Induction Heat

Services for
Pipeline Welding

Pipeline Induction Heat Limited (PIH)

The Pipeline Centre

Farrington Road
Rossendale Road Industrial Estate
Burnley
Lancashire
BB11 5SW
United Kingdom

Tel: +44 (0) 1282 415 323

Fax: +44 (0) 1282 415 326

E-mail: sales@pih.co.uk
Web: www.pih.co.uk Certificate No.25389
Services to the Pipeline Industry

Introduction to Induction Heating

The importance of fast, accurate and uniform heating as part of the pipeline welding specification
has grown significantly. This has resulted from the increased use of heavy wall pipe and modern
automatic and semi-automatic welding systems.

Traditional gas flame and resistance heating systems, are often impractical where higher
temperatures are specified. They are not only too slow to meet the cycle times demanded by the
industry, but also the heating is too inaccurate and lacks uniformity around the full circumference
and bandwidth of the weld joint.

Pipeline Induction Heat have solved these problems, by developing comprehensive induction
Finished Induction Coil on Load Test with Cooling Shells heating systems, which offer over 15 years of trouble free onsite performance, both onshore and
offshore:

P ipeline Induction Heat Ltd (PIH), a CRC Evans Company is a contracting company
specialising in the onsite application of anti-corrosion coatings, heat treatment and other
support services during construction of on shore and offshore oil, gas and product
Induction Heating - System Advantages
pipelines.

The pipeline industry is characterised by rapid advances in automatic welding and • Much faster temperature rise than gas or resistance heating
factory-applied linepipe coating technologies. Anticipating these trends requires PIH to • Variable control over temperature/time parameters
undertake innovative research and development to provide practical solutions, which • Accurate, uniform heating over a controlled bandwidth and around the full pipe circumference

satisfy these stringent new standards. This has resulted in an expansion from PIH's • Fast, accurate, reliable and cost-effective
traditional induction heating business, into diverse activities involving the site application • Minimal damage (if any) to factory coating
of sophisticated pipeline joint anti-corrosion, thermal insulation and infill coating systems. • Heat pattern is accurate and localised
• Designed with the lay contractor in mind
• Equipment is robust and reliable
As the most experienced independent field joint coating contractor, PIH fully understands • Simple, lightweight, user-friendly equipment operation
the necessity for working alongside both main contractors and owners to provide a total
• Induction heat is ‘direct into metal’
project service for field joint coating of their pipelines. On time, on budget and to • No deleterious surface residues are produced
specification are key parameters in the PIH business philosophy. However, this is never • No naked flames or exposed elements
• Heat is localised
allowed to overshadow the primarily important factor of health and safety on construction
• To ensure that temperature measurements stay within
worksites. Operating a fully BSI accredited health and safety management system, PIH specification
places primary focus on achieving zero accidents both in the field and throughout the • Does away with the need to set aside a large storage area for gas
business operation.
• Unlike gas heating, the induction system is not impaired by very low ambient temperatures
Pre-Weld Heating Post Weld Heat Treatment

P ipeline Induction Heat’s pre-weld induction heating systems have been designed for both onshore and
offshore field operation, at mainline / front end or double jointing locations.

Originally engineered for use on large diameter heavy wall pipes, in association with automatic welding systems,
induction pre-heat is equally useful where manual stick-welding is being employed during cold weather
conditions.

System Description
Typically PIH provide a proven method of induction heating of pipe ends prior to line-up and root pass welding,
utilising a diesel engine powered medium frequency PIH induction generator (100 or 200 KVA capacity), which
feeds power to two induction coils simultaneously.

The system consists of a special motor generator, located alongside the workstation (offshore), or on a prime
mover (onshore), with the two coils mounted on a pipe pup-piece close to the operating unit.

Two labourers operate the system, under PIH supervision. The coils are unhooked from the pup piece and
placed inside the respective pipe ends requiring pre-heat. The coils are an internal / external PIH design, built of
lightweight aluminium to facilitate ease of handling. The design allows the coils to easily locate on the pipe bevel
or pipe end, to ensure correct location. Once in place, the coils are energised using a manually controlled handset.

Typically, PIH supply coils, which provide a 100mm wide heat band, to a temperature of up to 350°C for each
pipe-end. (Bandwidth and temperature parameters can be altered to suit specific client requirements). Pipe
temperature is monitored using temperature sensitive crayons. After each pipe reaches temperature, power is
switched off and both coils are removed from the pipe and temporarily replaced on the pup piece.

Coil voltage is 150 volts maximum, to comply with electrical safety requirements.
Post Weld Heat Treatment
Re-Heat
PIH’s post-weld induction heating system is intended for laybarge operation, for diameters ranging
In certain circumstances, particularly for offshore fast production pipelay using automatic welding systems,
unexpected delays can disrupt the welding process on the laybarge firing-line. from 6” to 72”, with no limit on wall thickness. Temperature ranges are typically 0 to 650°C.

These ‘hold-ups’ can lead to degradation of the partially welded joint, which may require further filling before it is The purpose of induction post-heating is to provide a rapid, accurate heating cycle, to stress-relieve
fully completed. To prevent degradation and embrittlement of the weld, which could lead to a negative NDT / X-ray (anneal) a recently welded pipe joint. This is typically required following specialist automatic welding of
result downline, PIH have designed a ‘re-heat’ induction heating system. This consists of a hinged coil designed to
very heavy wall pipe, which can result in embrittlement of the weld metal, leading to unacceptable
pass heat into the localised area of the weld margin only.
‘hardness values’. To overcome this problem, the weld area must be subjected to a pre-calculated heat
Interpass Heating treatment programme, within the fast laybarge welding production cycle.
As an integral part of many modern pipeline welding specifications ‘Interpass heating’ is
performed at a number of welding stations, in order to prevent stresses building up in
System Description
the weld metal, which would otherwise necessitate a post-weld stress relieving
PIH’s induction post heat systems will heat the weld area, over a pre-determined narrow bandwidth to a
(annealing) cycle.
selected temperature. The weld is then held ‘at temperature’ for the desired soak period. Temperature
For offshore operations, hinged Interpass / Re-Heat induction heating coils are
rise, time and power is automatically controlled via a microprocessor to an accuracy of +/- 5%.
suspended by airhoists from a monorail which runs overhead to the welding
stations, either at the mainline or double joint areas. When required, the coil can
be rapidly located around the partly welded field joint. The coil is immediately
energised and the joint temperature boosted to a level which complies with the The system parameters can be readily adjusted in terms of :
welding specification, thus overcoming any hardness or minimum heat
requirements at the next welding station. • Variation of climb time • Temperature rise rate
• Soak temperature • Soak period
The PIH Interpass / Re-Heat systems are generally offered as an ‘extra’, when a client
selects to utilise PIH induction pre-heat systems.
System Components
PIH’s system consists of four main components as detailed below:
i) Weld Heating Unit
The special water cooled coil heating unit
incorporates a hinged design to allow easy
location on / off the pipe. The input power
enters through a power transfer box,
suspended from a monorail above the pipe.
The operator activates the system, which
then provides a totally automatic heating
cycle. Temperature sensors mounted on
the coil continuously monitor the weld
temperature and report this information
to the control console.
PIH’s system incorporates full manual
override and safety systems, and has been
designed to operate in conditions of
substantial pipe movement.
ii) Power Generation Unit
Each PIH solid state power generation
unit, produces induction frequency,
single-phase power to the coil, controlled
via a control console.
The unit is fed via a mains electrical supply.
iii) Control System
This unit provides constant monitoring and
overall control of the PIH system. The
microprocessors compute power requirements
and dynamically control power output, to bring
the weld area up to the required temperature
Temperature °C
under the selected temperature / time profile.
A remote control box, located in the workstation
displays the output from thermocouples
attached to the pipe at the weld line and
adjacent to the factory coating. Initially the
generator is run at full power to provide rapid
heating. Once the required temperature is
reached the power is reduced to a holding level
and a preset timer is automatically activated.
After the required holding time is passed the
generator is automatically switched off-load.
To prevent damage to the factory coating a
further safety measure is incorporated. If the
temperature at the coating interface exceeds a
preset level then the generator is automatically
switched off.
The control box also incorporates an electronic
data logger, which records the temperature
during the PWHT process.
The cycle time for the entire PWHT operation is
typically 12-15 minutes including a five minute
‘holding time’ this is in line with predictions
made at the outset of the development.
iv) Water Cooling Unit
The power generator units and weld heating
coils require a supply of fresh water cooled
using a fresh to seawater heat exchanger.
PWHT Induction Heating Tests
Test Number 2 - Coil Heat Profile Test Material 12% Chrome Pipe 12.75 OD
KEY
12 O’Clock
12 O’Clock Right
12 O’Clock Left
3 O’Clock Left
6 O’Clock Left
9 O’Clock
650°C
Elapsed Time
PIH Directory of Services
Surface Preparation = Pipeline Field Joints Heat Treatment Services: for Pipeline Welding
• Closed Cycle Abrasive Blasting system (CCAB) • Pre-weld heating
• Manual / Expendable Abrasive Blasting • Interpass heating / Re-heat
• Post-weld heat treatment
Fusion Bonded Epoxy “FBE” External Anti-Corrosion
• Lay barge induction heating installations
Coating for Pipeline Field Joints
• FBE onshore / offshore
High Density Polyurethane Foam “HDPF” Field Joint Infill:
Multi Layer Polyethlene / Polypropylene External for Concrete Weight-Coated Pipelines, as an alternative to
Anti-Corrosion Coating for Pipeline Field Joints hot-poured marine mastic
• Heat shrink sleeve: using induction pre / post heat) • Polyurethane foam systems “PUF”
• Multi-Component Liquid "MCL" automatic spray • Aggregate polyurethane composite systems
(i.e. Tar Urethane / Liquid Epoxy etc.)
• Polypropylene “PP” systems: Dual powder
Other General
“FBE / CMPP”
• Supply of Lay-barge induction heating systems
/ PP tape / Co-extruded PP sheet etc.
• Development of equipment and processes for new
Thermal Insulation Coating for Pipeline Field Joints generation of anti-corrosion & thermal insulation external
• Solid Injection Moulded IMPU elastomer systems “field joint coating” systems
• Syntactic polyurethane “SPU” systems • Pipeline buoyancy control systems – saddlebag weights