Powering Your Process

Read all articles in the blog category Powering Your Process

Home / Powering Your Process

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…

View Post

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…

View Post

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…

View Post
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…

View Post

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…

View Post
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…

View Post

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…

View Post

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…

View Post

Notable Project: TimkenSteel – Harrison Mill Final Stirrer

TimkenSteel - Harrison Mill Final Stirrer Problem: Caustic flux powder used in the continuous casting process was violently attacking the carbon steel weldment of TimkenSteel’s electromagnetic final stirrer. Solution: A new weldment of high-grade corrosion-resistant stainless alloy was designed, built and fabricated to stop corrosion. It’s not out the door yet, because we’re storing it…

View Post

Notable Project: CarTech’s Dual Station ESR Furnace bus tubes

Carpenter Technologies - Latrobe, PA Problem: The retrofit and rebuild of Carpenter Technologies’ dual station ESR furnace bus tubes took some finesse. The ESR is an older furnace built circa 1960, and consequently sourcing spare components and the craftsmanship to perform the work is difficult. Solution: The replacement bus tube components arrived at the customer’s…

View Post
DC Reactor Coils

Notable Project: Gerdau Long Steel – St. Paul DC reactor coils

Gerdau Long Steel - St. Paul, MN Problem:  Our customer’s existing DC reactor coils were beginning to leak coolant, and the OEM, General Electric, no longer supported the equipment. Gerdau Long Steel could not continue to operate their DC electric arc furnace with their existing coils, and were having difficulty solving their problem. Solution: The…

View Post
speech bubbles

Eager to find solutions, I2r POWER responds with collaboration, hand-crafted quality and accountability.