Flexible Ceramic Pad Heater

Flexible Ceramic Pad (FCP) heater is manufactured by multi-strand quality 80/20 Nichrome heating wire through passages within interlocking ceramic beads, complete with two electrically insulated camlock, which is protected from being heated by cold pure nickle wire that connects the heating wire. The alumina ceramic beads are made of sintered 95% Alumina Ceramics. It enjoys high temperature resistance, excellent insulating property, and efficient thermal conductivity, which provides FCP heaters with exceptional electrical insulating,and thermal shock resistance and thermal condutivity qualities.

FCP heaters are generally available to two standard volts: 80VAC, and 60VAC and using different connectors among different countries, one choice is Brass Camlock Connector, the other choice is Welding Cable Plug(System DINSE).

The FCP are available as follows for standard heater.Custom Heater can be provided, for example 220V/240V heater.

60V Heaters
Type             Width        Length        Rating         Current          Voltage
                     (mm)        (mm)            (kW)            (amp)             (volt)
CP3-60V         75               724            2.7kW          45amp           60 volt
CP4-60V         102             533            2.7kW          45amp           60 volt
CP6-60V         152             368            2.7kW          45amp           60 volt
CP8-60V         203             267            2.7kW          45amp           60 volt
CP10-60V       254             229            2.7kW          45amp           60 volt
CP12-60V       305             184            2.7kW          45amp           60 volt
CP15-60V       380             146            2.7kW          45amp           60 volt
CP18-60V       457             127            2.7kW          45amp           60 volt
CP21-60V       535             102            2.7kW          45amp           60 volt
CP24-60V       610              83             2.7kW          45amp           60 volt
CP26-60V       740              83             2.7kW          45amp           60 volt

80V Heaters
Type             Width       Length       Rating          Current          Voltage
                     (mm)        (mm)           (kW)             (amp)             (volt)
CP3-80V         75              991           3.6 kW          45amp           80 volt
CP4-80V        102             737           3.6 kW          45amp           80 volt
CP6-80V        152             501           3.6 kW          45amp           80 volt
CP8-80V        203             368           3.6 kW          45amp           80 volt
CP10-80V      254             368           3.6 kW          45amp           80 volt
CP12-80V      305             248           3.6 kW          45amp           80 volt
CP15-80V      380             203           3.6 kW          45amp           80 volt
CP18-80V      457             165           3.6 kW          45amp           80 volt
CP21-80V      535             145           3.6 kW          45amp           80 volt
CP24-80V      610             125           3.6 kW          45amp           80 volt
CP29-80V      740             100           3.6 kW          45amp           80 volt
CP33-80V      840               85           3.6 kW          45amp           80 volt
CP36-80V      915               80           3.6 kW          45amp           80 volt

Channel Heaters

The range of channel elements has been designed to provide modular heating units of a robust design suitable for connection to a mains or low voltage electrical supply. The heaters are portable and solid and are suitable for use in temporary furnace design or for the heat treatment of pressure vessel welds and sections,or other large fabrications. Heat transfer to the component is effected by combined radiation and convection. The heater element is manufactured from solid drawn 9swg Kanthal or nickel-chromium coiled wire. The coil may be embedded into a high conductivity cast refractory material within each of the unit stainless channels trays that form the heater. Alternatively the heaters can be manufactured with the traditional ceramic sleeves. The standard heaters are suitable for heat treatment temperatures upto 800°C. Temperatures above this value can be achieved by variation of the composition of the case/coiled wire and heater design.Standard heaters are supplied for arange of voltages upto 240V.

Standard heaters should deliver a current of 55 amps and unit heaters are designed for arange of voltages be tween 30 and 277V. The higher rating permits the connection of the heaters in groups of three to suit3-phase supplies. The heaters may be mounted onto supports for vessel heat treatments or directly to the components as may be suitable. Avoid contaminants(grease,paint,oiletc)on the metal surface.

Tank Track Heater

The Tank Track Preheater has the same design concept as the ceramic bead CPP in terms of their in sulation backing and stainless steel protection. The ceramic pad element is,however,replaced by full width beads,75mm wide.The heater has an over all width of 101mm. The construction of the element is simple with a facility to accommodate six longitudinal runs of the heater core wire.The standard heater is rated for 60V or 80V operation using a heat treatment transformer as the power source.

Localised heat treatment is often required after welding on circumferential welds or with the fitting or repair welding of nozzles/attachments to the shell.It is sometimes an advantage to undertake the heat treatment by the application of ceramic pad heaters to the external surface of the shell.This is particularly so where internal access is restricted or where there is a necessity for internal welding and the preheat and PWHT arrangements can be common.The use of larger pads can be useful under such circumstances,but special attentio nmust be given to safety precautions and also to the freedom of the metal surface from contaminants.