New Video Highlighting Custom Heat Treating Power Console Examples

This new video illustrates the variations in design and custom capabilities Hotfoil-EHS has for building specialized power consoles.  Special power requirements, corrosion-resistance, weather-proofing, custom paint or coatings, special control options and custom cable sets are all available from Hotfoil-EHS. Challenge them with your toughest heat treating requirement. You'll be pleasantly surprised with the response.

Hotfoil EHS Provides "The Heat" for Strong, New Tappan Zee Bridge

The Tappan Zee Bridge stretches over the Hudson River and connects South Nyack, NY with Tarrytown, NY. The original bridge, completed in 1955, was only intended to last 50 years. Construction on a new, $3.9 billion replacement bridge started in 2013 and is scheduled for completion in 2018.

Hotfoil EHS is working closely with the bridge contractors supplying welding heat treating equipment. Large metal structures, such as bridge supports, pilings, and girders need careful pre-heating and post heating to ensure strong, lasting welds. Contractors on the Tappan Zee Bridge specified Hotfoil EHS power consoles, electric heaters, and thermocouples for their welding heat treating requirements.

Clam shell heater.

Here are photos from the pre-heating of piling welds. The applications uses "clam shell" heaters with magnetic thermocouples. The clam shell heaters are named that because of their hinged design, making it easy to place them around large, round workpieces. The magnetic thermocouples are very convenient because the magnets keep them firmly in place and are quick to remove.

Close-up of heater fastener.

A Hotfoil 6-way (six zones) power console is used to control the temperature of the workpiece by controlling the power provided to the clam shell heaters.

For more information, visit http://www.hotfoilehs.com.

Piling with clam shell heater and
thermocouples installed.

   

6 Way Power Console

Custom Heat Treating Power Consoles Solve Many Potential Field Problems

Weather-proof, Stainless Steel
Power Console

Standard heat treating power consoles available from a variety of manufacturers pretty much cover the same set of basic welding requirements. In many field situations however, there can be unusual circumstances such as difficult locations, available power sources, and environmental concerns. In these situations custom manufactured power consoles will provide welding outcomes with fewer operational problems, higher quality output, and greater safety.

Standard power consoles are available 3, 6, 9, 12, 18, 24 and 36 zone configuration (zones are many times referred to as "way" such as 3 way console, 6 way console, 9 way console, etc.) Each zone provides a point of control. The type of control can vary depending on the requirement of the weld. Some zones only need simple on-off or proportional control. Some welding jobs require more sophisticated temperature control profiles, thus requiring tight control with temperature vs. time ramping. Additionally, these more sophisticated control requirements may also need data logging or recording for quality compliance. In many situations custom cable sets are required to deliver the heater power and thermocouples to the workpiece. A power console manufacturer should have the experience and knowledge to consult, recommend, and install whatever zone control and cabling requirements your job needs.

Power console and
custom cable sets

The operating environment is another important consideration for power console customization. Standard power console cabinets are usually made from a medium gage sheet metal and painted with an industrial grade rust-resistant paint. While fine for relatively dry and non-corrosive atmospheres, these are subject to quick deterioration when moved into areas where higher than normal concentrations of salt, chlorine, or other corrosive gasses exist. In these situations, careful consideration of exposed materials needs to be applied. Perhaps an all stainless steel design is needed? Or maybe special corrosion resistant paints or epoxy resins should be specified? Or maybe you only need a special color paint? Working with a power console manufacturer who has the flexibility in their manufacturing process and experience on the floor to provide these options is preferred.

Custom painted
power console

Finally, look for a power console manufacturer who can handle unusual power system requirements. A manufacturer who can adapt their systems to unique voltages and current requirements is a big plus. Look for an equipment company that has experience and production capabilities for a wide variety of transformers - single or dual- and can even supply custom built transformers.

And of course, always try and find equipment built right here in the USA.

For more information on ANY welding power console, contact:

Hotfoil-EHS
2960 East State Street Ext.
Hamilton, NJ 08619
Phone # 609.588.0900
Fax # 609.588.8333

www.hotfoilehs.com
Email: dap@hotfoilehs.com

New Video on Ceramic Mat Heaters for Welding Heat Treating

Just a short video on Hotfoil EHS pre and post weld heat treating mat heaters (also known as pad heaters).

New Hotfoil EHS Welcome Video

We just introduced a new Hotfoil EHS Welcome video for our YouTube Channel. Check it out!

Ceramic Pre Weld and Post Weld Heaters Get The Heat to the Weldment Efficiently

Ceramic mat heaters

The most important feature of a resistance heater is the ability to transfer the heat away from the resistance wire to the outer covering where it can be absorbed by the work piece. Even when accurately controlled, a poorly designed or poorly applied heater can cause the wire temperature to exceed the wires operational limits. Ceramic mat heaters, also known as ceramic pad heaters, are designed to produce more even and efficient heat transfer while maintaining maximum flexibility.

Design:

1) Sintered alumina oxide is formed into shapes and fired at precise temperatures to produce a ceramic insulator with a combination of high dielectric strength and efficient, fast heat transfer. This ceramic is also solid enough to withstand physical shock and resistance to oxidation and corrosion from a broad range of chemicals and atmospheres.

2) An accurately measured length of stranded nickel-chromium wire is precisely wound through the ceramic beads ensuring electrical isolation to produce a compact and flexible resistance heater. Suitable for operation at 2000 deg. F.

3) The resistance wire is then metallurgically bonded to a stranded nickel-copper wire to provide trouble free electrical continuity. The flexible stranded cold junction wire is connected to brass Twistlock connectors fitted with insulated sleeves. The cold junction extension leads are rated for 250 deg. C continuous temperature.

Ceramic mat heaters are efficient, time-tested, and proven heater technology in pre-weld and post weld heating, and are designed for the harsh realities of the welding environment.

For more information, contact:

Hotfoil-EHS, Inc.
2960 East State Street Ext.
Hamilton, NJ 08619
Phone # 609.588.0900
Fax # 609.588.8333
www.hotfoilehs.com

Use External Electric Heating Panels for Ease and Simplicity

ELP tank heater construction

When it comes to heating process tanks electrically, you have two options - immersion or externally mounted panels. Immersion heaters must penetrate the tank wall, or be placed of over-the-side in an open top tank. Both approaches add cost and/or safety considerations. Sometimes entry to the tank may not be possible at all.  A good alternative are electric heating panels.

One type of exterior heater design, the epoxy laminated panel (or ELP), is a very versatile tank heater. Possessing unique flexibility, ELP heating panels can be used in a variety of heating applications ranging from freeze protection to process heating up to 212 deg. F . These panels can be used on either vertical or horizontal tanks of metallic or non-metallic construction. They can be used in dry, wet, or corrosive environments in ordinary or approved hazardous locations.

ELP heating panels are quick and easy to install, require no special tools or skills. Heaters are usually installed by banding them to the tank with metal bands or polyester straps. Installation of several ELP heating panels takes only a few minutes.

Check out the following document for more information on the epoxy laminated panel heaters.

Epoxy Laminated Tank Heater Panels from Hotfoil EHS, Inc.