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TTI manufactures the ceramic (FCP) heaters that we use in the field, as well as, the cable assemblies used with the heat treating consoles. In addition, we offer these same products to customers who want do there own heat treating.
Construction
FCP heaters are manufactured by weaving multi-stranded 80/20 Nichrome
electric resistance heating wire through passages within interlocking
ceramic beads. The beads are molded from sintered 94% Alumina ceramic,
more than 3/8-inch thick. The Alumina has excellent high-temperature dielectric
properties which combined with the interlocking bead design provide FCP
heaters with exceptional electrical insulating qualities.
Flexibility
The interlocking bead design imposes rigidity along the heater length
while allowing flexibility along the heater width, enabling it to conform
to the curved surfaces of pipes and pressure vessels. A nominal 1-foot
length of nickel wire is welded to each end of the Nichrome wire to create
a cold tail to prevent the electrically insulated camlock connectors from
being heated.
Thermal Power
FCP heaters are generally available to two standard voltage values: 80-VAC
which is the most common and 60-VAC. Custom designed heaters, however,
can also be provided. All 80-VAC heaters are rectangular with a surface
area of 120 in2 and a thermal power of 3.6 kW, producing a power density
of 30 W/in2 with an electrical current of 45 amps. Their 60-VAC counterparts
are simply ¾ their size with a 90-in2 surface area and a 2.7 kW
thermal power but with the same power density and electric current. Their
rectangular shapes are available in the following variety of width and
length combinations:
Size
The following tables summarize the sizes of standard 80-VAC and 60-VAC
heaters. Note that each heater is identified by its characteristic flexible
width, which is the distance between the heater tails.
| Snake |
5001400 |
1 |
118 |
Snake |
5002600 |
1 |
85 |
| CP3 |
5000100 |
3 |
39 |
CP3 |
5002600 |
1 |
85 |
| CP4 |
5000200 |
4 |
29 |
CP4 |
5001500 |
3 |
28 1/2 |
| CP6 |
5000300 |
6 |
19 1/2 |
CP6 |
5001600 |
4 |
21 |
| CP8 |
5000400 |
8 |
14 1/2 |
CP8 |
5001700 |
6 |
14 1/2 |
| CP10 |
5000500 |
10 |
12 1/2 |
CP10 |
5001800 |
8 |
10 |
| CP12 |
5000600 |
12 |
9 3/4 |
CP12 |
5001900 |
10 |
9 |
| CP15 |
5000700 |
15 |
8 |
CP15 |
5002000 |
12 |
7 1/4 |
| CP18 |
5000800 |
18 |
6 1/2 |
CP18 |
5002100 |
15 |
5 3/4 |
| CP21 |
5000900 |
21 |
5 3/4 |
CP21 |
5002200 |
18 |
5 |
| CP24 |
5001000 |
24 |
5 |
CP26 |
5002300 |
21 |
4 |
| CP29 |
5001100 |
29 |
4 |
CP50 |
5002400 |
26 |
3 1/4 |
| CP36 |
5001200 |
36 |
3 1/4 |
|
5002500 |
50 |
1 3/4 |
| CP72 |
5001300 |
72 |
1 3/4 |
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Features
Because of their design and components, FCP heaters have the following benefits:
· Durability - The ductility of multi-stranded Nichrome wire means
long heater life
· Uniformity - Evenly woven wire means temperature uniformity throughout
the heater
· Ruggedness - Abrasion resistant ceramic means heaters withstand
rough handling
Variations
Due to the availability of different bead configurations and different
grades and gauges of electric resistance wires, a variety of custom heater
designs can be made available:
Shapes - Combinations of rectangles, trapezoids and triangles
Fingers - Non-interlocking designs that can conform to conical workpiece
surfaces
Higher Temperature - Special heaters for temperatures up to 2300 °F
Sizes - Smaller heaters that can be connected in series for standard voltages
Voltages - Different size heaters can be made for non-standard voltages
Reconditioned - Lower cost heaters are available, manufactured with used
ceramic beads
Insulated Pads - FCPs can be assembled to custom mesh mats for insulated
modules
Custom heaters are available, please contact us if you would like additional information.
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