Powering a Heating Revolution

Induction Heat Systems Solve Ongoing Preheating & Stress Relieving Problems
With the introduction of the Indoheat Induction Heat System, this simple and cost-effective
heating process can be applied in the following applications to deliver fast and consistent heat:
Welding fabrication and construction;
Preheating of welds;
Post-weld heat treatment;
Coating removal; and
Shrink Fit.
Applications that would typically require hours to heat can be done in minutes utilizing
induction heating. Discover the dramatic benefits of using induction compared to current
processes by using the calculators for time-to-temperature for typical heating applications of
pipe and plate.
In addition to the simplicity and efficiency of IndoHeat, this heating system solves many key
issues in todays environment:
Induction heating does not require the significant expense of fuel gases.
Induction heating produces fewer fumes than flame heating.
Induction heating produces less particulate from overheated insulation caused by high
temperature electrical wires and ceramic pads
Induction heating does not produce the exposure to burns associated with open flames and
electrical resistance wires (only the work part becomes hot).
These benefits of induction heating provide a more productive work environment and delivers
significant cost savings.

Application

Application: Pre-heating of pipe to 300F before welding on a transmission pipeline. Air-cooled

induction blankets are perfect for this application. The induction coil is sewn into a durable 3-D

woven silica material with preheat insulation on the bottom. The entire blanket can be moved
from joint-to-joint with minimal change over time. Induction blankets can be used to heat the
target material up to 400 F. Note also that Millers Induction power sources can be powered
from a portable generator set.

Application: Pre-heating of a valve body to 400F before welding on a repair. Water-cooled

induction coils (Miller patented) are flexible and easy to apply to a variety of geometries. Here a
pancake style coil has been wrapped around a repair area. Typical heat time for this
application is 10-15 minutes for both the inside and outside of the body to be at temperature.
Note also that this coil is protected with pre-heat covers to protect the coil from hot weld slag
and abrasive wheels. Because the heat is in the valve and not the coil, rope, plastic tie wraps and
tape can be used to hold the coil into place.

Application: Post Weld Heat Treating (PWHT) a P91 header to 1400F after welding. Watercooled induction coils (Miller patented) wrap around PWHT insulation that is applied to the
header. The 1 thick silica needle mat insulation traps the heat in the header while protecting the
coil from the high PWHT temperatures. The insulation is re-usable and does not emit dangerous
particulate into the environment. Thermocouples are attached to the weld joint to provide
temperature feedback to the power source. The integrated temperature controller on the
IndoHeat 35 has a standard PWHT program that will execute a controlled heating profile that
will ramp up to a set temperature, dwell there for a set time, and then cool down at a controlled
ramp rate. The unit also has a custom program feature that will allow parts to be heated with

multiple steps, ramps and dwells in a single cycle.

Application: Pre-heating of a Feed Water Heater to 300F before welding on a repair. Liquidcooled induction coils (Miller patented) are flexible and easy to apply to a variety of geometries.
Since the coil remains cool, common materials can be used to support the coil. Here a pancake
style coil is wrapped to the size of the needed heat zone on the water heater. A plywood form is
cut to size and the coil is fitted to the wood with common strapping tape. The coil is held to the
part using the studs on the water heater. The repair area is now set-up and heated in a fraction of
the time it used to take, and the heat is uniform, no hot spots.

Application: Post Weld Heat Treating (PWHT) a carbon steel pipe to 1250F after welding.
Water-cooled induction coils (Miller patented) wrap around insulation that is applied to the pipe.
The heat zone on this weld needs to be wider than the 13 wraps of the coil, so the coil is
widened some by spreading the coils apart slightly. This set-up also illustrates how to properly
terminate any unused portion of the coil. The ends of the coil should be twisted together or tied
together with tie-wraps, tape, rope or string in order to reduce the amount of losses in the unused
portion of the coil.

Application: Post Weld Heat Treating (PWHT) of a 12" carbon steel pipe transition at a valve to
1250F after welding. Liquid-cooled induction coils (Miller patented) wrap around insulation
that is applied to the pipe. The valve body has a heavier wall thickness than the 12" pipe, so
extra turns of the coil are applied to the valve to heat the extra mass.

Application: Pre-heating two joints to 300F before welding, with a single coil. Liquid-cooled
induction coils (Miller patented) are flexible and can be placed in multiple locations. Here a
single coil is used to wrap around both ends of the pipe where weld joints are prepped. As long
as the dimensions of the pipe are similar from joint to joint, the applied induction field will heat
both joints relatively the same.

Application: Pre-heating of structural steel tube to 300F. Air-cooled induction blankets are used
for this application. The induction coil is sewn into a durable 3-D woven silica material with
preheat insulation on the bottom. The entire blanket can be moved from joint-to-joint with
minimal change over time. Induction blankets can be used to heat the target material up to
400F.

Application: Pre-heating of an in-service pipeline to 100C before welding on a sleeve. Liquidcooled induction coils (Miller patented) are flexible and easy to apply to a variety of geometries.
Here a sleeve is being welded onto a pipe that has material flowing through it. Since the material
is taking heat away from the joint, a second unit is used to apply extra power to achieve the
desired heat in the joint. This also allows each side of the joint to have independent temperature
control.

Application: Pre-heating of structural steel I-Beam to 300F. Liquid-cooled induction coils are
used for this application. The induction coil is wound in a "pancake" style layout and secured to
a piece of plywood to hold its shape. There is a layer of preheat insulation placed between the
plywood and I-Beam to prevent overheating the wood. Note the ability of the magnetic fields to
pass through wood and insulation to induce eddy currents into the I-Beam for the desired
heating.

Application: Post Weld Heat Treating (PWHT) of a drill pipe to 1350F after welding. Here, two
PWHT joints are being processed with one water-cooled induction coil. As long as the
dimensions of the pipe are similar from joint to joint, the applied induction field will heat both
joints relatively the same. This set-up also illustrates how to properly terminate any unused
portion of the coil. The ends of the coil should be twisted together or tied together with tiewraps, tape, rope or string in order to reduce the amount of losses in the unused portion of the
coil.

Application: Pre-heating of an in-service pipeline to 100C before welding on a sleeve. . Liquidcooled induction coils (Miller patented) are flexible and easy to apply to a variety of geometries.
Here a sleeve is being welded onto a pipe that has material flowing through it. This operation is
called a "hot tap". Material flowing in the pipe is taking heat away from the joint, but here, a
single 35 KW unit is able to maintain the desired temperature at the joint. Note the use of
common inexpensive materials to hold the coil into place while welding. Hours were driven out
of the set up time and cycle time using the Miller IndoHeat 35 Induction system.

Application: Pre-heating, from the I.D. of a Flange to Pipe assembly, to 300F before welding.
Liquid-cooled induction coils (Miller patented) are flexible and easy to apply to a variety of
geometries. Since the coil remains cool, common materials can be used to support the coil. Here
an "internal diameter" style coil is wrapped onto a common piece of corrugated plastic sewer
pipe. The pre-heat temperature is cool enough that it does not affect the coil or plastic pipe.
Insulation can be used to protect the coil and pipe if higher temperatures are desired. The coil is
slid into the I.D. of the target work piece. The weld area is now set-up and heated in a fraction of
the time it used to take, and the heat is uniform, no hot spots. Similar set-ups can be used for
shrink fit applications.

Application: Pre-heating of an 8 o-let to a 20 manifold to 400F before welding. Water-cooled

induction coils (Miller patented) are flexible and easy to apply to a variety of geometries. One
coil can be used to wrap around multiple heat areas. Here a coil is wound 4 turns pancake
style onto the larger 20 manifold, then a 3 long loop is formed so the coil is clear of the weld
area for the welder, and finally a 4 turn solenoid style coil is wound around the 8 pipe.
Because the heat is in the pipe and not the coil, rope, plastic tie wraps and tape can be used to
hold the coil into place. This set-up was applied in less than 15 minutes and in another 15
minutes the temperature at the root was 400F, ready to weld. The control system automatically
regulates the power output to maintain the 400F temperature, so the pipe stays at temperature
during breaks, between shifts, or all week if you want

What is meant by postweld heat

treatment/stress relief heat treatment?
Frequently Asked Questions
Postweld heat treatment (PWHT), or stress relief as it is sometimes known, is a method for
reducing and redistributing the residual stresses in the material that have been introduced by
welding.
The extent of relaxation of the residual stresses depends on the material type and composition,
the temperature of PWHT and the soaking time at that temperature. A commonly used guideline
for PWHT is that the joint should be soaked at peak temperature for 1 hour for each 25mm (1
inch) of thickness, although for certain cases a minimum soak time will be specified.
In addition to reduction and redistribution of residual stresses, PWHT at higher temperatures
permits some tempering, precipitation or ageing effects to occur. These metallurgical changes
can reduce the hardness of the as-welded structure, improving ductility and reducing the risks of
brittle fracture. In some steels, however, ageing/precipitation processes can cause deterioration in
the mechanical properties of the steel, in which case, specialist advice should be taken on the
appropriate times and temperatures to use.
The necessity for PWHT depends on the material and the service requirements. Other factors that
influence the need for PWHT are the welding parameters and the likely mechanism of failure. In
some standards, PWHT is mandatory for certain grades or thicknesses, but where there is an
option, cost and potential adverse effects need to be balanced against possible benefits. The
energy costs are generally significant due to the high temperatures and long times involved, but
costs associated with time delays may be more important. Detrimental effects include distortion,
temper embrittlement, over-softening and reheat cracking, which means that control of heating
and cooling rates, holding temperature tolerances and the times at temperature are extremely
important, and must be carefully controlled in order to realise the full benefit of the process.
Quenched and tempered(Q&T) steels have the PWHT temperature limited to below the original
tempering temperature of the steel, as higher temperatures can change the microstructure of the
base material from what was expected or required.