As manufacturers and process operators move away from fossil fuel-powered heating systems, many face challenges related to power distribution, system complexity, and scaling up electric process heating to multi-megawatt applications. POWERSAFE addresses these challenges with an integrated platform that combines medium-voltage electric heating, advanced controls, and built-in protection systems into a single solution.

“Industrial operators need practical electrification solutions that can support large thermal processes without introducing unnecessary complexity,” said Tim Bruewer, senior director of strategic marketing at Watlow. “POWERSAFE enables direct connection to the medium-voltage grid, helping customers reduce infrastructure requirements, streamline installation, and accelerate the transition to electric process heating.”
Designed for industrial applications requiring significant thermal capacity, POWERSAFE supports multi-megawatt loads and supply voltages up to 7,200 V. By connecting directly to the medium-voltage grid, the platform reduces the need for step-down transformers, minimizes wiring requirements, and decreases overall system complexity.

Key features include:
Integrated medium-voltage control and heating platform compatible with applications with supply voltages up to 7,200 V;
Integrated protection systems, including arc flash protection, overvoltage, undervoltage, and overcurrent protection, phase loss detection, ground fault protection, and heater overtemperature monitoring;
Separate low- and medium-voltage compartments to enhance personnel safety and simplify maintenance;
Patented busbar and termination technologies designed to reduce the risk of partial discharges and ensure long-term system integrity;
Advanced heat transfer technologies that optimize process efficiency while helping to maintain fluid integrity;
Reduced wiring requirements and a smaller footprint compared to conventional low-voltage approaches;
Touchscreen monitoring and diagnostics for enhanced system performance visibility.
POWERSAFE also incorporates features designed to maximize uptime, including advanced termination systems, humidity management technologies, and monitoring capabilities that support predictive maintenance strategies.

“Successful electrification of large-scale thermal processes requires an architecture specifically designed for medium-voltage operation,” said Ashish Bhatnagar, Chief Technology Officer at Watlow. “POWERSAFE combines electric heating, control, and protection technologies into a single platform that helps customers improve operational efficiency, reduce maintenance needs, and support long-term sustainability goals.”