How Residential Water Heaters are Made?
The residential water heater was invented back in 1889, and the basic concept still holds water today. It heats water usually with natural gas propane or electricity; then it keeps it continuously hot so that you always have a supply on tap. Life without it would mean many cold showers water heaters may look uninspiring, but inside, they’re hot stuff to make one a hydraulic press transforms a round steel blank into a dome shape. This dome will form the base of a gas heated tank, and it will hold the burner next rollers behind and above the Perla sheet of steel around a cylinder. It forms the inner tank shape. A seam welder device then pinches the two ends of the tank shape together and welds them in the next step. A worker positions the tank body under a projection welder he selects a threaded fitting place it on the tank and lowers the welder.
This projection welder uses ten thousand volts of electricity to fuse fittings to the tank body. It also welds fittings to the top of the tank valves and other parts will be screwed into these fittings later next a press applies over 27 tons of force to fit atop onto the tank then they spray liquid enamel inside of the spinning tank it will be baked in at 900 degrees Celsius for 45 minutes to prevent rusting. Now it’s back to the bottom of the tank a worker inserts a flue tube in a hole in the center, and an automated welder joins it to the tank base the flue will vent gasses from the burner after anti-rust enamel coating is baked onto the base and flue they lower the tank body onto it.
Next robotic welding arms work both ends of the tank one welds the base to it the other bonds the flue to the top now the pressure test they pump air into the tank and then pour water over the outside if water bubbles on the tank it means air is escaping. There’s a leap that needs to be fixed here. They install elements in an electric water heater, and they hook up a thermostat and the wires that run to it. Now it’s time to make the tanks outer shell or jacket an operator slides a painted steel shape onto a mandrel so that it becomes cylindrical a lock former then moves along a rail folding and pressing the seam together next a former roll crimps the top and bottom edges so that lids can be easily installed where they drape a plastic apron over a tank and then slide on its jacket or tank shell with just the electric components exposed.
They screw steel cover over them. A chemical reaction causes polyurethane foam to expand in seconds. They inject this expanding foam into the plastic apron that’s now between the tank and outer shell the foam will insulate the tank now they finish installing the wiring on this electric heater and then do an inspection. It makes the grade on gas heaters they slide a burner into the dome-shaped base and then connect the burner tubes to the gas valve they attach some wiring that controls the burner ignition and then hook it up to the gas line for a test run that inner glow is the burner at work they light a torch on the flame and pass it over the valve to check for little gas leaks it didn’t ignite. Hence, there aren’t any it gets the seal of approval, and now it’s up to the consumer to test the waters when it’s installed.