TESI Induction Heating Equipment - Field Joint Coating

INDUCTION HEATING EQUIPMENT

Field Joint Coating Equipment Manual and Automatic Clamp Coils

Introduction Onshore and offshore pipeline construction projects have increased significantly in the last decade, and expectations outline a further growth in demand. There are two key processes establishing the quality of a pipeline in terms of reliability and lifetime: weldings and field joint coating (FJC).

Which are the requirements for a field applied coating to be approved?

• • • •

Be compatible with parent coating Withstanding pipeline operating conditions (e.g. temperature) Being resistant in construction/handling (if not foolproof) Being cost-effective

• • •

Block the ingress of humidity and oxygen Resisting soil-related stresses Guaranteeing safe application under a broad range of climate conditions

The field-applied coating is ideally required to have equal performances and features to those of the factory-applied coating, but there is a significant difference between these two processes.

Material

Method

Factory Applied Coating Performance

Machine

Man

Material

Mother Nature

Measurement

Method

Field Applied Coating Performance

Machine

Man

Mother Nature

Measurement

The main difference between Factory and Field applied coating are the enviromental conditions in which the two process are performed. In Factory applied coating we can reduce as much as possible the variables introduced by external conditions, but in Field applied coating this is almost impossible. Therefore, to compensate the gap we can only work on the other 5 factors. How?

Man Machine Material Method Measurement

Investing in people Recruitment,training,feedback,supervision Good machinery, well maintained, well calibrated Using the most suitable type of coating for the job Devices, systems and procedures are known and applied Inspecting, controlling and checking results

Induction heating is one of the most important processes affecting the quality of Field applied coatings.

With a very long experience acquired in over 25 years, Tesi responds with expertise and efficiency to the following demands:

Man Machine Material Method Measurement

Engineers and technicians with deep know-how and relevant experience Phone support 24/7 - Training course - Start-up and commissioning Modern, realible and new equipment - Fleet of equipment for rental, well manteined and calibrated Built-in modern multimedia interface available on machines Different equipment for different applications Heat-shrinkable sleeves - Epoxy based, PU based, ...

Clear and simple procedures controlled by the software Record of all the heating parameters to monitor the quality of the results

Tesi designs and manufactures different types of induction heating clamp coils to perform the different kind of processes required by field applied coatings. Each project has its own features: different joints geometries, steel grade and enviromental conditions. Therefore at every turn Tesi has to face different requirements.

The inductors for field applied coating can be distinguished in two main categories:

• Manual Clamp Coils • Automatic Clamp Coils

Manual Clamp Coil - SIC & HDC series These are the most used series for every kind of applications. According to the project specifications, they are designed in order to match the induction heating generator that powers them. The strong mechanical properties of the fiberglass used for the main structure guarantee the robustness typical of all the equipment used in the field, and also a complete electrical insulation for the operators.

The other parts - open and closing mechanism, levers, shaft, bolts and all the other metal components - are made of stainless steel. Electrical conductors are protected by high temperature resistant sleeves and all the electrically charged parts have adequate protections.

Opening and closing systems are available in two configurations: Hand operated (Handle) or Foot operated (Pedals).

Tesi developed an innovative thermodynamic software, Tesisoft, which allows to simulate the required temperature profile for a perfect tuning of coils and generators.

Temperature (°C)

Heat distribution on Pipe as of TesiSoft software simulation

Legenda Pipe Ø56” WT 12.7 P=100 kW Time 420 sec

Distance (mm)

A common feature on all Tesi inductors is the uniformity of heating, not only on the surface of the pipe but completely through the wall thickness, with limited tolerance range.

Features Dimensions Heating Width

Inches

8 ÷ 56

mm

300 ÷ 600

Power Supply

MAX Output Power *

IGH 120 ÷ 350

kW

350 **

Operating Temperature

°C (°F)

-40 / +45 (-40 / +113)

IP protection

IP22/IP66 (depending on the connection used)

MAX Input Voltage

V

500

Standards

MAX Input Current

A

750

Output Connectors

Frequency

Hz

600

Certifications

2006/42/CE PowerLOCK / Lugs CE

* More common Cutbacks ** Power declared are guaranteed only by using Tesi generators

Foreseen Heat distribution on Pipe

Temperature (°C)

Legenda Pipe Ø56” WT 12.7 P=100 kW - Time 420 sec Temperature after 10 sec “ “ 20 sec “ “ 60 sec “ “ 2 min “ “ 3 min “ “ 4 min “ “ 5 min “ “ 6 min “ “ 7 min “ “ 8 min

Distance (mm)

Automatic Clamp Coil - AIC series These series are usually designed for offshore applications and are available for J-Lay and S-Lay projects.

As the standard series, they are designed to match the induction heating generator that powers them.

They are composed of a stainless steel structure on which all the electro-pneumatic components (cylinders, valves, regulators, switches) are installed.

The coil is mounted into the structure and connected to the pneumatic actuators. It is made of fiberglass that guarantees the robustness typical of all the equipment used in the field and also a complete electrical insulation for the operators.

The other parts - like open and closing mechanism, levers, shaft, bolts and all the other metal components - are made of stainless steel.

Electrical conductors are protected by high temperature resistant sleeves and all the electrically charged parts have adequate protections.

Features Input Voltage

V

380-480 3 phases (NO neutral)

Input Current (Full Load)

A

340

Input Frequency

Hz

50/60

Max Output Power

kW

180

A

500

°C (°F)

-15 / +45 (+5 / +113)

Start-Up Current (for 20 sec) Working Temperature IP Protection

IP22

Standards

2006/42/CE

Certification

CE

MAX Output Power Duty Cycle S3

kW

50 % Max ON (6’ ÷ 20’) 180

Rated Voltage

V

265

Rated Current

A

680

Output PF

1

Thermal Gradient - Foreseen Profile

280°C

Legenda

260°C

Pipe Ø12” WT 12.7 P=100 kW Pipe Ø18” WT 12.7 P=100 kW Pipe Ø24” WT 12.7 P=100 kW Pipe Ø36” WT 12.7 P=100 kW Pipe Ø56” WT 12.7 - P=100 kW

240°C

Temperature (°C)

220°C 200°C 180°C 160°C 140°C 120°C 100°C 80°C 60°C 40°C 20°C 0°C

0

60

120

180

240

300

360

420

480

540

Time (sec)

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