Installation Procedure Refractory_0

ACE REFRACTORIES LIMITED REFRACTORIES

GENERAL INSTALLATION PROCEDURE Project

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CLIENT

CUSTOMER

M/s BHARAT HEAVY ELECTRICALS LTD. BOILER PLANT UNIT, TIRUCHIRAPALLI 620 014

M/s GUJARAT AMBUJA CEMENTS LIMITED, GUJARAT.

Rev. 0

Kind of Revision FIRST ISSUE

0 RAJIV CHOKS DKS 10.04.2006 REV PREPARED CHECKED APPROVED DATE ACE Refractories Limited reserves all rights on this document that cannot be reproduced in any part without its written consent. Approved:

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CONTENT 1. Storage of Refractory Material 1.1 1.2 1.3

Storage of Castable Material Storage of Bricks and Mortar Storage of Ceramic Items and Calcium Silicate Block.

2. Preparation for Working 2.1 2.2

Documentation Equipment at Site

3. Anchor Welding 4. Preparation for Installation 4.1 4.2 4.3 4.4

Surface Preparation Shuttering Preparation (for Dense and Insulation Castable) Fixing of Water Percentage for Castable Fixing of Mixing Time for Castable

5. Back-up layer Fixing and Inspection 5.1 5.2 5.3

Calcium Silicate Block Insulation Bricks Insulation Castable

6. Installation Procedure for Brick Lining 6.1 6.2 6.3

Tools Required Basic Guidelines Installation Procedure 6.3.1 6.3.2

6.4

Mortar Preparation Brick Lining Method

Inspection

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7. Shuttering Fixing Details 7.1 7.2

For Dense and Insulating Castable Shuttering Preparation (in case of roof and any completed design for Refractory Castable)

8. Installation of Insulating Castable 8.1 Mixing of Castables 8.2 Casting 8.3 Removal of Shuttering 8.4 Inspection 8.5 Natural Curing 8.6 Inspection Report 9. Installation of Dense Castable 9.1 Mixing of Castable 9.2 Casting 9.3 Removal of Shuttering 9.4 Inspection 9.5 Natural Curing 9.6 Inspection Report 10. Acceptance Criteria 11. Precautions.

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Storage of Refractory Material 1.1

Storage of Castable Materials Castable are hydraulic setting. To protect these materials during storage, primary precautions against easy ingress of water or moisture from air are required. Additional care should be taken if they are stored for longer periods and in humid atmosphere. The following precautions should be taken during storage of castables and gunning materials: • • • • • •

1.2

Material should be stored at a dry place. If the floor is not dry, it should be raised using timber boards standing on bricks. Bags of refractory castables should be stacked away from the walls. In case it is absolutely necessary to store bags in open for short durations during construction operations the bags should be protected from water or moisture. Castables should be used in the same order in which they are delivered, so that their consumption can be on first-in first-out (FIFO) basis. In case they are stored for longer periods than recommended, it is preferable to get them tested before being put to use. 01

Stack away from the walls on wooden pallets.

02

First In First Out (FIFO) is must.

03

Best to be used within self-life period.

04

Can be stored for long life.

Storage of Bricks and Mortar It is most important that the materials like Dense Bricks, Mortars, insulation Bricks and Boards should be stored properly as they are either hygroscopic in nature or having tendency to absorb moisture from atmosphere. The following precautions are must for storing above materials.

1.3

Storage of Ceramic Items and Calcium Silicate Block Calcium Silicate Block and Ceramic Items has to be covered with polythene sheet to avoid absorption of moisture. The Box should be opened as and when required for site installation work. Consume all the items issued for installation work before drawing new material. Approved:

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Preparation for Working 2.1

Documentation -

2.2

Refractory Engineering Drawings with BOM. Installation Procedure. Standard formats for Refractory Installation. Materials stock at site. Space and storage condition for equipments & materials. Working record.

Equipment at Site -

Mixer Machine should be located as close as possible to the installation site. Check the mixer conditions (RPM, gap between scraper and bottom plate, discharge door, gear oil, DOL starter, etc.)

-

Check the working of Needle Vibrator and ensure the availability of adequate needle size with spare.

-

Ensure easy availability of potable water

-

Ensure availability of ice if, intended to be used.

-

Ensure availability of following items: -

Carpentry Tools and Masonry Tools Water measuring jar Hand lamps (24V) with transformer First aid box with necessary medicine Drums for storing Potable water Pulley and Rope for lifting castable bags, water and other materials required at higher elevation. Welding machine, electrode etc. Thermometer for measuring water temperature. Brick Cutting Machine with required nos. of Diamond Cutter. Brick lining tools like meter stick, plumb level, brick layer string and etc. Handsaws for cutting Insulation Bricks, Ceramic items. 50~100 Kg Drums for mixing mortars. Sufficient nos. of scaffolding pipes and clamps with wooden planks / steel working platform (2m x 0.3m). Shuttering Materials for Castable lining works. Approved:

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3. Anchor Welding 3.1

Mark the location in the shell as specified in the drawing as per decided spacing. Ensure marking orientation of the anchors as per drawing.

3.2

Weld one anchor (ensure services of qualified welder only).

3.3

Hammer test the welded anchor.

3.4

If satisfactory, continue welding of other anchors.

3.5

Check the perpendicularity of anchor with respect to shell.

3.6

Hammer test randomly to ensure proper welding.

3.7

Fill the welding inspection report after inspection with client.

.

4.

Preparation for Installation 4.1

4.2

Surface Preparation 4.1.1

Clean the shell, before application of refractory. The surface must be free from grease, oil, dust and any other foreign material.

4.1.2

Wrap the tip of anchors with insulation tape or provide plastic cap for expansion allowance.

Shuttering Preparation (for Dense and Insulation Castable) 4.2.1

Make a plan for casting as per site condition (shuttering details, panel length, from which area casting has to be started, and etc).

4.2.2

Prepare shuttering as per casting plan.

4.2.3

Decide the panel size, if not already decided.

4.2.4

Plan staggered panels as far as possible to ensure staggered joints with respect to hot face and backup layer.

4.2.5

Shuttering materials can be either wooden or metal. But ensure shuttering has to be strong enough to bear the load of material, vibration, ramming and etc., if Approved:

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required give further supports. Ensure shuttering material is having vent holes at an interval of 250 mm..

4.3

4.4

4.2.6

Ensure orientation of shuttering for casting suitability.

4.2.7

Apply Grease / oil on shuttering surface for easy removal and prevention of water absorption.

4.2.8

Ensure sufficient number of shuttering available at site to avoid delay in castable installation for want of shuttering.

Fixing of Water Percentage for Castable 4.3.1

Take one batch of 100 Kg material in mixer.

4.3.2

Mix dry for about 1 min.

4.3.3

Add water as per specification data sheet.

4.3.4

Mix for 3 - 5 minutes for conventional castables and mix for 5 - 7 minutes for low cement castables.

4.3.5

Check for workability by ‘ball in hand’ consistency method.

4.3.6

If required increase water percentage step by step till satisfactory mix is obtained.

4.3.7

The exact amount of water to be added will be decided by ACE’s Site Engineer during application as per the working consistency, since the same varies for different castables and for different sites depending on the climatic condition.

Fixing of Mixing time for Castable 4.4.1

Charge known quantities of castable in the mixer.

4.4.2

Start the mixer and mix dry for about one minute.

4.4.3

Add water slowly as per requirement fixed in 4.3 slowly without stopping mixer.

4.4.4

Continue mixing for 3 - 5 minutes for conventional castable and 5 - 7 minutes for low cement castable.

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Check the workability / consistency by ‘ball in hand’ method. This can be studied time to time during installation of castable at site by the ACE Engineer and decide about the method of mixing to achieve better quality of material.

Back-up Layer Fixing and Inspection 5.1

5.2

Calcium Silicate Block 5.1.1

Check thickness of Calcium Silicate Block.

5.1.2

Cut into pieces as per site requirement, so that it can be easily fixed in between two anchors.

5.1.3

Fill the gap (at anchor location / joint of two Calcium Silicate Block) with fine Calcium Silicate Block mixed with sodium silicate solution.

5.1.4

Near the anchor, fill the gap with loose ceramic wool / loose ceramic blanket / fine Calcium Silicate Block mixed with Sodium Silicate Solution.

5.1.5

Check the thickness of the Calcium Silicate Block after fixing.

5.1.6

Make Installation Report as per the format.

Insulation Bricks 5.2.1

5.3

For Insulation Brick Laying Procedure, refer application procedure of Installation Procedure for Brick Lining (Sl. No. 6).

Insulation Castable 5.3.1 For Installation of Insulation Castable, refer application procedure of Installation Procedure for Insulating Castable (Sl. No. 8).

6. Installation Procedure for Brick Lining 6.1

Tools required 6.1.1

Trowel for applying and spreading mortar.

6.1.2

Metallic / Wooden / Rubber hammer for alignment and hitting laid brick. Approved:

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6.1.3 Rigging chisels. 6.1.4 Handsaws for finishing insulating brick 6.1.5 6.2

Measuring tools i.e. meter stick., level, plumb, brick layer string, measuring tape etc.

Basic guidelines 6.2.1

The construction dimensions in the design drawing must always be observed taking the indicated tolerances into consideration.

6.2.2

Thickness of the joints must be observed.

6.2.3

All joints must be completely filled over the entire surface with the joint material. it is not permissible to apply the mortar with a “collar “.

6.2.4

Expansion joints must never contain any contamination.

6.2.5

Already laid brick can be readjusted in the direction of bed/vertical joints.

6.2.6

Readjustment is not allowed if mortar has started to harden to a greater degree. then it is advised to remove them ,clean and install with fresh mortar.

6.2.7

Brick lining work should be carried out section by section layer by layer.

6.2.8

The hollow space will have to be filled by unshaped material (Castable can be used at the junction of corner).

6.2.9

The bottom (Floor) lining should be installed last.

6.2.10 Cold setting mortar is recommended to compensate unevenness in the casing. 6.2.11 Ensure correct geometric alignment of all bricks. 6.2.12 The joints must be strong and sealed tight. 6.3

Installation Procedure 6.3.1

Mortar Preparation 6.3.1.1 Transfer known quantity of Mortar in the 50 Kg Bucket.

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6.3.1.2 Add specified quantity of water / binder. The requirement of water should be as per site condition to obtain the working consistency. 6.3.1.3 Mix it uniformly. No lumps formation in the mix. If there is lumps formation, it should be broken and mixed uniformly. 6.3.2

Brick Lining Method 6.3.2.1 Refractory Lining must be always laid as per drawing. 6.3.2.2 First layer must be installed with extreme care. 6.3.2.3 The mortar has to be applied uniformly on the surface of the brick and should be covered the entire surface of the bricks. Non-uniformity in mortar applied on the brick surface will lead to the hollow space formation in the mortar joints. 6.3.2.4 At any case, the mortar thickness should not be more than 2mm. 6.3.2.5 In the case of usage of any cutting brick, then the cut brick size should be more 60% of the original length. 6.3.2.6 The final layer at any junction / any layer completion along horizontal or vertical direction, don’t use any cut bricks. 6.3.2.7 Check the verticality and horizontality of brick lining for each and every layer of installation with the help of 2meter long straightedges, plump, bricklayer string, leveling instruments. 6.3.2.8 For Brick alignment, use wooden hammer for insulation brick and metal hammer for dense brick. Don’t apply too much of force for aligning the brick, it will damage the surface of the brick. 6.3.2.9 “Pointing“ has to be carried out after brick lining is completed.

6.4

Inspection 6.4.1

Check for uniformity of lining.

6.4.2

Check for uniformity of mortar filling (if any gap is observed, then pointing is to be carried out for filling up gap with mortar).

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6.4.3

7.

Make inspection report and final protocol.

Shuttering Fixing Details 7.1

7.2

For Dense and Insulating Castable 7.1.1

Ensure the proper shuttering available at site as per the casting plan with required tools & tackles and supports for fixing the supports.

7.1.2

Ensure the required numbers of shuttering and stopper plate at site to avoid stoppage of work due to want of shuttering / stopper plate.

7.1.3

Ensure separate manpower for fixing the shuttering, while many fronts are available for casting.

7.1.4

Apply a coat of grease / oil over the form - work. Check it before placement.

7.1.5

Fix the shuttering as per required thickness. This can be maintained by fixing small stopper / wedge at the top of the shuttering.

7.1.5

Check the verticality by plumb that will ensure the uniform thickness through the panel.

Shuttering Preparation (in case of roof and any complicated design for Refractory Castable) 7.2.1

Make a plan for installation of refractory castable as per site condition (shuttering details, panel length, from which area lining has to be start and etc.)

7.2.2

Prepare shuttering and raptor length (in the case of roof lining) as per installation plan.

7.2.3

Shuttering materials can be either wooden or metal. But ensure shuttering has to be stronger enough to bear the load of material, ramming pressure during application, etc., if required provide further supports.

7.2.4

Provide holes of Ø 5mm, for making vent holes at an interval of ≅ 250 mm.

7.2.5

Apply one coat of grease / oil at shuttering surface for easy removal and prevention of water absorption.

7.2.6

Ensure number of shuttering available at site to avoid delay for want of shuttering. Approved:

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Installation of Insulating Castables 8.2

Mixing of Castables 8.1.1

Clean the mixer thoroughly. Charge known quantity of castable in the mixer.

8.1.2

Mix dry for about one minute.

8.1.3

Add specified quantity of water.

8.1.4

Mix as per predetermined schedule.

8.1.5

Discharge the mixed material from the pan mixer.

8.1.6

Insulating castable can also be mixed manually in case quantity is small or adequate number of manpower is available to carryout manual mixing.

8.2 Casting

8.3

8.2.1

The mixed castable should be cast as early as possible.

8.2.2

Fill the mixed castable in the shuttering and tamp the material thoroughly.

8.2.3

Fill the material uniformly in the shuttering and castable leveling should be uniform through out the panel after tamping. In any case, settling of material at one place / corner should be avoided.

8.2.4

In slope area, the insulation castable can be installed by provided only side stopper plates. This will give good compaction in slope area.

8.2.5

Ensure proper filling of material in the shuttering.

8.2.6

Check the surface for proper setting.

8.2.7

Remove shuttering carefully after material has set.

Removal of Shuttering 8.3.1

Check and ensure proper setting of castable.

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8.3.2 8.3.3 8.3.4 8.4

Remove all the supports provided for fixing the shuttering / stopper plate one by one. Don’t apply heavy force for removing the supports. If heavy force is applied for removing the supports it will disturb the castables. Remove the shuttering slowly.

Inspection 8.4.1

Check for honeycomb, rat hole, segregation, lamination, etc. Mark the area to be repaired.

8.4.2

If repair area is very less, carry out necessary repair work by removing the loose material and filling it with new fresh material and compact with rodding.

8.4.3 If the repair area is more, dismantle the repair area and recast. Make the casting installation details. 8.5

8.6

9.

Natural Curing 8.5.1

Allow air drying for minimum 8 hours after casting.

8.5.2

Allow wet curing if possible for 12 hours minimum

Inspection Report 8.6.1

Complete the castable installation details Report

8.6.2

Make a joint inspection along with client and any other third party.

Installation of Dense Castable 9.1

Mixing of Castables 9.1.1

Clean the mixer thoroughly. Charge known quantity of castable in the mixer.

9.1.2 Mix dry for about 2 minutes. 9.1.3

Add specified quantity of water.

9.1.4

Mix as per predetermined schedule.

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9.1.5 9.2

Discharge the mixed material from the pan mixer.

Casting 9.2.1

The mixed castable should be cast as early as possible.

9.2.2

Fill the mixed castable in the shuttering and vibrate thoroughly.

9.2.3

Fill the material uniformly in the shuttering and material leveling should be uniform through out the panel after vibration.

9.2.4

Draw back the needle slowly in running condition.

9.2.5

Ensure proper filling of material in the shuttering.

9.2.6

Once casting is over, provide steps in the surface, this will avoid the straight joints between the two consecutive panels as mentioned in the drawing. This has to be done after 15 – 30 minutes of casting.

9.2.7

Check the surface for proper setting.

9.2.8

Remove shuttering carefully after material has set.

Correct Percentage of Water in the mix – looks shiny surface in ball in hand.

Higher Percentage of Water in the mix

Lower percentage of water in the mix

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9.3

Removal of Shuttering 9.3.1

Check and ensure proper setting of castable.

9.3.2

Remove all the supports provided for fixing the shuttering one by one.

9.3.3 Don’t apply heavy force for removing the supports. If heavy force is applied for removing the supports it will disturb the castables. 9.3.4 9.4

9.5

Inspection 9.4.1

Check for honeycomb, rat hole, segregation, lamination, etc. Mark the area to be repaired.

9.4.2

If repair area is very less, carry out necessary repair work by removing the loose material and filling it with new fresh material and compact with rodding.

9.4.3

If the repair area is more, dismantle the repair area and recast.

9.4.4

Make the casting installation details.

Natural Curing 9.5.1

9.6

Remove the shuttering slowly.

Allow air drying for minimum 8 hours after casting if ambient temp. is very low.

Inspection Report 9.6.1

Complete the castable installation details Report

9.6.2

Make a joint inspection along with client

10. Acceptance Criteria 10.1

The shell surface and anchor shall be cleaned properly to ensure that these shall be free from any loose material, rust or foreign materials etc.

10.2

The anchor welding shall be tested for spacing and welding. If spacing is found to varying more than 10 % then it shall be re-welded, and the welded anchors shall be checked for strength as per the satisfaction of the client and site in charge as per normal procedure by hammer testing. Approved:

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10.3

Wherever shuttering is required, its strength and workability shall be good enough to bear the load and dimension shall be ensured as per the refractory drawings.

10.4

The exact amount of water to be added will be decided by ACE’s Site Engineer during application as per working consistency. Lower % water with no workability as well as higher % of water leading to slurry formation shall be avoided.

10.5

Normal drinking water at temp. around 20 – 30 deg. C shall be used.

10.6

After the removal of shuttering and 24 hrs of natural curing the surface shall soundness to be decided by hammer test method.

10.7

After initial drying if superficial surface hairline cracks is found then the same shall be acceptable.

Precautions 11.1

Unnecessary extra load shall not be put over the lining before and after setting.

11.2

It shall be ensured that all equipment’s and tools used for mixing are free of foreign material particularly Portland cement and lime.

11.3

The inner surface of wooden form shuttering shall be plain and smooth. Machine oil or grease etc shall be applied on the surface of wooden form to make it waterproof and easy to remove after installation.

Approved: