 180Hx289Wx95mmD 157Hx95Wx45mmDWeight 4kg 0.74kg

Max operating voltage 60V 100VCharge Voltage 110 or 240V a.c. 6V

Discharge energy 20-40 Joules 20-50 Joules

T/couple types Type K, Type K,Standard Wire size 0.711mm dia 0.711mm dia

Approx no of applications

before re-charge 450 250Stock Ref 350001 350020

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OPERATION OF THERMOCOUPLEWELDING UNITS

Remove loose scale or rust by wire brushing or othersuitable means.

Dress a small area no more than 100mm fromattachment point to bright metal for return magnet.

Set the output to approx 80% of maximum output.

Push back insulation on thermocouples conductor wireto expose 5mm of bare wire.

Grip conductor wire 4mm from wire end with pliers &firmly touch wire end to attachment point at 90

Press discharge button

Gently bend wire through 90 3-4mm above surface.If weld is sound, repeat for second conductor wire.Welds to be approx 5mm apart.

Stock Ref. 350020

Stock Ref. 350001

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Section through Weld between Type KConductor and Ferritic Steel Component.

THERMOCOUPLE ATTACHMENT WELD

Preheating for thermocouple attachment is notnormally necessary. The typical depth of penetration of the weld is only in the order of

0.20mm and the associated heat affected zone inthe parent metal extends by up to a further 0.10mm.

On completion of the heat treatment process, thethermocouple conductor wires can be readilyremoved and the area lightly dressed.

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APPLICATION

The use of heat treatment power sources giving a

secondary output voltage of 80V is common inNorth America. Thermal Hire therefore offers arange of standard ceramic pad heaters for use with80V equipment.

All of the heaters deliver a current of approximately45amps. Secondary cable lengths should beminimised to limit the reduction of secondaryvoltage at the heater. Check the current delivered.

Fit heater pad securely to component by bandingor other suitable means and lock connectors fullyhome.

Avoid contaminants (grease, paint, oil etc) on themetal surface.

80V CERAMIC PAD HEATERS

80V CERAMIC PADS

Ref No. X, Width,mm Y, Length, mm Volts kW

400031 76 924 80 3.7400032 102 693 80 3.7

400033 152 462 80 3.7

400034 203 357 80 3.7

400035 254 294 80 3.7

400036 305 231 80 3.7

400037 381 189 80 3.7

400038 432 168 80 3.7

400039 534 147 80 3.7

400040 838 84 80 3.7

400041 1676 42 80 3.7

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APPLICATION

Localised heat treatment is often required after

welding on circumferential welds or with the fittingor repair welding of nozzles/attachments to theshell.

It is sometimes an advantage to undertake the heattreatment by the application of ceramic pad heatersto the external surface of the shell. This isparticularly so where internal access is restricted orwhere there is a necessity for internal welding andthe preheat and PWHT arrangements can becommon.

The use of larger pads can be useful under suchcircumstances, but special attention must be given tosafety precautions and also to the freedom of themetal surface from contaminants.

220/240V CERAMIC PAD HEATERS

220/240V CERAMIC PADS

Ref No. X, Width,mm Y, Length, mm Volts kW

400121 330 672 240 10.8

400122 660 336 240 10.8400131 330 610 220 9.9

400132 600 336 220 9.9

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CHANNEL HEATING ELEMENTS

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DESIGN

The Tank Track Preheater has the same designconcept as the ceramic bead CPP in terms of theinsulation backing and stainless steel protection.The ceramic pad element is, however, replaced byfull width beads, 75mm wide. The heater has anoverall width of 101mm.The construction of the element is simple with afacility to accommodate six longitudinal runs of theheater core wire. The standard heater is rated for60V or 80V operation using a heat treatmenttransformer as the power source.

PREHEATER ELEMENTS TANK TRACK BEADS

TANKTRACK PREHEATER ELEMENT

Stock Ref Width,mm Length, mm Volts kW

400331 101 775 60 2.7400301 101 1024 80 3.6

Heater tails are across the width of the heater.

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INTRODUCTION

Thermal insulation blanket is available as mats

encased in 18/8 stainless steel mesh or inunmeshed rolls. Insulation blankets are supplied inboth Superwool 607 and Ceramic Fibrematerials for a range of thicknesses and densities.

Pre-meshed mats can be readily applied to theworkpiece for preheat and PWHT processes havingthe advantage of re-use.

DESCRIPTION

Both Superwool and Ceramic Fibre insulationblankets have outstanding thermal properties athigh temperatures. The standard Superwool 607and Ceramic Fibre blanket materials haveclassification temperatures of 1100C and 1260Crespectively. Both are therefore suitable for preheatand PWHT applications on carbon and low alloysteels, where the heater temperature lies belowthese values.

An alternative to Superwool 607 material isrecommended for exposure temperatures above1100C.

THERMAL INSULATION

BENEFITS

The materials offered have outstanding insulationproperties. They have low heat storage valuesand good thermal stability.

The blankets are produced with no binder orlubricant.

The blankets have good resistance to tearing, areflexible and immune to thermal shock.

Superwool 607 is exonerated from anycarcinogenic classification under nota Q of directive 97/69 EC

The applicable temperature ranges for use aregiven in the chart opposite.

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KEY SPARE PARTS& ACCESSORIES

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CERAMIC PAD ELEMENTSReference Number Description712001 Main body bead, pink712002 Main body bead with hole, pink712003 Female end bead, pink712004 Female end bead with hole, pink712005 Male end bead, pink712006 Male end bead with hole, pink712007 Main body bead, white712008 Main body bead with hole, white712013 Small single hole tail bead, white712014 Small single hole tail bead, pink712053 Large single hole tail bead, pink701601 Heater core wire, 80/20, (19 strand), 0.29 /m701603 Heater core wire, 60/16, (19 strand), 0.28 /m701631 7 strand cold tail, nickel 212705042 60A, male camlok connector complete705019 60A, male camlok connector - sleeve705028 60A, male camlok connector - pin704830 Mild steel welding ferrule for tail junction,

6mm diax25mm long704831 Stainless steel crimping ferrule for tail junction,

6mm diax13mm long

CERAMIC PAD PREHEATERSReference Number Description724032 Superwool 607 meshed insulation mat for preheater

element 400181, 101x775x25mm724076 Superwool 607 meshed insulation mat for preheater

element 400182, 127x610x25mm724040 Superwool 607 meshed insulation mat for preheater

element 400189, 620x126x25mm720201 Stainless steel backing for ceramic pad element

400181, 101x75mm720202 Stainless steel backing for ceramic pad element

400182, 127x604mm720210 Stainless steel backing for ceramic pad element

400189, 620x126mm800092 Round magnet fixing assy c/w strap800106 Round magnet 800115 Straight strap708225 S/steel split pins for backing707201 S/steel flat washers for backing


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