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THERMAL EQUIPMENT &

ULTRA-THERMAL EQUIPEMENT

DOCUMENTATION

THERMAL EQUIPMENT

Gouging out axles Dismantling steel constructions Burning off dam walls Burning through (tram)rails ( ± 30 sec. per cut) Burning through cast iron Burning through slag and oven masonry Making holes in (reinforced) concrete Making holes in natural stone Burning through steel alloy

THERMAL EQUIPMENT

3.1.1

WHAT IS A THERMAL LANCE? A thermal lance is a steel pipe filled with metal wires which at one end are connected to a cylinder of pure oxygen. The thermal lance is connected to the oxygen cylinder when the end of the lance has reached a temperature of ±800/900 °C through pre-heating. At the end of the thermal lance, the steel is submitted to strong oxidation, which results in the following: - A very hot, strong flame is created, with a tongue

temperature over 2500 °C. This tongue has different lengths, depending on the

used diameter of the thermal lance and the used amount of oxygen. The heat created in this way, can be used to drill, cut and burn ferrous and non-ferrous metals, including cast iron.

- Iron oxide is created as a "fluidizing means". - The melting point of concrete and other stone drops

(from 2000 °C/2500 °C to 1100 °C/ 1500 °C.) and the drainage of the substance created in this way is simplified. This characteristic allows the use of thermal lances when drilling and cutting in concrete and most other stones.

WHICH MATERIALS DOES THIS SYSTEM REQUIRE ? A. Industrial oxygen source - Oxygen cylinder for smaller works. - Battery of oxygen cylinders or another source,

for larger works. B. Reduction installation of 0 up to 12/ 15 bar in case of large-scale use. (85 Nm 3/h.) These installations can be supplied by us. We can also provide you with further information. C. Flexible supply line (high pressure hose) We recommend using reinforced supply hoses (suitable for a pressure of 15 BAR). These can be supplied in lengths of 10 and 20 meters. D. Handle The handle with closing device recommended by us was developed and tested in practice. This type of handle allows a quick attachment of the thermal lance. The amount of oxygen supplied can be controlled by means of the closing device.

THERMAL EQUIPMENT

3.1.2

- Thermal lances operate by means of oxygen. The safety measures that apply for this must be

complied with: e.g. avoiding grease, when using oxygen.

- The user should wear protective clothing, which we can supply upon request.

We advice you to wear : - Fireproof clothing protected by a long apron of

supple leather. - Boots or shoes that can be taken off quickly

without using your hands. Note that the trouser legs should not be worn within the shoes.

- Leather gloves with long arm pieces protecting the arms.

- A helmet made of synthetic material, with a foldable visor of coloured material. This visor will protect the face against sparks and splashes, and the eyes against too much light radiation.

THERMAL EQUIPMENT

3.1.3

VARIOUS USES OF THE THERMAL LANCE For instance, making holes in and dismantling and cutting virtually all materials.

A. Concrete, with or without reinforcement. B. Natural stone like granite, basalt, etc. C. All types of cast iron. D. Alloyed steel, brass, copper, etc. E. Slag, oven masonry, etc. F. Cutting steel dam walls, (tram) rails or concrete under the water line.

VARIOUS TYPES OF THERMAL LANCES AND THEIR CHARACTERISTICS

A. Type 1/4’’ , length 3000 mm., core temperature ± 2300°C. Bore diameter; in concrete 20 mm. ; in steel ± 20 mm. Bore depth ; in concrete 1500 mm. ; in steel ± 1200 mm.

B. Type 3/8’’ , length 3000 mm., core temperature ± 2300°C. Bore diameter; in concrete 30 mm. ; in steel ± 20 mm.

Bore depth ; in concrete 2000 mm. ; in steel ± 1500 mm.

C. Type 1/2’’ , length 3000 mm., core temperature ± 2300°C. Bore diameter; in concrete 50 mm. ; in steel ± 30 mm. Bore depth ; in concrete 2000 mm. ; in steel ± 1500 mm.

These characteristics strongly depend on circumstances under which the work is performed and the experience of the person operating the thermal lance. NOTE The bore diameter can be strongly affected by oxygen pressure and by rotating the thermal lance. The most popular type is the 3/8’’ lance, length 3000 mm., temperature ± 2300°C. This article can be supplied from stock. The other lances have a delivery period of approximately 14 days.

THERMAL EQUIPMENT

3.1.4

Thermal lances

Thermal lance holder

Rubbers

Thermal lance type 3/8” * 3000 mm., HBS art.no. 04V0961808 Thermal lance type 1/2” * 3000 mm., HBS art.no. 04V0093219 Thermal lance type 1/4” * 3000 mm., HBS art.no. 04V0093218

Thermal lance holder complete, suitable for 3/8” lances, HBS art.no. 04V0009115 You need a modified head for using 1/4” and 1/2” lances (see parts).

Rubber type 3/8” HBS art.no. 04V0093242 Rubber type 1/4” HBS art.no. 04V0093241 Rubber type 1/2” HBS art.no. 04V0093243

On stock

DOCUMENTATION

ULTRA-THERMAL EQUIPEMENT

Gouging out axles Dismantling steel constructions Burning off dam walls Burning through (tram) rails Burning through all steel alloys Making holes in (reinforced) concrete, natural stone Can be used above and under water A very accurate and quick result

ULTRA -THERMAL EQUIPMENT

3.2.1

ULTRA -THERMAL GOUGING AND CUTTING. Ultra-thermal flame cutting offers benefits compared to other cutting processes, because of its high operating temperature, the little time that is required to put it in operation, its portability and its safety. For the maintenance of industrial materials and machines, ultra-thermal cutting is complementary to traditional oxyacetylene and air carbon arc cutting. Ultra-thermal cutting is a burning process fuelled by oxygen. The system can be used to remove the teeth of loading shovels of excavating machines; it removes bolts and rivets, cuts construction steel on shipyards; drills, cuts and gouges on ship's decks. The ultra-thermal method has benefits over other methods because of its high operation temperature, its simple application, the little time that is required to put it in operation, its portability and its safety. Ultra-thermal equipment comprises a cutter, ultra-thermal cutting electrodes, a copper ignition plate, an oxygen source with reducing valve, a 12 volt battery, an oxygen hose and cables. The cutter has a pistol grip with a copper manifold and a collet plus nut holding the electrode. A valve plus handle regulates the flow of oxygen through the cutter. The ignition plate is connected to the battery in order to ignite the electrode. THE ELECTRODE IS THE KEY. The ultra-thermal electrode was originally developed in 1978 for use under water at offshore oil platforms. They replaced the less effective electrodes made of steel pipe. When the oil industry slowed down in the eighties, manufacturers redeveloped the electrode for use above water. A hollow, copper-coated steel pipe filled with wires made of steel alloy forms the electrode, the heart of the process. Circular notches in the pipe will keep the steel wires in their place. The user can bend the pipe in order to reach difficult places. Inside, the wires are a little shorter at one side of the pipe in order to prevent sparks backfiring. The user inserts the hollow parts of the electrode in the cutter. Oxygen will flow through the pipe and around the wires. The user can choose between two different diameters. Thinner electrodes are suitable for drilling up to 15 centimetres deep, gouging welding joints and cutting materials up to 3cm thick. Thicker probes can drill through and cut thicker workpieces, gouge away cracks and heavy welding joints and remove deposits. The maximum cutting thickness in steel is virtually unlimited.

ULTRA -THERMAL EQUIPMENT

3.2.2

HOW TO GET STARTED.

Prior to operating the equipment, the user should remove all inflammable products from the workshop and inspect the equipment; if necessary, he should replace worn or damaged parts of the equipment. If work has to be done to pipe lines or containers, they should first be flushed by means of an inert gas. In order to start cutting, he will connect the reducing valve to the oxygen cylinder and the hose of the cutter. He will connect the electricity cables for the ignition to the cutter and the ignition plate to the battery. Then he opens the tap of the reducing valve until the flow rate required is reached, usually 2.8 to 5 Bar, depending on the material to be cut and its thickness. Using gloves, he will unscrew the collet nut of the cutter and insert the hollow side of an electrode in the cutter. He makes sure that the electrode is fully inserted in the collet in order to prevent oxygen leaks. The collet nut is tightened by hand. In order to ignite the electrode and start the flame, the user will hold the cutter in his one hand and the ignition plate in the other. A slight squeeze in the oxygen handle will allow oxygen to flow through the cutter and the electrode. Under an angle of 45° the electrode is slowly rubbed over the ignition plate, until it ignites, the electrode will begin to spark. The user can now start working. The electrode will burn as long as there is oxygen flowing through it, until it is completely burnt up. The temperature at the end of the electrode is 5000° Celsius. TECHNIQUES. The users apply the electrode to pierce pins, rivets and bolts. To pierce, the electrode is held perpendicular on the workpiece and with a slight flow of oxygen (slight pressure on the handle), the burning point is pushed into the workpiece. The oxygen pressure is set to 2.5 Bar to prevent backfiring or sparks. As soon as the point is approximately 7mm deep, the oxygen handle can be pressed in order to work faster. By moving the point in and out of the piece, the melted material is blown away. When a depth of more than 10cm is reached, the oxygen pressure will be increased tot 3.5 Bar in order to continue the process. To avoid the electrode from getting stuck in the hole, the oxygen supply will not be interrupted until the point is removed from the workpiece. In order to start a gouge, the user will place the electrode at an angle of 45° on the workpiece and will point the burning point in the direction of the gouge that has to be made. The oxygen pressure is at 2.5 up to 2.8 Bar for shallow gouges and at 2.8 to 3.5 Bar for a deep gouge. As soon as a little hole is formed, he will reduce the angle to 5 up to 10° and will push the probe in the direction of the gouge to be made.

ULTRA -THERMAL EQUIPMENT

3.2.3

Contrary to air carbon arch gouges, you do not need a welding device or compressor. Moreover, there is no danger of high currents, noise or smoke. The process does not build up carbon and does not require prior cleaning or sanding the workpiece. In order to cut with the electrode, the user will pull it over the workpiece. The working angle at the surface can fluctuate between 45 and 90 degrees; always keep the tip in the groove in order to prevent backfire. Melted material must be blown out of the groove in a forward direction; if is flows backwards, you must work at a lower pace. The oxygen pressure is 2.1 to 2.8 Bar for soft steel and iron up to 1.5cm thick; 2.8 to 3.5 Bar for non-ferrous metals up to 2.5cm and iron of 1.5 to 2.5cm.; 3.5 to 4.2 Bar for all metals up to 5cm and 4.2 to 5 Bar for all heavier work. APPLICATIONS. Maintenance crews use ultra-thermal systems to remove fixed bolts. They first pierce the pin and cool it with water; as a result, it will shrink approximately 2.5mm. The process is repeated until it is possible to hammer the pin out. An ultra-thermal electrode can loosen a fixed pin in approximately 30 seconds. Fast repairs to the teeth of excavation devices can be performed on site. A bent tooth of a bulldozer shovel can be obstructive when trying to reach the ground. The tooth can be quickly removed without taking the machine out of operation. After the excavation works, at the end of the day, the welding joint of the tooth and the shovel can be gouged out and a new tooth can be welded to it. Also on site, it is possible to gouge out stress cracks in bridges and other structures. In order to repair the cracks, holes will be drilled at the end of the crack and then the crack will be gouged out in order to prepare the basic material for repair by means of a welding joint.

ULTRA -THERMAL EQUIPMENT

3.2.4

ULTRA -THERMAL EQUIPMENT

3.2.5

PARTS OF THE ULTRA-THERMAL CUTTER . THE CUTTER. The proven reliability of the cutter was obtained through our durable and simple design. Manufactured from wear-resistant, stroke-resistant materials, the cutter was ergonomically designed to prevent tiredness for the user. The spark stopper was specially designed with the internal screen, in order to intercept sparks. The heavy and doubly ACME treated screw of the collet is big and easy to loosen or tighten with gloves. The proven design helps preventing contamination from mud, sand, slag or other blemishes and makes sure that the electrode can be inserted and removed quickly and reliably. Each cutter can be supplied with two collets for both 1/4" and 3/8" ultra-thermal electrodes. The handle for oxygen supply is also easy to operate with gloves, so that the user is able to finely adjust the oxygen supply during ignition of the electrode or while gouging, drilling or cutting. Its unique design, makes it very easy to disassemble and maintain the cutter in the field. (Sets of replacement pieces are available). THE ULTRA-THERMAL ELECTRODES. The ultra-thermal electrodes comprise bars and burn at the end with a temperature of more than 5000°C. Our electrodes cut and melt or can make any material fluid. These internal bars were forced back at the end. Due to this unique characteristic, our electrodes are the safest on the market. A number of circular notches secure the internal bars so that they can be bent without interrupting the oxygen supply. This unique design allows the user to treat the most difficult places or places that could not be reached otherwise. The electrodes are available in 1/4" or 3/8" diameters and various lengths. This range of sizes makes them efficient and adjustable to various applications. Electrodes are offered in bulk packages of 25 and 60 items. All electrodes are manufactured under severe quality control and inspected before they are being packaged, in order to guarantee a reliable performance.

ULTRA -THERMAL EQUIPMENT

3.2.6

ULTRA-THERMAL CUTTING SYSTEMS BENEFITS

UNIQUE POSSIBILITIES.

The unique method of burning with ultra-thermal electrodes will make literally all encountered materials fluid, while the material itself is used as fuel. They cut or melt through any known material, such as cast iron, steel, stainless steel, concrete, granite, nickel, titanium and aluminium. Because our systems are able to cut so quickly, there is a minimum build-up of heat, as a result of which tempered materials remain virtually unchanged. Our ultra-thermal electrodes burn in moist surroundings, even in mud or water. This unique performance adds a very important benefit over other equipment, especially within industries with difficult working environments such as mining or heavy industry. TIME AND COSTS SAVING PERFORMANCE. If time saving is the criterion, then this system will be the professional's first choice for applications such as gouging, drilling or cutting. Maintenance and repair companies are able to perform difficult tasks much quicker, that would be very time-consuming with conventional methods. The time that heavy excavation machines are out of operation is dramatically reduced when removing attachment pins from the caterpillars or repairing them. Or when removing solid deposits. This system saves costs and working hours. Because our ultra-thermal systems operate at temperatures over 5000°C, it is not necessary to pre-heat the surface. As no permanent electric energy is required, repairs can be performed without burr formation on roller bearings and bushes. Moreover, you do not have to sand or clean surfaces when gouging, as our system does not deposit carbon. SAFETY AND USER COMFORT. This system is safer than other systems, as no high currents or potentially dangerous acetylene or any other fuel are required. The comfort and safety of the user are also improved, as this system produces less noise, smoke or toxic gases than other systems. The user friendly characteristics were designed with focus on simplicity in use. The 12 Volt DC ignition system, single 0² source with reducing valve and fully autonomous portable sets make sure that this system is easy to use.….even for a beginner.

ULTRA -THERMAL EQUIPMENT

3.2.7

THERMISCH EQUIPEMENT

3.2.8

Ultra-thermal electrodes

Ultra-thermal electrodes

Ultra-thermal cutting set

Ultra-thermal electrodes, uninsulated, size Ø 9,5 * 1000 mm., HBS art.no. 04V0961636 Ultra–thermal electrodes, uninsulated, size Ø 9,5 * 450 mm., HBS art.no. 04V0961888 Ultra–thermal electrodes, uninsulated, size Ø 6 * 450 mm., HBS art.no. 04V0961637

Ultra-thermal electrodes, isolated, size Ø 9,5 * 450 mm., HBS art.no. 04V0094430 Suitable for under water.

Ultra-thermal cutting set, complete, Can be used above and under water, HBS art no. 04V0961862 Suitable for under water.

On stock

ULTRA -THERMAL EQUIPMENT

THERMISCH EQUIPEMENT

3.2.9

Ultra-thermal electrodes

Various

Collet for ultra-thermal cutting set, type Ø 9,5 mm., HBS art no. 04V0961813 Collet for ultra-thermal cutting set, type Ø 6 mm., HBS art no. 04V0961814 Rubber for ultra-thermal cutting set, type Ø 9,5 mm., HBS art no. 04V961813B

Oxygen hose 9 * 16 mm., HBS art no. 04V0214865 Oxygen hose 13 * 22 mm., HBS art no. 04V0204775 Earth wire for ultra-thermal cutting set, HBS art no. 04V0204776 Reducing valve, large flow type, flow 0-20 bar, HBS art no. 04V972557B Head for ultra-thermal cutting set, for use above water, HBS art no. 04V961862B Head for ultra-thermal cutting set, for use under water, HBS art no. 04V961862A

On stock

ULTRA -THERMAL EQUIPMENT