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Avoid EAF Cable Failure by Relieving Torsion!

A majority of the electric arc furnace power cables we inspect have the most damage at the transformer vault end of the cable. The copper conductor package and heavy cover hose typically have suffered excessive wear due to torsional force or twisting of the cable when the conductor arms and furnace roof swings back and…

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What happens during a cable inspection?

Steps go something like this: You send in your used induction power cable. We'll open it up. Remove the cover hose. We'll expose the conductor. But more importantly, I believe there's a deeper understanding that power cables can give us. Power cables are the arteries of an induction melting system. Just like high blood pressure…

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Keep Your EAF/LMF Power Cable Spares Ready for a Really Bad Day

The unthinkable has just happened. You got the word that a power cable needs to be replaced, and NOW! So…where are the spares? Are they in the storeroom? Behind the furnace? Outside in the yard? Here's what I'm hoping you'll find: Spare cables are laying flat in stackable trays or suspended vertically to maintain wire…

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Terminal flare end of induction power cable

How to measure your power cable length

There's more than one way the industry measures induction power cables, unfortunately creating confusion. Some measure the hose length. We prefer to go with the overall length, and by that we mean we measure from copper terminal flare to the terminal flare edge on the other side of the cable. This flare-to-flare method is an…

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BIT Solutions, Karrich Industries provide international representation

CANTON, OH – (December 11, 2020) I2r POWER leadership is pleased to announce BIT Solutions of Naucalpan de Juárez, Mexico and Karrich Industries of Selkirk, Manitoba, Canada have been selected to exclusively represent water-cooled power cables, electrical bus systems and  electromagnetic stirring service among steel mills, foundries and metal casters. Effective immediately Karrich Industries, servicing…

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How much torque to apply when installing induction cables?

How much torque to apply when installing induction cables Often we’re asked for recommendations when tightening or loosening fittings on an induction power cable. First, this is a job for two wrenches! And, depending on your connection, be sure to avoid tightening or loosening soldered pipe threads. Here is the procedure for applying torque to…

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Maching copper bus

Work In Progess: Intricate Bus for Tight Quarters

Custom Bus for Tight Quarters Problem: This high capacity titanium producer was facing limited space for a bus system carrying 40,000 amps and it's cooling interconnections in a new Vacuum Arc Remelt (VAR) system. Solution: Using modeling software, I2r POWER engineers were able to design a series of cooling passages for a large section of bus. Heat…

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Notable Project: Haynes International’s new power pass thru assembly

Haynes International – Kokomo, IN Replacement Pass Thru Assembly Problem: Haynes International needed a new replacement for their 10-ton vacuum master melt furnace. We are all for having spare parts on hand for emergencies! Solution: I2r POWER engineers and designers make power efficiency improvements to pass through assemblies to ensure controlled atmosphere integrity, and they…

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Carpenter Bros to represent in 14 Midwest, Southern states

CANTON, OH – (July 15, 2020) I2r POWER leadership is pleased to announce Carpenter Brothers of Wisconsin has been selected to exclusively represent water-cooled power cables and electrical bus systems among foundries and metal casters in 14 Midwest and Southern states. Effective immediately, Carpenter Brothers sales representatives will be offering I2r POWER foundry and metalcasting…

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Notable Project: Enormous CMC Steel-Sayreville EAF power cable

CMC Steel – Sayreville, NJ Massive Rotating Terminal Design Problem: The customer needed to enhance the longevity of their EAF power cable and mitigate hose binding during operation. Solution: In what might be the largest EAF rotating terminal assembly built in North America, our engineers custom designed a 14,000 MCM terminal assembly measuring 27.25” with…

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Video Gallery

Video Shows Cable Core Construction Best Practice

In this 2-1/2 minute video, Founder and President Mike Pinney reveals the mysteries of what can go wrong when there’s a power cable construction failure. Frustrating as it is, steel makers and maintenance professionals cannot see the problem from the outside. In “Cable Core Construction Mysteries Revealed!,” Mike shows the basic components of an Electric…

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