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27 Minute Coupling Hub Removal

11 November, 20 1:46 pm · Leave a comment · reddarc
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Rotating Equipment Induction Heat Application

induction heating applied to coupling hub

Red-D-Arc’s latest customer success story highlights the benefits of using induction heating in rotating equipment applications.
A client contacted Red-D-Arc to inquire about the use of induction heating to remove a coupling hub from a motor shaft. The hub was 12 inches in diameter and roughly 4 inches thick.

The overall work scope was straightforward: the client needed to remove an old motor and replace it with a new motor. The coupling hub had to be reused, so the hub would need to be removed from the old motor and installed on the new one. Two things made this job challenging: the location and the time limit. The work was to take place on an offshore platform. Use of an open flame was not an option, as it would have led to a safety violation.
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Seized Blow-Out Preventer Issue Resolved in Under 1 Hour After Being Stuck for 9 Years

06 October, 20 11:18 am · Leave a comment · reddarc
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A blowout-preventer (special valve or device used for preventing blowouts on oil and gas wells) which had been stuck together for 9 years is finally separated with the quick application of a Miller induction heating system from Red-D-Arc.

In addition to the many welding heat treatment applications, our heating specialists have years of experience applying this technology in numerous applications from hydro dam maintenance to heavy equipment repair. Contact a specialist to find out how induction heating can be applied to your next challenge.

Thanks to Michael Hernandez AWS CWSR from our Houston location for providing the footage.

 

Unraveling the Mystery of Heat Treatment

05 October, 20 11:19 am · Leave a comment · reddarc
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This article originally appeared in Connector Magazine, Fall 2020 Edition

Erectors can save cost and time by taking this welding technique in-house

welding technique

Large steel erection projects commonly require heat treatment for welding because of the thick materials used in structural steel construction. Proper implementation is critical; so often this work is outsourced. The perceived level of expertise to perform this work can make the prospect of using in-house personnel daunting. However, most welding contractors are actually fully capable of performing on-site heat treatment operations.

The two primary methods for heat treating metal are preheating and post-weld heat treatment (PWHT). Preheating is the process of heating the base metal to a specific temperature prior to welding to minimize the temperature difference between the welding arc and the base metal. This process helps to reduce internal stresses that occur as substantial temperature differences between the weld and the base metal normalize, which can cause cracking and distortion. Slowing the cooling rate also allows hydrogen to escape from the weld, which minimizes the potential for cracking.

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Storage Tank Fabricators Build Efficiently with Induction Heating

10 September, 20 9:29 am · Leave a comment · Geoff Campbell
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Applications and Advantages in Tank Fabrication and Maintenance

Tank Fabrication and Maintenance

In the fabrication of storage tanks, as in most other welding applications, there are two crucial processes that storage tank fabricators must carry out to ensure the final quality and durability of the tanks. They are weld preheating and post-weld heat treatment.

Pre-Heating

Preheating involves heating the material to be welded to a particular temperature before welding. This process reduces shrinkage by minimizing the temperature between the arc and the base material. It also removes moisture, lowers hydrogen, and slows the weld cooling rate. These reduce the risk of cracking, brittle welds, and failure of the welds. Preheating is crucial for storage tanks as they are to withstand high pressures during operation.

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Post-Processing Welded Parts

20 March, 20 4:52 pm · Leave a comment · Geoff Campbell
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Post-Processing Welded Parts

In welding, like in many other manufacturing and fabrication processes, the process is not complete until the necessary post-processing has been carried out. Post-weld operations are usually performed for reasons such as improving mechanical properties, relieving stress, and improving aesthetics. The two most common Post-weld operations are Post-Weld Heat Treatment (PWHT) and Finishing.

Post-Weld Heat Treatment

During welding, the welded materials are exposed to very high temperatures that can cause micro-structural changes in them. Also, residual stresses build up in welded materials when they are allowed to cool naturally.  If left unaddressed, these stresses and structural changes can severely compromise the mechanical properties of a material and can lead to failure during use. To prevent this, PWHT is required for welded parts. There are two major types of Post-weld heat treatment and they are as follows.
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Supporting Maintenance at the Grand Coulee Dam

04 June, 19 2:09 pm · Leave a comment · reddarc
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Grand Coulee Dam interio

Originally built in the 1930s, the Grand Coulee Dam in Washington State has been undergoing a series of maintenance projects to ensure that it will continue to produce safe and reliable power into the future. One stage of the project required the heating of a 40-ft wide, 7-ft tall outer headcover of the turbine shaft to specific core temperature.  In order to achieve this temperature, the engineers applied induction heating to one side of the workpiece.

Only when the opposite side of the workpiece reached target temperature could the maintenance engineers be certain that the required core temperature had been achieved.  The team from Red-D-Arc provided induction heating systems and assistance with training and set up during this essential part of the maintenance process.
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Construction Firm Beats Competition With Fast Induction Heating

31 May, 19 5:22 am · Leave a comment · Colin Brown
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pipeline welding project using induction heat

19 Hours Faster Than the Competition

Texas – One of our customers was trying to heat 42” diameter pipe using pear burners so that welders could weld out the joints. Our team saw an opportunity to create a solution that would help our customer get the job done much more quickly. To make this in-the-field heating job go faster, we put together a package including a Miller ProHeat 35 induction heating system, a 60kVA generator and a DP25 power distribution panel.

Red-D-Arc provided a reliable RDA Induction heating solution to a pipeline construction and maintenance company in Houston who needed to maintain consistent temperatures for their welders to weld out joints from pipes. Our induction heating specialist supplied our customer with a portable induction heating package consisting of a 60 KVA generator, a Miller Pro-Heat 35 induction heating system, and a DP25 power distribution panel. As a cost-effective alternative to their existing propane burners, induction heaters allowed them a secure heating, consistent temperature control, increased weld time, and improved safety.

With this setup we were able to get the pipe up to 250 degrees in about 5 minutes. Our customer was able to beat the competition’s target time by over 19 hours and has been asked to quote on other pipeline work for their client. Needless to say they were pleased with the solution and the opportunity for extra work it created.
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Induction Heating vs Other Methods

29 April, 19 4:48 am · Leave a comment · Colin Brown
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Pre-weld and post-weld heat treating is critical for many welding operations. Without proper thermal manipulation, welds and heat affected zones can have mechanical properties that are undesirable. Worse yet, inadequate heat treatment can result in cracks and devastating weld failures. While temperature and time are the primary concerns when heat treating a weld, the heating method should also be considered diligently when selecting a process. Induction heating is one of the most popular types of heat treating methods, and rightfully so. The benefits of induction heating are many, and Red-D-Arc has the equipment you need to successfully implement an induction heat treating operation for your projects.
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92% Improvement – Turning Problems into Possibilities with a Custom Welding Package

31 August, 18 11:30 am · Leave a comment · reddarc
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Induction Heating with Submerged Arc Welding

When one of our customers was tasked with an electrical motor shaft rebuild that required them to weld new fins onto a 7” diameter shaft, they called on Red-D-Arc’s team of experts for assistance. The job required the shaft to be preheated to a temperature of 400°F and welded using a submerged-arc process (SAW). Using the Miller Proheat 35 and Lincoln’s LT7 sub arc package, a job that was originally bid at 40 hours took just 3 hours to complete.
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Red-D-Arc Company Overview Video

11 May, 17 9:13 am · Leave a comment · Colin Brown
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Red-D-Arc is recognized around the world as the welder rental specialist. We have been renting welding equipment for more than 60 years and our welding-equipment fleet is now more than six-times larger than our closest competitor. But did you know that Red-D-Arc is a leader in Weld Automation, Diesel Generator Rental, Induction Heating Systems, Pipe Welding Equipment, Blast Cleaning Equipment, Specialty Equipment, and Cutting Tables? Over the past 20 years we have been listening to our customers and continuously adding new products and services to meet their needs.

We produced a short video showcasing some of our many products and services. Enjoy!

Induction Heating Speeds up Repair of the World’s Largest Rock Crusher

09 January, 17 2:47 pm · Leave a comment · Geoff Campbell
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Red-D-Arc staff at the Moncton, New Brunswick branch recently helped a customer save time and money repairing the world’s largest rock crusher through the use of induction heat. The hydraulic cylinder that operates the pressure plates used by the enormous rock crusher needed to be brought to a temperature of 500 °F and that temperature needed to be maintained for 3 full days. This was required in order to allow welders to repair the lifting tabs on the cylinder. Normally 3 workers would have used blow torches to heat the metal which would have taken 2 weeks or longer. Red-D-Arc Induction Heating Equipment allowed them to get the job done in less than half the time. Induction heating has many applications in construction, shipbuilding, hydro dam maintenance and bridge building. Red-D-Arc technicians are recognized in the industry for their innovative application of this technology, ready to meet any variety of customer challenges.

Ask us how induction heating can save you time and money on your next project.

Have a look at our entire selection of weld preheating equipment available for rent.

heat treatment button

Customer Project: Minnesota Vikings’ New Stadium

08 June, 16 11:52 am · Leave a comment · Geoff Campbell
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Scheduled for completion in July 2016, U.S. Bank Stadium, the new home of the Minnesota Vikings, is a fixed roof structure that will be nearly 30 stories tall at its highest point. During construction, the base plates of some of the structural support columns needed to be pre-heated to 400o prior to welding. Traditional heating by flame proved to be difficult. It was determined that induction heating was the right solution to safely and efficiently heat the steel to an exact temperature. Induction heating is the preferred method to address challenges associated with the pre-heating of structural steel because it provides a safe and accurate method of heating the metal to a precise temperature.

Red-D-Arc offers Miller ProHeat 35 Induction Heating Systems (IHS) available for rent, lease and sale. This highly efficient technology uses non-contact heating to induce heat electromagnetically rather than using a heating element in contact with the part.

UPDATE:  This project was completed ahead of schedule.

Induction Heating Used for Removal of Hydroelectric Generator Rotor

20 April, 16 3:30 pm · Leave a comment · Colin Brown
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Induction Heating for Rotor Expansion Lift
A customer involved in the rebuilding of a hydroelectric power generation station came to Red-D-Arc with a unique challenge: Use induction heat to help separate a massive rotor from its center shaft assembly. A traditional approach is to use a combination of open flame along with dry ice which would have taken several weeks to set up and also ran the risk of being ineffective due to the scale and complexity of the project.

Sil Nonis, an induction heating specialist at Red-D-Arc, suggested using 6 induction heating units activated in sequence to provide thermal growth in a uniform pattern; releasing the interference from the center shaft before lifting the rotor. The 6 Miller ProHeat 35 Induction Heating Systems powered two half circle assemblies, positioned at the bottom of the locking ring which was 5′ in diameter as well as two half circle assemblies positioned on a top locking ring which was 4′ in diameter. Massive rotor arms also had 4 pads attached to them, positioned in sequence.

Setup took approximately 2 days and removal of the rotor was completed in a single day. The same process will be used to reinstall the rotor after it has been rebuilt. Over the next few years two additional rotor assemblies will be removed, rebuilt and reinstalled using the same process.

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Airgas, an Air Liquide company, is the nation's leading single-source supplier of gases, welding and safety products. Known locally nationwide, our distribution network serves more than one million customers of all sizes with a broad offering of top-quality products and unmatched expertise.