All posts by Nadine LAURET

TUS & SAT Thermocouples for heat treatment

Industries, , , , , , , , , , ,

Description of the Thermocouples

When two different materials are welded together to make a junction and heated up, an electromotive force (EMF) is generated make the measurement of temperature possible.

The EMF generation uses the Seebeck effect.

The thermocouples measure temperature differences.

The EMF are generated in Temperature gradients.

The sensitivity of the thermocouple is the sum of the thermoelectric power of each conductor.

The advantage of a higher EMF means a better temperature resolution.

The thermocouples are standardized. The basic values of the EMF and the tolerances are laid down in the IEC584-1+2 standards.

Thermocouples cover a temperature range from -200°C to +2300°C.

The essential THERMOCOAX thermocouple construction is that both conductors, insulation and metal protecting sheath are combined as a cable :

  • The two wires make the thermoelectric pair
  • The mineral insulator is a highly compacted powder
  • The continuous metal sheath provides the mechanical and chemical protection of the pair.

 

At the end, the cores and the sheath are welded and constitute the junction.

 

 

For the aerospace industry and more recently for the automotive industry, the heat treatment of high end materials has to conform to the ASM 2750 E and CQI-9 standards respectively.

Those standards give the pyrometric requirements for thermal processing equipment used for the heat treatment of metal parts.

The System Accuracy Tests (SATs) and the Temperature Uniformity Surveys (TUS) are key parts of state of the art heat treatment operations.

The SAT is performed to assure the accuracy of the furnace control and recording system in each controlled zone.

TUS shall be performed to measure temperature uniformity and to establish the acceptable work zone and qualified operating temperature range(s).

Thermocouples shall be installed in the thermal processing equipment within the work zone or as close as possible to it.

The load sensors are attached to or in contact with production material.

Those temperature homogeneity standards concern atmospheric pressure (air) furnaces as well as vacuum furnaces.

The homogeneity of the furnace temperature depends on the quality and accuracy of the measuring instruments used.

When choosing survey TCs, their maximum correction factor needs to be below the required specification and tolerances of the furnace.

To meet the demanding requirements of heat treatment applications, thermocouple types R / S / B / J / T / E / K / N / C have to conform to precise calibration requirements, especially in terms of tolerance.

Tolerance values are governed by standards, such as NF EN 60584-1 and ASTM E230.

The ASTM E230 “Special tolerance” is more restrictive than the NF EN 60584 “Class 1” below 375°C.

Tolerance values are given as a deviation in degrees Celsius or a function of temperature. The larger value is applicable.

For example, for K type thermocouples, the special tolerance value to conform to the ASTM E230 is +/-1.1°C or 0.4%

SAT & TUS thermocouples must be calibrated every 6 months for Type B, R & S and every 3 months for N & K thermocouples. The allowed error is +/- 1.1 ° C or + / 0.4% for SATs thermocouples and +/- 2.2 ° C or +/- 0.75% for TUS thermocouples.

We also talk about tolerance classes for thermocouples.

Thermocoax inspects the whole thermocouple production chain.

The mineral insulated cables that represent the core of the technology, are manufactured in the French factory of Athis de l’Orne (61).

Furthermore, THERMOCOAX has its own calibration laboratory certified by a national COFRAC accreditation No.2-1384 with an international recognition.

If required, we can deliver a COFRAC calibration certificate for each thermocouple manufactured.

  • Calibration Laboratory – COFRAC Certified
  • CERTIFICATE No. 2-1384 rev. 3
  • International recognition
  • Range of validity accessible on the COFRAC website

http://www.cofrac.fr/annexes/sect2/2-1384.pdf

 

To offer the full range of temperature calibration points for heat treatment manufacturing, we use two different calibration process: The fixed points calibration and the calibration by comparison.

 

 

 

THERMOCOAX owns a wide range of means for calibration by comparison, as well as by fixed points. This variety of equipment allow us to perform comparisons between the different measuring instrument in order to ensure the validity of our results and our uncertainties. We also frequently perform inter-laboratory comparisons in accordance with the international standard EN ISO/IEC 17043.

Our team of specialists with our 60 years of experiences in thermal applications and in the management of regulatory requirements of the aerospace and automotive industry, gives us an international reputation.

The quality of the thermocouples, the homogeneity of the production and a high-performance calibration process, make it possible to improve reliability and efficiency of the heat treatment plants.

 

 

 

Drum heaters solution for industrial areas

ISOPAD

 

 

Most media stored in drums before processing can begin will require heating to reduce viscosity and to enable easy removal of the liquid or semi-liquid from the drum. Other media stored in drums require temperature maintenance for a period of time to keep the media in its liquid or semi-liquid form.

All of our drum heaters are available for hazardous and nonhazardous locations, can heat metal or plastic drums, and will heat up to 300°C.

                                  

 

High efficiency

The drum heater is designed to be energy-efficient through its ideal combination of power, thermal insulation and temperature control.

Temperature control of the drum contents allows easy heating of liquid to your desired temperature, easing removal and optimizing usage of the liquefied product.

Our drum heaters provide a clean and compact way of attaining uniform surface heating of drums.

Safe, easy handling

With a unique “clam shell” design and castors, our drum heaters can simply be wheeled up to, and closed around, the drum. The clam shell design also allows the heater to be stored open, against a wall, taking up less space.

Castors are antistatic and have parking brakes to stop heaters from moving while in use.

State-of-the-art technology for hazardous locations

We currently offer IECEx and ATEX certifications to the latest European market standards. Drum and drum-base heaters for hazardous areas are equipped with a self-regulating heating system that does not require a separate temperature limiter for compliance with the temperature class.

Electrical supply options

Our nonhazardous drum heaters are available for single-phase and three-phase operation (230 V / 400 V).

Drum heaters for hazardous locations are available for single-phase only.

Solid construction

All drum heaters are made of heavy gauge sheet steel with a double skin construction, which houses the electric heating elements, which cover the whole of the inner surface. The heating elements are equipped with reinforced thermal insulation to prevent heat loss through the outer wall.

 

Electrical heating system for high voltage (HV) cables and ultra-high voltage (UHV) cable manufacturing and maintenance

ISOPAD, , , , , , , , , ,

High voltage (HV) and ultra-high voltage UHV cables are very rigid.

The inner wires of the high voltage cables have strong mechanical tensions. It is very difficult to bend this cable.

Most of the time the cable is laid in a straight line underground. But it is sometimes necessary to bend the cable to follow a precise path, to make junctions or terminations.

The solution is to pre-heat the cables prior to bending.

The heat makes the inner wires and the complete cable more flexible. The operators can then bend the cable or start the connection.

Thermocoax, with its product range ISOPAD, provides flexible heating jackets that meet the requirements of manufacturers and installers of high voltage (HV) cables.

The challenge

The challenge is to provide flexible heating jackets based on heating cable technology with the following performance:

  • An efficient safety system to prevent any risk of overheating,
  • Strong, durable and easy-to-use fasteners
  • Heating jacket lengths up to 2 m
  • Sensors positioned so as to optimize the temperature control of the heating jacket
  • An electronic control system for up to three heaters mounted in parallel

  

The configuration of the heating jacket for high voltage (HV) cables

One contact temperature limiter at 100 °C for PTFE cable protection.

One heating wire temperature limiter at 230 °C.

Contact temperature sensor for the controller.

Pluggable heating jacket with strain relief system at jacket outlet.

 

An efficient fastening system

  • Belts with fasteners.
  • Strong fixation to support outdoor operation with high voltage (HV) cables.
  • Easy attachable and detachable belts
  • Quick fasteners

 

ISOPAD provides jackets that fit perfectly with various diameters of high voltage (HV) cables.

The diameter is clearly marked on the jacket.

A homogeneous and efficient heating solution

The performance of the ISOPAD electrical heating jacket has been validated by laboratory tests.

The temperature required for the bending operation of high voltage (HV) cables is around 85 °C.

The graph below shows temperature over time.
Measurements were made at different points of the cable structure using temperature sensors.
Sensors have been positioned on the surface of the jacket, on the surface of the cable and inside the HV high voltage cable.

 

Special temperature regulation controller for three heaters in parallel
  • Flexible and mobile
  • IP65
  • SSR controlled
  • Optional metal case

 

 

 

Specifications – heating jacket for high voltage heating cables

  • Material: glass silk with aluminum coating on the outer surface
  • Area classification, ordinary area , non-hazardous, IP20
  • Electrical protection class: class I with metal sheath
  • Maximum withstand temperature (power off): 260 °C for the inside of the jacket – 100 °C for the outside because of the PE tapes.

 Heater Construction 

  • Type: Resistance heating cable
  • Material of insulation: PTFE
  • Material of outer sheath: glass silk with aluminum coating
  • Thickness of thermal insulation: 10 mm glass wool

Temperature Control 

  • Sensor type: two-wire PT100
  • Two temperature limiters: one at 100 °C for the PTFE cables and one at 230 °C for the heating wires

 

Technical Data 

  • Frequency 50-60 Hz
  • Maximum operating voltage: 240 Vac others available on request
  • Maximum area load: 0.2 W/cm² – Typical: 6 W/dm²

 

 

 

 

 

Immersion heater for maintaining aluminum bath temperature and for pre-heating of foundry ovens

Industries

Introduction

The quality of the extruded or molded aluminum parts depends mainly on the quality of the alloy components and the temperature homogeneity of the liquid aluminum.

Foundries are looking for efficient solutions that maintain heat and temperature in terms of energy consumption and performance.

This project for developing a high efficiency immersion heater started a few years ago at Thermocoax with a very specific R & D project for the aluminum foundry.

The challenge was to offer a high efficiency immersion heater for the aluminum industry, using the Thermocoax mineral-insulated cables and our expertise for applications in harsh environments.

The immersion heater is used in the aluminum industry to keep the aluminum in its liquid state upstream of the extrusion or molding processes.

Liquid aluminum is extremely corrosive. Immersed steel tubes or Inconel tubes are destroyed in a few hours.

The challenge of Thermocoax was to offer a sheath resistant to the corrosion caused by molten aluminum and to optimize the heating efficiency of the immersion heater.

The Thermocoax solution for the immersion heater sheath

Thermocoax’s R & D team has worked closely with a major manufacturer of high quality aluminum in order to verify the results of its internal studies under real conditions.

There is no metal capable of resisting immersion in an aluminum bath. Similarly, thermally deposited ceramic coatings (plasma, HVOF, etc.) on steels have a very limited lifetime (see figure below).

The usual ceramics containing silica cannot be immersed for long periods without suffering significant deterioration either.

Only one ceramic is capable of meeting the challenge : Sialon which has the crude formula Si3Al3O3N5. Sialon is a solid solution of alumina (Al2O3) in silicon nitride (Si3N).

Sialon is an expensive but essential material for applications related to liquid aluminum.

It is an extremely rigid material that does not allow for matrixing which could increase heat transfer.

Tests of ceramic coatings on steel tubes

immersion-heater-1          24h later       immersion-heater-2

 

Thermocoax solution to optimize thermal efficiency of the immersion heater

During the molding process, liquid aluminum is at a temperature of 750 ° C.

In order to heat the aluminum bath homogeneously without compromising the reliability of the immersion heater, Thermocoax engineers have developed a design that places the heating element closer to the wall of the ceramic tube. This mechanically stable concept, even at high temperatures, limits the thermal resistance between the heating element and the ceramic.

Thanks to this new design, we guarantee high efficiency over the long term, without degrading the level of heat exchange over time.

Tests and calculations

immersion-heater-3           immersion-heater-4

 

Thermal gradient observed » 140 ° C

Optimizing the immersion heater reliability

The heating elements used are Thermocoax mineral-insulated cables with a cold part allowing a low temperature connection with the connectors.

The double insulation offered by the ceramic tube and the electrically-insulated heating element make this immersion heater a completely safe solution for operators.

The insulation resistance of this immersion heater provides a very low level of leakage current.

A thermocouple positioned strategically inside the immersion heater allows a precise and permanent control of the temperature of the heating element and continuous monitoring of the immersion heater.

Thermocoax uses a ceramic metal connector with a very high dielectric strength. This connector has been specifically designed to meet the requirements of immersion heaters in an industrial environment.

 

immersion-heater-5

 

Tests conducted at the end of the manufacturing process :

– Insulation resistance > 1012 Ohms at 1000 VDC
– Dielectric resistance at 800 VAC for 1 min
– Leakage current < 10mA at 800 VAC
– Heating test at 850 ° C in air

Design verification

An initial verification of the design was made on site at an aluminum manufacturer. Pre-heating tests were conducted in an 800 kg oven for 3 weeks. The results were very conclusive with a leakage current which remained very low.

A second long-term test in production was carried out continuously over 2 ½ years in a 5 tonne furnace

The design has been verified by professionals in the aluminum industry.

Technical specifications

  • Heating zone : 300 mm
    • Temperature control
    • Adjustable power
    • Typical power: 7 kW (up to 20 kW)
    • Thermal flow: 14 W / cm²
    • Cold shares
    • Leakage current <10 mA at 900 ° C (double insulation)

Developed for specific high quality aluminum foundries with a very high level of technical requirements (insulation, temperature control, energy efficiency, etc.)

immersion-heater-6

 

THERMOCOAX Aeronautic Products : Carbon Brake Temperature Monitoring & Aircraft Brake Monitoring System

Aeronautic, ,

Thermocoax Pedigree :

THERMOCOAX has been a worldwide key player for 20 years in designing, developing and manufacturing with thermocouple sensors for the aeronautical market.
Based on the 60 years Mineral Insulated Cable produced in-house, we are providing our customers with solutions for:
– Ground applications:
 R&D programs with institutes
 Ground aero test equipment

– Flying models:
 Thermocouples and RTDs for air cabin management system.
 Thermocouples for helicopter engines with 15 000 units installed
 Alternator Bearing temperature measurement on twin aisle and double deck platforms

– Scientific tasks:
 Skin temperature on supersonic frame
 Engine Space launcher

image-4

 

Technical Applications of the Brake Temperature Sensor :

New technologies are rapidly developing and the brake industry is working hard to make aircraft operations safer and offer passengers more comfortable travelling conditions.

A new generation of brakes has been installed on modern aircraft. Carbon brakes developed by key brake manufacturers is the result of a long and costly program of investment in research and development.

The new carbon disk generation provides more power braking during landing but also during braking in an emergency.

Firstly, the brake thermocouple gives the brake temperature in real time and can be transformed in a “hot brake” alert to the pilot when the value goes over a predetermined temperature threshold.

It gives valuable information to the cockpit on the temperature of the right and left brakes. If these differ too much, an asymmetric friction on the brakes can cause difficulties when maintaining heading and keeping speed under control.

Thanks to this system, the pilot receives a “Go/No Go” clear message for takeoff authorization. The brake thermocouple indicates that in case of a braking emergency event during takeoff, the brake will have his full capacity to stop the aircraft on time for the safety of all passengers.

Secondly, during takeoff in hot climates, this temperature monitoring avoids a too early landing gear retraction. This avoids a risk of tyre explosion in the wheel compartment.

The brake thermocouple is now a key piece of equipment that airlines use to reduce turnaround times (TAT) in short-haul operations to around 30 minutes.

frein-carbone

This new generation of carbon brakes replaces the old metallic brake.

Each brake manufacturer develops their own carbon technology. Specialists agreed to give carbon technology products a longer life, more braking cycles and much higher efficiency of braking especially for heavy airliners.

But carbon brake technology produces high amounts of heat energy during braking and the temperature can get very hot if the dissipation of kinetic energy is not optimum. This temperature rises to nearly 1000°C during normal braking. In case of emergency braking at full power during takeoff at full weight, the friction off the carbon disks is so powerful that the energy produced causes the temperature to rise to 2000°C.

Temperature monitoring is implemented on every aircraft platform, commercial and military. One thermocouple per brake/wheel is the rule. A typical single-aisle aircraft is equipped with 4 thermocouples, a twin-aisle aircraft 8 to 12 thermocouples, double-deck aircraft 16 thermocouples and military fighter 2.

This is an opportunity for THERMOCOAX to contribute to this program and improve the safety of the airframe and passengers every day around the world.

 

Technical description of brake thermocouple

When measured at nominal temperature, the thermocouple typically has the following properties:

  • K type thermocouple
  • Single-circuit, 2 wires

19-09-2016-17-36-50

  • Class 1 in accordance with IEC and ASME
  • Ceramic insulator
  • Dielectric under 500V
  • Insulation resistance:
    • 1011Ω.m at room °T
    • 107 Ω.m at 600°C
  • Inconel 600 sheath
  • Ø 2.5 to 4.75mm
  • Hermetic connector EN2997
  • Hermetic connector D38999
  • 2 compensated pins

image1

  • Oval base or mesh for easy removal from the torque tube when replacing

image3

  • Mass: <100g
  • Environmental and safety of flight tests
  • Impact: RTCA/DO160 Sect 7 cat B, D
    • Cat B
    • Cat D
  • Vibration: RTCA/DO160 Sect 8
    • Cat R curve W
    • Cat T curve E
    • 2000 hz, 200G

19-09-2016-17-05-50

  • HALT Tests

 

Acceptance Test Criteria of the Brake Thermocouple :

  • Temperature calibration
  • Helium leak test
  • XRay by sampling
  • Time constant
  • Visual and mechanical inspection
  • Overvoltage
  • Line resistance
  • Polarity
  • Insulation resistance
  • Dielectric 500Vac, 60Hz/60s
  • Mass
  • Final manufacturing report

 

Packaging and Cleanliness :

THERMOCOAX focuses on high quality Brake thermocouple products for the best stability and repeatability while in operation.

We understand our customers’ challenges to manufacturing braking systems and to make the aeronautical industry reliable and the millions of passengers safer.

At THERMOCOAX, we are working hard to contribute to these incredibly challenging programs.

THERMOCOAX has supplied many commercial programs and military platforms.

THERMOCOAX designs, develops, qualifies and produces in accordance with aircraft specifications such as :

  • Airbus 350
  • Embraer EJet
  • Mitsubishi Regional Jet
  • Irkut MC21
  • Sukhoi Super Jet100
  • COMAC C919

 

THERMOCOAX is the major player for brake thermocouples and is a proud contributor to great aeronautic programs.

 

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THERMOCOAX and NIAC certification

Nuclear, , , , , ,

Nuclear Quality Assurance : Sharing data to reduce TCO (Total Cost of Ownership)

Introduction

On the nuclear market, there is no compromise with safety. That’s why quality assurance is key. Nevertheless cost associated with auditing is significant, but how do we reduce it?

The challenge : make the associated cost for quality assurance of THERMOCOAX nuclear solutions more affordable.

What quality standards are internationally recognized ?

THERMOCOAX have a quality program that meets or exceeds the requirements of 10CFR50 Appendix B or ASME NQA-1 and accepts 10CFR21.

The Code of Federal Regulations (CFR) is a codification of general and permanent rules laid down by the US Nuclear Regulatory Commission (NRC). For THERMOCOAX the significant part is from the 10 CFR 50 – Domestic licensing of production and utilization facilities, specifically, the Appendix B – Quality assurance criteria for NPP and fuel reprocessing plants [3],

The 10CFR50 App B establishes the 18 fundamental requirements for the design, construction, manufacture and operation of SSC with regard to safety. Another American Quality Assurance Standard is NQA-1 which also has the 18 fundamental requirements and a few extras.

American Society of Mechanical Engineers (ASME) has developed more clear standards for implementation of the Code. ASME NQA-1 have described the Code requirements and implementation in more detail for the end users.

The requirement : to demonstrate compliance with 10CFR50 Appendix B or ASME NQA-1 and accept 10CFR21, as well as sharing information and making it available to our customers.

 

NIAC auditing within ASME compliance

NIAC is the acronym name used by the Nuclear Industry Assessment Committee ( http://niacusa.org/)

The process of forming NIAC started in 1992/1993. The founding members, working with their legal departments, created the NIAC Charter which established broad guidelines for conduct at meetings, operations, membership, committees, officers and applicability to 10CFR21.

The Charter defines the sharing of audits-only to members pre-authorized by the audited supplier.

NIAC members are companies who supply goods and services to the nuclear industry that have a quality program that meets or exceeds the requirements of 10CFR50 Appendix B or ASME NQA-1 (1989), and accept 10CFR21.

The NIAC organization develops and maintains the procedures and processes necessary to plan, guide, and share supplier evaluations with authorized member companies.

NIAC maintains a database of supplier evaluations, provides schedules, procedures, and checklists to guide supplier evaluation activities, and maintains interfaces with member organizations and the Nuclear Procurement Issues Committee (NUPIC). NIAC also organizes working meetings for members and the steering committee twice a year.

NIAC membership offers considerable cost and schedules savings through the sharing of supplier evaluations.

Audits are performed on a pro rata basis, whereas a company should perform about 1 audit for every 3 received (shared from another performing member).

 

The benefits of Thermocoax’s NIAC certification

THERMOCOAX has been audited and will be NIAC approved. Our customers can share the benefit of this certification. Those savings have a direct impact on the Total Cost of Ownership of our solutions. For the mutual benefit of Thermocoax and its customers.

 

  THERMOCOAX and nuclear SOLUTIONS

THERMOCOAX Nuclear specializes in In-core and Ex-core SOLUTIONS such as :

  • Radiation sensors (neutron flux & gamma flux)
  • Temperature measurement
  • Level and flow measurement

We also offer SERVICES such as DESIGN, EXPERTISE, INSTALLATION, and COMMISSIONING.

Mould electrical heating solution for foundries

Industries

Introduction

Standard practices in industry heat the moulds using gas burners, infrared panels or ovens. However, it is difficult to accurately control the temperature of the mould with indirect heating processes.

 

Electric mould heating solutions already exist with heating cartridges  but power delivered is much lower ; therefore the temperature is less homogeneous than the Thermocoax  heating solution.

Mould heating solutions are requested in many industries : metallurgy, glass, thermoplastic.

SCAN_1_9

                                      

The Challenge : offer a mould heating solution with Thermocoax mineral insulated cables

  • Several heating zones
  • Reaching high temperatures quickly enough.
  • Optimize the heat transfer on steel moulds, stainless steel or cast iron by optimization of :
    • the cable design and the cable repartition on the support
    • the specific fixation solutions developed by Thermocoax to fix the cables depending on the application and the mould material

 

  • Our ability to integrate elements on rotary systems.

 

The benefits of Thermocoax MI cable heating solution

 

  • Process adapted to metals, glass and thermoplastic industries
  • Ability to follow complex 2D & 3D forms
  • High temperature homogeneity
  • Low electrical consumption
  • Fast temperature ramp-up
  • Electrical insulation and low leakage current
  • Low maintenance required

 

Main heating parameters for THERMOCOAX MI cable heating solutions :

Homogeneity

  • Due to their specific design, the Thermocoax Mineral Insulated Cables have the advantage of generating uniform temperature.
  • The homogeneous distribution of heat over the entire mould is guaranteed by the design and cable fixing solution.
    The design and fastening of cables is specific to each application and depend on the support materials.

 

Implementation of the Thermocoax heating solution :


The heating elements can be directly brazed to the mould to favour heat exchange and temperature increase.
This fastening system also makes it possible to meet the demands of moving moulds for applications of roto-moulding for example.

Halve shells and heating plates can be designed to be removable.

Temperature control is carried out by thermocouples and a specific electrical control system provided by THERMOCAX.
Several thermocouples can be installed in different places of the mould to measure its thermal profile in real-time.

 

Adaptability of the Thermocoax heating solution to specific designs :

The mechanical properties and the small bending radius of Thermocoax mineral insulated cables make it possible to cover any type of complex geometry with different heating zones.
Each zone can be controlled independently.

 

 Conclusion

Thermocoax developed an innovative mould heating solution.
This solution can be adopted on rotary systems.

The heating elements and thermocouples are welded directly onto the prints, they are an integral part of the mould.

The temperature can be controlled with extreme precision.

Thanks to appropriate positioning of the heating elements, the THERMOCOAX heating solution provides the homogeneous temperature that moulding industries require.

The Thermocoax heating solution makes it possible to reach temperatures of up to 700 °C, which are necessary to process various materials or to maintain the temperature of metals during the moulding process.

 

Thermocoax mould heating solution applications :

Shell foundry: Pressure or gravity foundry
Glass moulding: mould preheating, temperature control


Rotational-moulding of thermoplastics using a rotating Process

Appl-067 SCAN_1_25

MI Cable welded onto the print     

We would be more than happy to present you our mould heating solutions – You can contact us through our website www.thermocoax.com or directly at : + 33 1 41 38 80 61

 

Presse release : THERMOCOAX to build Pressurizer heaters for the first Hualong reactors Fuqing 5 & 6

Nuclear

THERMOCOAX the expert in heating solutions for hash environment has been
awarded a contract with DFHM , the leading Gen 3 large vessel manufacturer in
China, to manufacture and deliver pressurizer heaters for Fuqing 5&6.
Those heaters will offer an enhanced life time compared to existing technologies
without compromise on safety and reliability.
This project represents an important milestone in THERMOCOAX nuclear
business unit expansion and pave the way for others applications with utilities
or Tiers 1 pressurizer supplier.
THERMOCOAX offers support to its customers through the design, delivery and
support phases of a program.

About THERMOCOAX
THERMOCOAX has over 50 years of expertise in instrumentation and heating solutions. It provides solutions in the world of nuclear, aerospace and semicon industries. It design, qualify and manufactures sensors for harsh environment with a focus on nuclear on temperature and radiation measurement.

About DFHM
Dongfang Heavy Machinery (DFHM) is a subsidiary of Dongfang Electric Corporation (DEC),
DEC with its headquarter in Chengdu has become a comprehensive group specialized in
manufacturing industry, R&D of cutting edge technology, contracting international
engineering projects, exporting complete plants and equipment, and conducting international economic and technical cooperation.

nuclear-slide-home-1024x343

THERMOCOAX Space Products : New Generation of Catalyst Bed Heater

Space

Spacecraft Propulsion

Coiled cable design for :

Green propulsion : Thrusters 1 to 200N

Deorbiting operation : Thruster 400N

 

Thermocoax Pedigree

THERMOCOAX has been a key player worldwide for 15 years in the designing, developing and manufacturing of heating systems for the space market.

We provide solutions for:

– Ground applications:

  • R&D programs with institutes
  • Ground equipment

– Flying models :

  • Heating management system on Satcom.
  • Catalyst bed heater for chemical propulsion
  • Heating solution for Hall Effect thruster

-Scientific Mission :

  • Heating system on Curiosity Rover
  • Heating Element on ISS for MSL
  • Heating Element for pyrolysor on Cassini-Huygens Titan probe

CBH8

 

Technical Application of Coiled Catalyst Bed Heater

The new generation of Green propulsion thrusters and deorbiting thrusters is a great opportunity to supply the market with a new generation of catalyst bed heater for better efficiency, increased reliability and greater cost-effectiveness.

Until now, the cartridge design heater has been mostly used and 2 to 4 systems are implemented on the thruster to reach 12 watts.

pic 1

THERMOCOAX is able to simplify the catalyst bed heater system by offering its technology solution of a heating cable which has a diameter of only 1 mm. This cable is then coiled around the catalyst and fixed by brazing or another fixation mode.

13-06-2016 12-02-25       14-06-2016 11-58-43

This new design is based on long-proven cable technology that has been adopted by aircraftavionics and space missions, such as for the Prisma spacecraft. Currently, this new design is qualified to equip the 40-satellite constellations dedicated to taking 3D pictures of the Earth.

Technical Description of the Catalyst Bed Heater

We use our best mineral insulated cable.

Mineral Insulated Cable with 4 resistive wires to shape 2 heating loops

Cold part in two stages, the first stage with a diameter of 2.3mm, the second stage with 1.5mm and a heating part with a 1mm diameter

13-06-2016 16-31-29

The cable is then coiled around a ring to be fixed onto the catalyst.

13-06-2016 16-35-30

Example 1 :

pic 2

Example 2 :

OLYMPUS DIGITAL CAMERA

 

Catalyst Bed Heater :

  • 2 redundant electrical loops
  • Nominal Power supply: 28 volt to 55 volt
  • Power version per loop :
    • 10 watt under 28Vdc
    • 100 watt under 55 volts
  • Max exposed temperature :
    • 1000 °C with Inconel
    • 1600°C with Platinum

 

Other power available by playing on the cable geometry :

14-06-2016 14-17-13

Mineral Insulated Cable :

Version exposed 1000°C :

  • Inconel 600 sheath
  • 4 Nickel-Chromium wires

Version exposed 1600°C

  • Platinum sheath
  • Platinum-rhodium wires

CBH7

 

Lead Wires :

  • 4 wires
  • Color code for each loop
  • AWG24 or 26
  • Strength 1.4 kg

CBH6

Acceptance Test Criteria of the catalyst bed heater :

  • Helium Leak Test
  • X-Ray of the heating cartridge
  • X-Ray of the MIC/lead wires junction
  • Lead attachment strength test
  • Visual and mechanical examination
  • Overvoltage
  • Line Resistance
  • Insulation Resistance under 500volts
  • Burn-in test
  • Dielectric 100/300/500Vac, 60Hz/60s
  • Weight
  • Final Manufacturing Report

 

Test List for Qualification Program of the Catalyst Bed Heater

  • Thermocoax conducts and realises the qualification test program in accordance with our customer’s specifications.

Our engineers write the QTP for customer approval prior to test execution.

Most of the tests (thermal, humidity, electrical…) on the Catalyst Bed Heater are performed in THERMOCOAX’s testing lab facilities.

Those requiring heavy equipment (vibration, acceleration, shocks…) are subcontracted to external laboratories or supported by our customers with the complete propulsion system.

-Typical Qualification Test list on Catalyst Bed Heater :

  • Vibration
  • Acceleration
  • Mechanical shock
  • Pyrotechnic Shock
  • Helium leak test
  • Burn-in test
  • Humidity test
  • Hot Firing test
  • Electrical Cycling test
  • Thermal cycling test
  • Lead Attachment Test
  • Dielectric Test
  • Destructive Physical Analysis
  • X-Ray Examination

cbh2

 

  • Packaging and Cleanliness :

The Catalyst Bed Heater is shipped in a specific packaging to ensure excellent conditions during transportation and storage :

CBH3 CBH4

 

Thermocoax supplies new green propulsion programs (1, 5, 20, 200 and 400 Newton thrusters). Here are few examples :

  • Prisma
  • Google Constellation


THermocoax is the market leader in Catalyst Bed Heater production and is proud to participate in challenging international space programs.

THERMOCOAX focuses on high quality Catalyst Bed Heater products for the best stability and repeatability during operation. For 15 years, we have witnessed the challenges faced by our customers to manufacture spacecraft and to improve the quality of life of humanity.

 

New large constellation programs are taking shape, THERMOCOAX is now ready to support the market with cost-effective catalyst bed heaters.