Heater repairing

Common Heater Problems & Repairs

Problems with heater may present in many ways. We have listed the most common heater problems that tend to pop up.

Resistance wire electrical heating elements failure
Resistance wire electrical heating elements have been commonly used in many different applications. When the heating element fails, due to the reduction in cross section by oxidation, due to elongation of the loops, due to formation of hot spot, or anything else, no heat is produced in that area and the profile of heating may be shifted such that parts being processed will be unsuitable for the intended end use.

Ceramic Disc, insulation failure
Ceramic disc and insulation are critical to ensuring that the heater runs safely and efficiently. It may becomes weak due to the long usage, due to the over current drawn regularly, due to heater expansion, due to short circuit may takes place, and also due to manufacture defect

Center Rod
Used to keep heater central and support. It is longer than the terminal rods. Center Rod requires high-quality material and withstand the same high temperature.

Common Heater Problems & repairs

Problems with heater may present in many ways. We have listed the most common heater problems that tend to pop up.

Terminal welded in bad condition
Terminal welding condition is not good, cross section area of ther welding line is small which, current high density will lead to increase in themperature then terminal will be melted or broken.

bad welding series
Heater wire series welding condition is not good, cross section area of ther welding line is small, current density become high lead to increase in thermal then heater wire will be melted or broken.

Difference material grade between Thread and Terminal
Generally, welded area was considered inherently weaker because it included a weld seam and sometimes maybe crack because the materials are difference. So, our terminal and heater are made of the same material to avoid failure.

Hemisul board
Due to drilling hole of hemisul board not fit for terminal rod, there is a possibility of fracture by crack innition around the drilling hole.

Common Heater Problems & repairs

Problems with heater may present in many ways. We have listed the most common heater problems that tend to pop up.

The heating element touches with the middle of the protection tube malted
Insulation to protect the electrical current and prevent the heat from heating element, if it is low quality, it may break and cause the shot to fire.

The heating element touchesthe bottom of the tube makes the tube melted
Ceramic insulation to protect the electrical current and prevent the heat from heating element, if it is low quality, it may break and cause the shot to fire.

U-Type Radiant Tubes ( SCH22 )
We need to know the name of your existing protection tube because the differences in the physical and mechanical properties of material should be considered to avoid dissimilar metal welding problem.

Protection tube in stock

We supply high quality protection tubes at very competitive prices and we only use the highest quality production, and materials from the leading names in the industry to ensure our customer satisfaction.

welded stainless steel tube
While it’s true that welded pipe does include a seam that makes it theoretically weaker, we provide all tube from our partner that have manufacturing techniques and quality assurance regimens each have improved to the extent as desired as long as the temperature, pressure and other service variables do not exceed parameters noted in the applicable standard.

Seamless Stainless Steel Tube
Seamless tubes is often considered to be a higher integrity product than welded tube. They can offer superior corrosion resistance. Using seamless tubes allows you to avoid the potential for defects and differences in malleability that may be associated with the welded area in welded tubes. Therefore, seamless tubing is often more suitable for critical applications.

Before
The heater are damaged and un-usable. PROLIFIC Will analyze all damage and conclude to the customer.

Conditions

Electrical specifications
– Power: 6 kW
– Voltage: 55 V
– Resistance: 0.49 ohm

Working conditions
– Operating temperature: 850-880C
– Operating time: 24/

Material specification
– Protection tubes: SUS310
– Heater: KANTHAL A1

Emergency heater repairs: 7 days

ONSITE INSPECTION

Beside analyzing heater, our team will also check the furnace condition, to make sure 2 asses the cause of heater damage.

REPAIRING

After assesing the damage, we will conclude which heater can be repaired, then reparation process will be done, either at Prolific’s factory or at customer’s site.

FINISH If the repair is done at Prolific site, we will arrange for re-package & delivery to customer’s site. We also provide the service for heater insulation.

CASE STUDY

U-TYPE RADIANT TUBES REPAIRING

Before
The broken radiant tube will be initially analyzed by PROLIFIC team to conclude to customer whether it can be repaired & how to repair than.

Repairing process
After analyzing the damage’ the tube then to be cut, grind & reshape to be it’s original state, then finally to be cleaned.

Finish

Before sending the repaired tubes, the product will go through strict QC checking which includes color test leak test, etc. until the product is ready to be returned to customer.

REPAIRING PROCESS

The repair process of heater by PROLIFIC putting forward our strict & accurate procedure to get the best work.

Our Heat is Your Improvement

For over 15 years, we have supplied quality products, technical support, and customer services to deliver the best results, safest and reasonably priced to our customers. So, our service is regarded as the top-rated company in Thailand for the following reasons:

THE COST REDUCTION

We can repair only the parts that are damaged, but acceptable quality. Not only will our repairs make sure that your heater lasts as long as possible, but can also keep your heater running efficiently, which will save you money on your monthly energy costs.

SKILLED AND EXPERIENCED TEAM

We are very proud to have a dedicated in-house team of specialists who are available to help customers with heater design or specification issues and to clarify matters around energy efficiency and performance.

DESIGN ENGINEER

Our team utilise the latest design software including SolidWorks and AutoCAD, along with in-depth industry knowledge, enables us to produce heater designs specific for the requirements of our customers.

REW MATERIALS INVENTORY

PROLIFIC heating wire stock imported from Japan more than ten tons of various sizes. There are also ceramic tube, ceramic disc, ceramic former and other materials that are accessories of the heater. In stock materials will be shipped within 1 week from emergency order.

service engineer

In the event that the customer can not provide the specification of the heater and use of a heater problem PROLIFIC a team to verify customer applications. To analyze the problem and to design a heater for customers can use.

QUALITY CONTROL

Customers expect to buy qualified, health and safety products. Our quality control inspections at various stages of the production process can help customer confident of heater quality to ensure requirements are being met and safety.