The Flexible Ceramic pad (FCP) is the Game Changer of on-site heat treatment. In view of their flexibility, they may be applied to flat or curved surfaces. They are ideal for the pre-heat and PWHT of pipework butt welds.
As the design is modular they are suitable for a wide range of sizes and shapes
The Ceramic Pad is manufactured from high alumina ceramic beads with a nickle-chromium flexible core wire serpentined within the bead. Nickle tails are weld to the core wire.
The pads are flexible and suitable for heat treatment temperatures up to 1050°C. Temperatures above this value can be the variation of the composition of the core wire.
Highest quality materials available in the construction of our Ceramic Pad (FCP) heating elements.
Any pipe size or pipe configuration can be covered from the extensive range of FCP heating elements, so that the correct amount of heating power can be applied to successfully heat treat the pipe weld or other fabrication.
Flexible Ceramic pads heating elements are manufactured with a range of power ratings for use with a selection of standard voltages.
If you require any special heating element configuration, voltage or power rating, Innovative Heat Treatment will use their heat treatment engineering expertise to provide you with a heating element custom built to meet you exact needs.
If handled correctly, FCP heating elements can be used approximately fifty times at temperatures up to 1050ºC (1922ºF). Innovative Heat Treatment can provide higher temperature heating elements if required which can be used repeatedly at temperatures up to 1200ºC
FLEXIBLE CERAMIC PADS
c. = LENGHT OF PIPE CIRCLE
d = EXTERNAL DIAMETER OF PIPE ( r X 2)
r. = radius of pipe
t = thickness of pad ( 10 mm or 0.39”)
L = 3.14 X ( d + t )
EXAMPLE:
d. = 6.37”
t. = 0.39”
c. = 3.14 X ( 6.37 +.39 )
c. = 22.91”
PAD RECEOMMENDED:
CP21
X = 21”
Y = 5.75”
HOW MANY PAD’S REQUIRED:
Q = QUANTITY OF PADS REQUIRED?
P = LENGHT OF HEAT BAND ( 64” )
X = 21”
Y = 5.75”
Q = P / Y
Q = 64” / 5.75 “
= 10 TO 11 PADS
CALCULATING THE SIZE OF A FCP- FLEXIBLE CERAMIC PAD
Formula to calculate length of the pipe circle:
L = 3.14 x (Du + t), in which Du = external diameter of the pipe; t = thickness of the heating resistor = 10 mm
EXAMPLE:
Selecting heating element for tube (Ø508 x 25 mm). Using standard EN ISO 17663:2009 on formula:
2,5√(2Du – 4e)e , Max 12 x e
Heating zone W = 300mm and length of pipe circle P = 1626 mm.
Preheat is a term associated with the application of heat to metal component prior to and during welding. Mainily Pre-heat treatment of butt welds.
Industry applications;
(For heat treatment cycle up to 800C)
To be used as a guide only. Reference should always be made to specific code or specification heated width
| Nominal Bore | Pipe Wall Thickness Inches / (mm) | ||||||
|---|---|---|---|---|---|---|---|
| Inches | mm | 0-0.8 / (0-20) | 0.8-0.9 / (20-23) | 23) 1.1-1.4 / (23-28) | 8) 1.1 – 1.4 / (28-36) | 36) 1.4 – 1.8 / (36-46) | 1.8 – 2.4 / (46-61) |
| 1 | 25 | 1 x CP48 | N/A | N/A | N/A | N/A | N/A |
| 2 | 51 | 1 x CP8 | N/A | N/A | N/A | N/A | N/A |
| 3 | 76 | 1 x CP12 | N/A | N/A | N/A | N/A | N/A |
| 4 | 102 | 1 x CP15 | N/A | N/A | N/A | N/A | N/A |
| 6 | 152 | 2 x CP12 | 2 x CP12 | N/A | N/A | N/A | N/A |
| 8 | 205 | 2 x CP15 | 2 x CP10 | 2000 | N/A | N/A | N/A |
| 10 | 254 | 3 x CP12 | 4 x CP8 | 2001 | N/A | N/A | N/A |
| 12 | 305 | 4 x CP10 | 4 x CP10 | 4 x CP10 | 2 x 4 x CP10 | N/A | N/A |
| 14 | 356 | 3 x CP15 | 4 x CP12 | 6 x CP8 | 6 x CP8 | 2 x 4 x CP12 | N/A |
| 16 | 406 | 2 x 4 x CP12 | 2 x 4 x CP12 | 2 x 4 x CP12 | 2 x 5 x CP10 | 2 x 5 x CP10 | N/A |
| 18 | 457 | 2 x 4 x CP15 | 2 x 4 x CP15 | 2 x 4 x CP15 | 2 x 5 x CP12 | 2 x 5 x CP12 | N/A |
| 20 | 508 | 2 x 5 x CP12 | 2 x 5 x CP12 | 2 x 5 x CP12 | 2 x 5 x CP12 | 2 x 6 x CP10 | 2 x 6 x CP10 |
| 22 | 559 | 7 x CP10 | 7 x CP10 | 8 x CP10 | N/A | N/A | N/A |
| 24 | 610 | 2 x 5 x CP15 | 2 x 5 x CP15 | 2 x 6 x CP12 | 2 x 6 x CP12 | 2 x 6 x CP12 | 2 x 7 x CP10 |
| 47 | 1194 | 2 x 12 x CP12 | 2 x 12 x CP12 | 2 x 12 x CP12 | 2 x 12 x CP12 | 3 x 12 x CP12 | 3 x 12 x CP12 |
| 63 | 1600 | 2 x 15 x CP12 | 2 x 15 x CP12 | 2 x 15 x CP12 | 2 x 15 x CP12 | 2 x 15 x CP12 | 3 x 15 x CP12 |
| STOCK REF. | 21113 |
| FCP REF. | CP3 |
| X DIMENSIONS (TAIL TO TAIL) | 3 inches |
| Y DIMENSIONS (TAIL TO END) | 31 inches |
| VOLTS | 80 |
| kW | 3.6 |
| AMPS | 45 |
| STOCK REF. | 21114 |
| FCP REF. | CP4 |
| X DIMENSIONS (TAIL TO TAIL) | 4 inches |
| Y DIMENSIONS (TAIL TO END) | 29 inches |
| VOLTS | 80 |
| kW | 3.6 |
| AMPS | 45 |
| STOCK REF. | 21116 |
| FCP REF. | CP6 |
| X DIMENSIONS (TAIL TO TAIL) | 6 inches |
| Y DIMENSIONS (TAIL TO END) | 19.5 inches |
| VOLTS | 80 |
| kW | 3.6 |
| AMPS | 45 |
| STOCK REF. | 21118 |
| FCP REF. | CP8 |
| X DIMENSIONS (TAIL TO TAIL) | 8 inches |
| Y DIMENSIONS (TAIL TO END) | 14.5 inches |
| VOLTS | 80 |
| kW | 3.6 |
| AMPS | 45 |
| STOCK REF. | 21110 |
| FCP REF. | CP10 |
| X DIMENSIONS (TAIL TO TAIL) | 10 inches |
| Y DIMENSIONS (TAIL TO END) | 12.5 inches |
| VOLTS | 80 |
| kW | 3.6 |
| AMPS | 45 |
| STOCK REF. | 21112 |
| FCP REF. | CP12 |
| X DIMENSIONS (TAIL TO TAIL) | 12 inches |
| Y DIMENSIONS (TAIL TO END) | 9.75 inches |
| VOLTS | 80 |
| kW | 3.6 |
| AMPS | 45 |
| STOCK REF. | 21115 |
| FCP REF. | CP15 |
| X DIMENSIONS (TAIL TO TAIL) | 15 inches |
| Y DIMENSIONS (TAIL TO END) | 8 inches |
| VOLTS | 80 |
| kW | 3.6 |
| AMPS | 45 |
| STOCK REF. | 21218 |
| FCP REF. | CP18 |
| X DIMENSIONS (TAIL TO TAIL) | 18 inches |
| Y DIMENSIONS (TAIL TO END) | 6.5 inches |
| VOLTS | 80 |
| kW | 3.6 |
| AMPS | 45 |
| STOCK REF. | 21121 |
| FCP REF. | CP21 |
| X DIMENSIONS (TAIL TO TAIL) | 21 inches |
| Y DIMENSIONS (TAIL TO END) | 5.75 inches |
| VOLTS | 80 |
| kW | 3.6 |
| AMPS | 45 |
| STOCK REF. | 21124 |
| FCP REF. | CP24 |
| X DIMENSIONS (TAIL TO TAIL) | 24 inches |
| Y DIMENSIONS (TAIL TO END) | 5 inches |
| VOLTS | 80 |
| kW | 3.6 |
| AMPS | 45 |
| STOCK REF. | 21129 |
| FCP REF. | CP29 |
| X DIMENSIONS (TAIL TO TAIL) | 29 inches |
| Y DIMENSIONS (TAIL TO END) | 4 inches |
| VOLTS | 80 |
| kW | 3.6 |
| AMPS | 45 |
| STOCK REF. | 21136 |
| FCP REF. | CP36 |
| X DIMENSIONS (TAIL TO TAIL) | 36 inches |
| Y DIMENSIONS (TAIL TO END) | 3.25 inches |
| VOLTS | 80 |
| kW | 3.6 |
| AMPS | 45 |
STANDARD —> WORLD WIDE
FLEXIBLE CERAMIC PADS
| STOCK REF. | 26076 |
| X. WIDTH. MM | 76 |
| Y. LENGTH. MM | 672 |
| VOLTS | 60 |
| kW | 2.7 |
| AMP | 45 |
| STOCK REF. | 26102 |
| X. WIDTH. MM | 102 |
| Y. LENGTH. MM | 504 |
| VOLTS | 60 |
| kW | 2.7 |
| AMP | 45 |
| STOCK REF. | 26152 |
| X. WIDTH. MM | 152 |
| Y. LENGTH. MM | 336 |
| VOLTS | 60 |
| kW | 2.7 |
| AMP | 45 |
| STOCK REF. | 26203 |
| X. WIDTH. MM | 203 |
| Y. LENGTH. MM | 252 |
| VOLTS | 60 |
| kW | 2.7 |
| AMP | 45 |
| STOCK REF. | 26254 |
| X. WIDTH. MM | 254 |
| Y. LENGTH. MM | 210 |
| VOLTS | 60 |
| kW | 2.7 |
| AMP | 45 |
| STOCK REF. | 26305 |
| X. WIDTH. MM | 305 |
| Y. LENGTH. MM | 168 |
| VOLTS | 60 |
| kW | 2.7 |
| AMP | 45 |
| STOCK REF. | 26381 |
| X. WIDTH. MM | 381 |
| Y. LENGTH. MM | 147 |
| VOLTS | 60 |
| kW | 2.7 |
| AMP | 45 |
| STOCK REF. | 26406 |
| X. WIDTH. MM | 406 |
| Y. LENGTH. MM | 126 |
| VOLTS | 60 |
| kW | 2.7 |
| AMP | 45 |
| STOCK REF. | 26534 |
| X. WIDTH. MM | 534 |
| Y. LENGTH. MM | 104 |
| VOLTS | 60 |
| kW | 2.7 |
| AMP | 45 |
| STOCK REF. | 26610 |
| X. WIDTH. MM | 610 |
| Y. LENGTH. MM | 84 |
| VOLTS | 60 |
| kW | 2.7 |
| AMP | 45 |
| STOCK REF. | 26122 |
| X. WIDTH. MM | 1220 |
| Y. LENGTH. MM | 42 |
| VOLTS | 60 |
| kW | 2.7 |
| AMP | 45 |
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