Water Cooled Cable for Electric Furnace

A BrandwithReliability

A water cooled cable is mainly used as a secondary conductor in a steelmaking arc furnace. It is interlocked
integrally with the arc furnace at the time of tilting the furnace body for tapping molten steel or in the eventof rotating the furnace cover for injecting scraps. This means that bending, twisting or other stresses apply tothe cable.
In addition, while the furnace is in operation, it is exposed to radiant heat from the electrodes. An
electromagnetic effect produced by a high electric current applies to the cable repeated stress generated
from the attracting and bouncing force in the same phase or between different phases of the cable.
The water cooled cable is used under severe conditions with high temperature atmosphere and mechanicalexternal forces described above. Since 1965, we have delivered a large number of products to manydifferent sectors of steelmaking. We have made several technical improvements to match the cable withthe operating conditions of steelmaking furnaces to achieve quality enhancement and prolongation of theservice life.

Configuration
Terminal

Reinforcing hoseExternal hose

Conductor

Plated with silver for reducing
contact resistance at the timeof contacting a bus bar.

Added to the external hose for thejoint between the terminal and theconductor to reduce the stress thatconcentrates on the conductor
close to the joint and to prolong theservice life of the conductor.

Adopting a structure in which layers of multiple
materials are stacked in consideration of electric
insulation, wear resistance, heat resistance,water pressure resistance and elasticity and othercharacteristics to retain required properties for along period of time under severe conditions of use.

Adopting conductor twist
configuration in considerationof elasticity for ensuring a longservice life of the product.

Fastening band
Securely fastening the terminal with theexternal hose with the use of a non-magnetic
high tension copper band to prevent waterleakage from the gap between the terminal
and the external hose as well as detachmentof the fastening part even if the weight of theconductor is applied to the external hosewhen the conductor is disconnection.

Flute core

SpacerAimed at keeping the position of thetwisted conductor and at feeding
coolant water to the whole length ofthe conductor in order to cool theconductor more uniformly.

Placed in necessary quantities on theexternal hose to weaken the impact ofcontacting between water cooled cables
and to reduce wearing of the external hoseand the conductor.

Conductor tube

Flexible copper tube

Designed to reduce abrasion of conductor
wire at the time when the cable is in motion toachieve a long service life of the cable.

Placed near the joint between the terminal
and the conductor to reduce the bending
stress that concentrates on the position
concerned and to slow attrition betweencomponents caused by strong vibrations.

Table of Configuration of Water Cooled Cables (standard models)Nominal crosssection area
(mm2 )

Diameter ofexternal hose(mm)

Diameter (mm)

1,000

101

127

Length (mm)Direct current
conductor resistance(10-6Ω/m at 20 deg. C)

Rated current(kA)

Approx. netweight(kg/m)

Bend radius
(mm)

700

18.8

5.0

16.0

500

Reinforcing hose

1,500

129

155

1,000

12.0

7.5

24.0

650

1,750

129

155

1,000

10.4

8.8

26.5

650

2,000

136

163

1,000

9.20

10.0

29.5

680

2,250

145

174

1,000

8.23

11.335.0730

2,500

145

174

1,000

7.30

12.5

37.0

730

2,750

159

191

1,000

6.69

13.8

42.0

800

3,000

159

191

1,000

6.18

15.0

44.0

800

3,500

171

205

1,000

5.02

17.5

53.0

860

4,000

179

212

1,000

4.46

20.0

58.5

900

4,500

189

224

1,000

4.01

22.5

65.0

950

5,000

198

233

1,000

3.65

25.0

70.0

990

Notes: 1. We offer this product with a cross-section area of up to 6,500 mm .
2. According to the environment for use, we propose an optimal configuration, such as extra spacers and an external hose with a thicker wall.
2

PT- C "Terminal Dimensions (standard models)A
B

E-DøF ℓ ℓ ℓ ℓ´GTL

Dimensions of the plate part of the standard terminal (mm, or inches for C only)

Nominal crosssection area(mm2)

A

B

C

DE

F

G

L

ℓℓ’

T

1,000

74

50

1

14

830

55

250

55

─

45

1,500

87

51

1

18

1040

40

300

55

55

50

1,750

87

51

1

18

1040

40

300

55

55

50

2,000

96

64

1

18

1040

50

310

55

55

50

2,250

104

70

1 1/4

18

1045

55

320

55

55

50

2,500

104

70

1 1/4

181045

55

320

55

55

50

2,750

116

74

1 1/22285060

320

70

─

50

3,000116

74

1 1/2

2285060

32070

─

50

3,500

124

74

1 1/2

2285060

32070

─

55

4,000

134

80

1 1/222850

60

350

80

─

55

22850

60

350

80

─

55

22850

60

350

80

─

55

4,500

14180

1 1/2

5,000147

80

1 1/2

Notes: 1. E represents the quantity of processing for making holes on terminals.
2. The dimensions of the plate part of the terminal may be changed on request.
3. According to requests, the tip of the terminal will be processed to enable attachment of an eye bolt.

Quantity of Coolant Water (reference)
Table of Estimated Quantity of Coolant Water
140130120

Water Quantity (ℓ/min)

110
100
90

6A/mm2An exterior view of the water cooled cablein the process of manufacturing

80
70
60
50
40
30

5A/mm220
101,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500 5,000

Cable Size (mm2)Notes: 1. Cable strip length: 10 m
 ater temperature rise: 5 deg. C (Example: water entry temperature: 32 deg.
2. W
C, water exit temperature: 37 deg. C)
3. Use within the electric current density range from 5 A/mm2 to 6 A/mm2.
4. Standard pH level of coolant water: 6.5 to 10

State of application to an electric furnace

Maintenance1. Spare water cooled cables in stock
Water cooled cables are prone to deterioration or damage
to the hose, as well as to breakage caused by accumulationof fatigue of the conductor. While the arc furnace is inoperation, they are exposed to radiant heat from theelectrodes. An electromagnetic effect produced by a highelectric current applies to the cable repeated twisting,bending, vibrating and other stresses generated fromattracting and bouncing force in the same phase or between
different phases of the cable.
Breakage of a water cooled cable means that operation
cannot be continued. It is considered necessary to keepspare water cooled cables in stock and to be prepared torestore the furnace operation in a short while.

2. Deterioration check(1) Investigation conductor burnout rate
For ensuring stability of operation, it is desirable to replacewater cooled cables as expendable items in a regular cycle
before they come into breakage or other trouble and werecommend replacing them in each phase at a time.
We propose regularly performing the deterioration checkto measure the conductor burnout rate as a means ofunderstanding and determining the cycle of replacementof water cooled cables and probing into the correlations
between the number of charges on the water cooled cables
and the conductor burnout rate.

A[Method of Measuring
Conductor Burnout Rate]
The four-terminal method isemployed to measure theconductor resistance in awater-cooled cable. Fromthe measurement results andthe specification value of theconductor resistance, theburnout rate is calculated.

(2) Visual inspectionWe propose checking thewear of the external hose andreplacing the water cooled
cable or the external hose
if hose breakage or waterleakage is likely.

RVA resistance measuring circuit
based on the four-terminal method
Heat resistancelayer
Abrasionlayer

Reinforcement
layer
Insulation
layer(3) Proposal on operation cost cuts

A General Structureof an External Hose

According to the deterioration check results and the findings from
subsequent operation confirm, we propose a configuration change. For
example, if it is confirmed that the external hose is worn relatively quicklyin comparison with the number of charges until the conductor breaks, wepropose a thicker wall of the external hose as a measure for achieving a long
cycle of replacing water cooled cables.

http://www.feic.co.jp/english/
Overseas Business Development
6-48-10 Higashi-Nippori, Arakawa-ku, Tokyo 116-0014 Japan
Phone: +81-3-3803-1152 Fax: +81-3-3801-0581●For online inquiries, please visit:●For other inquiries, please contact:

http://www.feic.co.jp/english/formmail_08jp.htm* The information contained in this brochure is correct as of July 2015.
* The information contained in this brochure is subject to change without prior notice.
DE-061 2G8 TR 200