Powering Your Process

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EAF/LMF Cable Protection for Steel Makers

A lot of EAF water-cooled power cables come through the shop showing signs of extreme wear and tear. There's no avoiding it, steel making environments are demanding on equipment. The dirt, heat, and collisions are inevitable. Typically, failed cables suffer from ambient heat, molten metal splash and spills, and chaffing and/or friction. A variety of…

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Constant Flow Ring terminal design

CFR rings are a must for swivel nut terminal designs

The lifeblood of any induction melting system is coolant. Loss of coolant in an induction system creates all kinds of issues, and none of them are good. We see a lot of coolant flow disasters come through the shop. To ensure coolant flow at I2r POWER, we employ the Constant Flow Ring (CFR) in our…

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DRLO_3 Tests Video Capture

3 Tests to ensure your spare Induction Power Cable performs

I'm often asked by customers, "How will I know my induction power cable is going to work when needed?" There's a lot of money spent on spare components, and power cables are no exception. When they are needed, they are NEEDED! And if the cables don't work when required, it can be catastrophic. There are…

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Induction power cable terminal design options

Metal casting power needs are as varied as each induction melt system and application. The good news is you've got power cable design options! The industry standard is a conventional crimped, swivel nut design. At I2r POWER we recommend promoting better coolant flow by building into this design a Constant Flow Ring (CFR). A CFR…

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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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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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