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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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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…

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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…

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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…

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Winner of Virtual Metal Caster Drawing from Rolls-Royce

Congratulations to Jonathan Weaver, winner of the Virtual Metal Casters Drawing! On April 23 Jonathan’s entry was drawn live on Zoom. A member of the Engineering team at Rolls-Royce, Jonathan won an exclusive autographed Class of 2020 HOF collector edition football. Watch the video on the I2r POWER LinkedIn page. We look forward to seeing…

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Comprehensive Machine Shop Offers Value

Terminals have met their match with our expert machinist Preston Flott and our comprehensive machine shop. Full machining capabilities on modern lathes and mills right here, in-house, expedite your power cable order. As always, your components are handcrafted using top-grade materials by skilled technicians for maximum power and to minimize loss. Have questions about this…

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COVID-19 UPDATE

During this time I2r POWER remains open and in full operation ready to serve and assist our customers. We are following guidelines from public health authorities to protect the well-being of our customers, employees and community.