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Induction Heating Systems | MillerWelds

Heating Equipment

Induction Heating

The right system for your heating needs

Why Induction Heating?

Induction heating is easy to set up, offers a fast time-to-temperature, and delivers exceptional heating efficiency, accuracy, and uniformity in part temperature. In addition, induction offers safety benefits compared to open flame and resistance heating methods.

Applications

  • Preheating and maintaining weld temperature
  • Hydrogen bake-out
  • Post-weld heat treatment (PWHT) up to 1450° F
  • Shrink-fit processes
  • Various other applications which requires heating

Industries

  • Oil and Gas
  • Structural
  • Power plants
  • Petrochemical/Refineries
  • Process/Power Piping
  • Pressure vessels
  • Shipyards
  • Mining

This highly efficient technology uses non-contact heating to induce heat electromagnetically rather than using a propane torch or resistant heating.  With induction, the part becomes its own heating element, heating from within.  This makes induction very efficient since little heat is lost in the process.
Time to temperature is dramatically faster than flame or resistance heating -- reducing cycle time. Setup and tear down times are quick and unlike flame or resistance, induction allows continuous heating and fabrication.
Induction heating lowers operational costs because reaching target temperatures is dramatically faster, resulting in reduced consumable costs and labor expenses. In addition, it eliminates the expense of fuel gases, fire watch personnel*, and heating subcontractors.
Provides exceptional joint temperature uniformity.  Induction eliminates the inconsistencies and quality issues associated with flame or resistance heating.
Welders are not exposed to open flame, explosive gases, and hot elements associated with flame and resistance heating.  Induction’s method of heat transfer results in a cooler environment that reduces operator fatigue and improves work conditions.  

Compare Induction, Flame and Resistance Heating Methods

 
INDUCTION HEATING
FLAME HEATING
RESISTANCE HEATING
SETUP/TEARDOWN ✔ EASY
20 minutes or less per joint. Teardown time is fast, as induction tools can immediately be moved to the next joint without cooldown time.		 ✔ EASY
 		 ❌ COMPLEX
Approximately 3 hours per joint. Teardown times are also lengthy, as crews must first wait for the heating equipment to cool.
TIME TO TEMPERATURE ✔ FAST
20 minutes or less per joint		 ❌ SLOW
Up to 3 hours, depending on part/material size and thickness 		❌ SLOW
Up to 3 hours, depending on part/material size and thickness
JOINT TEMPERATURE UNIFORMITY ✔ EXCEPTIONAL
Thorough and even heat profile		 ❌ POOR
Subject to hot and cold spots		 ❌ MARGINAL
HEATING EFFICIENCY ✔ EXCEPTIONAL
90% efficient		 ❌ POOR
Much heat lost to air; reheating needed after breaks and off hours		 ✔ GOOD
Marginal heat lost to air
SAFETY ✔ EXCEPTIONAL
Tools do not heat up; no toxic byproducts or noise		 ❌ POOR
      
  • Risks burn injuries, fires and explosions
    •   
  • Excessive noise levels
    •   
  • Toxic, combustible byproducts
 ❌ MARGINAL
      
  • Ceramic pads are as hot as the work surface, bringing risk of burn injuries
    •   
  • Damaged/incorrectly used heating tools bring risk of electric shock
    •   
  • Inhaling insulation fibers/particles is a health hazard
OPERATING COST ✔ LOW
      
  • Delivers strong return on investment
    •   
  • Electricity cost: $5/hr
    •   
  • Induction air-cooled cables and air-cooled quick wraps are ruggedly constructed for repeatable uses
 ❌ HIGH
      
  • Fuel cost: $50/hr
    •   
  • Fire-watch personnel must often be hired*
 ❌ HIGH
      
  • Preheating contractors can charge up to $2,000 per joint, and final project costs often exceed original bid pricing
    •   
  • Requires installation of electrical infrastructure
    •   
  • Ceramic pads require frequent replacement
    •   
  • Used insulation is considered hazardous waste; proper disposal is costly

Products

ArcReach Heater 8 kW system for preheat and bake-out applications. System requires an ArcReach welding power source.
ProHeat 35 35 kW system for preheat, hydrogen bake-out, post-weld heat treatment and various other heating applications. System requires 3-Phase, 50/60 Hz power.

One-On-One Induction Specialist Consultation

Questions About Induction Heating?
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Articles and Videos

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New Preheating Technology for Rolled Pipe in Fabrication Shops The majority of pipe welds completed in fabrication shops are rolled, and it's easy to understand why. Rotating pipe while welding provides many benefits, including ease of achieving quality welds by eliminating out-of-position welding; reduced welding operator fatigue; and improved productivity from higher wire feed speeds and increased deposition rates. Read More

Miller Preheating Technology for Roll-Welded Pipe Increases Quality, Productivity and Safety

Gaining consistency in preheating rolled pipe, or flat plate or seam welds, without the hassle and hazards of open flames, increases safety and efficiency.

ProHeatâ„¢ Rolling Inductor Provides Safer Alternative to Preheating Rolled Pipe

Preheating is critical to achieve high weld quality; it eliminates moisture and reduces the opportunity for hydrogen cracking.
*As specified in ANSI Z49.1, Supervisors shall assure that fire watchers are assigned and hot-work authorization procedures are followed where required.

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