TOTAL PAGE: 18 PAGES
REFRACTORY LINING PROCEDURE
(for 17223 INCINERATOR)
2009.02.18
1
FEB. 18, 2009
ISSUED FOR APPROVAL
NO
DATE
DESCRIPTION
MYUNG SUK KIM MYUNG SUK KIM
BY
CHECKED
LTD
CERA ENGINEERING CO
CO.,LTD
APPROVED
DOC. NO.
CERA
CERA - 17223 - 01
REFRACTORY LINING PROCEDURE
PAGE
1
OF
CONTENTS
1 GENERAL
2 PROJECT
3 REFERENCE DOCUMETS FOR REFRACTORY INSTALLATION
4 LOCATION
5 MATERIALS
6 INSTALLATION GENERAL
7 REFRACTORY INSTALLATION METHOD
8 INSTALLATION PROCEDURE
9 CURING
10 TESTING
11 INSPECTION
12 REPAIRS
13 DRY-OUT
＊ATTACHMENT
# 1. REFRACTORY INSTALLATION LOG - FORM
# 2. INSPECTION REPORT- FORM
-----------------------------
1
2
SHT
SHTS
14
DOC. NO.
CERA
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REFRACTORY LINING PROCEDURE
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1. GENERAL
1-1 This specification describes their methods of application for brick lining & plastic/castable installation.
1-2 This specification shall be used by the brick / castable lining applicator to
prepare , if required , for approval by the owner or his authorized
representative prior to start of work.
2. PROJECT
PROJECT : 17223 THERMAL OXIDIZER
3 REFERENCE DOCUMENTS FOR REFRACTORY INSTALLATION
REFRACTORY DWG
: CERA-R01-01/02/03
CERA R01 01/02/03
: CERA-R10-01
INSTALLATION PROCEDURE
: CERA-17223-01
4 LOCATION : SAMSHIN SHOP/ PYEONG TAEK , KOREA
5 MATERIALS
5-1
90% ALUMINA BRICK , CEHA-90
5-2
70% ALUMINA BRICK , CEHA-70
5-3
LIGHT WEIGHT BRICK, GT-26
5-4
5
4
LIGHT WEIGHT BRICK, GT
GT-23
23
5-5
HIGH ALUMINA MORTAR, SP-85W
5-6
I.F.B.MORTAR , SP-3000
5-7
PHOS.BOND PLASTIC, HAPT-80S
5-8
5
8
LIGHT WEIGHT CASTABLE, INCT
INCT-120
120
5-9
LIGHT WEIGHT CASTABLE , INCT-140
5-10
ALUMINA SILICA PROTECTION COATING, PLISTIX MIX #464 COATING
5-11
CERAMIC ANCHORS
DOC. NO.
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REFRACTORY LINING PROCEDURE
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6 INSTALLATION GENERAL
6-1 STORAGE AND CARRIAGE OF REFRACTORY MATERIALS
1)) Upon
p receipt
p of the materials,, check the q
quantity
y with p
packing
g list
and inspect the appearance to make sure of no damage to the materials.
2) Record the damage seems to have been caused during transportation.
3) Store the materials in order of work procedure.
4) Store insulation and refractory materials in a manner as not to wet
them since they are damaged easily by rainwater.
6) The storage life of castable is 12 months.
7) Handle the materials with care since they are apt to be damaged with a rough handling.
6-2 APPLICABLE TOOLS
1)
3)
5)
7)
9)
11)
13)
CASTABLE MIXER
WATER PUMP
BUCKET
TROWEL
MEASUREMENT
HAMMER
AIR RAMMER
2)
4)
6)
8)
10)
12)
BEAKER
CYLINDER
SPADE
CONVEYOR
LEVEL MACHINE
CUTTER
7 REFRACTORY INSTALLATION METHOD
INCINERATOR
ROOF
UPPER WALL
LOWER WALL
FLOOR
FLUE GAS DUCT
HAPT-80S
8"
INCT-140
CEHA-70
GT-23
CEHA-90
GT-26
CEHA-90
2 1/8"
4 1/2"
2 1/2"
4 1/2"
4 1/2"
4 1/2"
INCT-140
HAPT-80S
4 1/2"
INCT-120
3"
ALL
14
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8 INSTALLATION PROCEDURE
8-1 INCINERATOR ROOF, DUCT TO CHENCH, FLUE GAS DUCT
A PREPARATION
1) Field measure the steel dimensions to verify that they match the construction drawings.
2) All equipment for mixing and handling must be thoroughly cleaned before use.
3) No mixtures of any kind should be added to the premixed refractory.
4) During hot weather, the refractory lining and the surface to which it is applied shall not exceed a
temperature of 95℉(35℃) during application. If required, the exterior surface of the incinerator shall be
cooled by shading spraying with cold water, air conditioning, or other means before and while the
refractory lining is being applied. Installation at night, when it's cooler and there is no radiant heat
from the sun, may be considered. After refractory application, cooling of shell in no longer required.
B MIXING AND LINING THE CASTABLE
1) All water used for mixing refractory must be clean, potable, have between
PH 6.5~8.35 and may vary between 10℃ ~ 21℃.
2) Different materials should not be mixed with each other.
3) The full contents of each bag of refractory material shall be used.
4) Do not mix more materials that is immediately required or can be installed.
5) C
Castable
t bl can b
be iinstalled
t ll d within
ithi 20 minutes
i t from
f
the
th adding
ddi off water.
t
In
I no circumstances
i
t
castables
t bl
shall be remixed after they have started to set.
6) Check the anchroage system, clean the surface of the area to be refractoried by a steel brush
Apply the coat of plistix mix #464.
7)) Refractoryy materials should be thoroughly
g y dry
y mixed before being
g combined with clean p
potable water.
8) Mixing and the addition of water shall be in accordance with instructions found on the bags of
the refractory using a paddle type mixer of adequate capacity.
9) Do not mix more materials that is immediately required or can be installed.
10) Mixing time for a batch is 5 minutes.
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REFRACTORY LINING PROCEDURE
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11) The amount of water to be added to the refractory mateiral shall be sufficient to produce proper hydration.
Under no circumstances should more water be and the mix retempered as per material manufacturer's
recommendation.
① INCT - 120 : 30~40% by weight
② INCT-140 : 25~30% by weight
12) Use castable as soon as possible after mixing. Do not use material that has started to stiffen.
C PLASTIC LINING
1) Job sequence
①
Weld the hanger anchor bracket
③
Line the insulation castable
②
Hang the ceramic anchor
④
Ram the plastic refractory
2) Placeing plastics
Plastic is usually supplied already cut in approx. 50/65mm thick slices.
If not supplied in this form slices 50/65mm thick should be cut. A spade which may be used for this and for
trimming finished wall surfaces is illustrated.
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3) Air pressure
An air pressure of 5~6 bars should be maintained at the manifold with 0.55m3/min supply.
Air pressure
4) Wall
The positioning of anchors is critical. Before starting any work in the furnace, the position of every anchor should
p
g
be set out on the enclosure and clearlyy marked. Fix the specified
insulation material to a convenient height
having marked out and drilled or welded attachment points for anchors in the proper places.
Lay slabs of plastic on the wall with the long direction parallel with the face of the wall. Similar to a stretcher
course in brick work. Stagger succeding courses as in brickwork.
Every 4 to 5 courses lay the plastic slabs as headers. Lay the slices tight together with one face in line with the
wall hot face, fit the small pieces and trimmings in gap behind the full slices.
5) Ramming
Thoroguhly ramm each 50/75mm course before laying succeeding courses. Hold the rammer in a vertical position.
Start ramming midway between the hot face and cold face of the wall. Move the rammer in the direction of the wall
length at a rate that ensures that each succeeding impact of the head covers approximately half the area of the
previous impact. Move the rammer back and forth from the centre of the wall to the cold face metal cases or
insulation. When all voids in this portion of the wall are closed up, start again and work from the centre line of the
wall to the hot face in the same manner.
As the rammer nears the hot face of the wall, rotate the wrist so that the rammer turns through 90ㅇ down to a
horizontal position and peen over the edge of the wall. Then return the rammer to the vertical position and run it
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10 to 15mm beyond the line of the hot face. This allows for trimming or shaving the wall. Should the wall become
excessively bulged beyond the line of the hot face (due to careless ramming) the material must be shaved off rather
than forced back with the air rammer. The wall should be built up evenly from end to end.
Each installer should work a 1 to 3m length of wall depending on thickness and anchor pitching.
Continue in this manner to the top of the wall if possible. When no longer possible to do so (due to the proximity of
the roof) start at each end, placing the slices on edge against the end walls so that they reach from the last course
to the top level of the wall (approx. 12in or 300mm). Ram sideways or against the ends of the wall. Work to the
centre of the wall
wall. Close in by laying the slab vee fashion,
fashion finally ramming the last square foot (300 x 300mm)
on the hot face.
6) Trimming
Prior
ram lilightly
off the
P i to trimming
i
i the
h surface,
f
h l around
d each
h anchor
h fface to completely
l l fill the
h corrugations
i
h anchor.
h
Place the back of the trimming spade against the plastic at an angle which will prevent the point digging in beyond
the hot face line. Shave off the surplus material using the anchor faces as guides.
Do not attempt to pry the material away from the wall.
Avoid any smoothing or trowelling of the surface.
7) Venting
Vent the surface immediately after trimming. Stream evolved during heat up can force slabs of material off the hot
face of the lining unless vent holes provide a means of escape. Use a 5mm diameter rod. Make rod into the full
depth of the plastic up to 230mm. For thicker wall make vent holes to minimum 230mm depth : alternatively to half
the wall thickness. Where plastic is rammed directly onto a steel casing, make vent holes the full depth of
the plastic.
8) Joints
Joints- surface expansion cuts
Where these are required by the designer, they should be formed and located as shown on drawings.
They should never coincide with the anchor positions.
Surface expansion cuts should be made using a bolster to the depth required. Thus work must always be
l
db f
l
f
kf
h d
Ah d
f
h fi i h d
f
i h
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8-2 INCINERATOR WALL, FLOOR
A PREPARATION
1) Ascertain that all fittings are installed in place.
2) Inspect inside and outside of shell and make sure is no damage or stain on the surface.
3) If the steel shell is damaged, report it to owner so as to have field construction repair it.
4) Brick lining shall be carried out according to the shop drawing.
B BRICK LAYING
1) Apply the plistix mix #464 by means of trowel up to the 3mm thickness.
Also the hardening of this mortar shall be completed within 24 hours.
2) Apply GT-26 brick in the bottom part of the Incinerator , after having wet the same with plistix #464 coating.
3) Brick and shapes will be installed with jointing cement, maximum thickness of joint between bricks : 2mm.
4) Refer to the refractory lining drawing which show quantity and the sizes of bricks to be used in each area.
5) No bricks overlap shall be done across the brick rows.
6) The layer of insulating brick shall be applied starting from the bottom part for 210o extension.
7) The upper part of the lining for 150o extension shall be made by using a formwork to support the bricks.
The top part, bricks shall be installed with a free space from the surfaces as radial joint.
8) The gap shall be filled by ceramic blanket, gradually inserted during the bricks installation.
9) Adjusting bricks, no more than two for each ring and no thinner than 40mm , shall be installed at 30o at least
from the top, and positined alternately at right in first ring, and at left in the next one.
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10) Near the nozzles, the bricks shall be cut to suit the shapes shown in the drawing.
At the elliptical head the insulating bricks shall be installaed in circular rings, starting from the bottom part of
the periperical ring. After the completion of the first ring, the installation proceeds with the internal rings.
11) If cutting is necessary in order to position the keystone, cutting must not, in any case, exceed one third
of the relevant part, otherwise cutting must be performed on the last two parts positioned in the roll.
12) High alumina bricks shall be wet cut when required.
13) Insulation bricks shall be dry cut when required, using an abrasive saw.
14) The closing of the brick rows shall not be done at the top of the furnace but at 30o at least from the top.
15) All joints shall be completely mortar-filled
mortar filled and not exceeding 1.5mm.
16) Any mortar excess shall be scraped by means of a trowel after a short drying period.
17) Each brick shall be positioned by hammering, in order to remove any excess quantity of bonding mortar
18) Special care shall be given in the positioning of any performed block. A trial fit up of each block
near the nozzles shall be made in order to minimise the cut of the adjacent bricks.
C EXPANSION JOINTS
1) Expansion joints have to be done according to the indications shown on the refractory lining drawing.
2) Expansion joints will be lined with ceramicfiber blanket without mortar addtion.
8-3 INTERRUPTION OF CASTABLES APPLICATION
1) When application is interrupted before completion of the lining,
the refractory lining shall be cutback immediately to the shell with a steel trowel.
This cutback should be made at locations where the full final thickness has already been appled.
All material beyond the cut and material left in the gun hose and mixer over 30 minutes shall be discarded.
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9 CURING
During the curing period , the castable lining shall be treated as follows;
1) The curing shall begin immediately upon lining application for min 24hrs
until hard set has developed
developed.
2) During the curing period,
the temperature
of
the
exchanger and
castable lining shall be kept above 50℉(10℃) but must not exceed 90℉(32℃).
3) Water spray shall be done as protection of
moisture loss during
g the curing
gp
period
the
castable
lining
from
4) one pound hammer at about one foot intervals over the entire surface.
Any voids of dry filled spaces will emit a dull sound.
5) After the curing period has been completed, the castable lining shall be air dried for at least another 24 hours
by natural or forced ventilation.
10 TESTING
The Owner or his
authorized
representative inspect the V-anchors
and castable lining during all phases of preparation, application,
removall and
d clean-up.
l
Th
The ffollowing
ll i
operation
ti
will
ill b
be witnessed:
it
d
1) Mixing of castable lining materials and water to ensure that correct materials and procedures
are used, that containers are clean and water is drinkable.
2) Application of castable lining materials to ensure that full lining thickness is attained
with proper application.
3) Curing of the castable lining to ensure the proper curing technique.
After curing, the lining shall be inspected for voids and cracks.
4) Removal and replacement of unacceptalbe castable lining to ensure that
the work is compatible to the original application.
5) The hammer test shall consist of striking the entire refractory surface with a hammer
at about 12 inchs ( 305 mm ) intervals.
When areas with voids, laminations or areas filled with dry material
are struck with the hammer, a dull sound will be produced.
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11
11 INSPECTION
11-1 BEFORE APPLICATION
1) MATERIALS
a. Upon receipt of the materials, check them in the manner descriped.
b. Check the material with accompanied certificate.
c. Materials having shelf life shall be checked it before application.
2) SHELL
a.
inspection.
a Make sure of no damage or stain on the lining by visual inspection
11-2 DURING APPLICATION
The following works will be carried out paying attention to the respective points listed below.
A . BRICKLAYING
a. No damage to corner or edge part of a brick.
In case any damage is found, take total measurment of A+B+C or D+E shown in fig.22
and discard the brick which has a damage of 50mm or over in the measurements
such brick, however, may be used for cutting or installed where out of sight.
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① Dimension and surface
TOLERANCE (mm)
DIMENSION
Upper limit
Lower limit
Length
+3.5
-3.5
Width
+2.0
-2.0
Thickness
+2.0
-2.0
② Surface
S f
breakage
b k
CORNER
a+b+c < 30mm
Note : when a,b, or c< 10mm
d
a
e
f
We don't regard it as a defect.
EDGE
b
c
d+e+f < 30mm
Note : when d,e,or f < 10mm
We don't regard it as a defect.
Fig.22
③ CRACK
Injurious crack, the length of which is more than 60mm.
(
(two
p
places < 50mm)) shall not be acceptable.
p
Hair crack shall be acceptable.
b. Bricklaying is to be performed in accordance with dwg.
c. Bricks are to be in accordance with the type an shape stipulated in dwg.
d Bricks
d.
B i k are to
t be
b laid
l id h
horizontally
i
t ll and
d vertically.
ti ll
e. Width of each joint is to be within 1.5mm.
f. Width and position of each expansion joints are to be in accordance with dwg.
All expansion joints are to be filled with ceramic fiber blanket.
12
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13
g. Expansion joints for accessories such as nozzle are to be provided in accordance with dwg.
h. No damage to be surface of laid brick.
i. Mortar is to be applied properly. Extruded mortar is to be removed
8-3 AFTER APPLICATION
1) BRICK LAYING
A . There is no damage bigger than X:20mm , A:100mm or B:100mm
B . Width of each joint between laid bricks is to be within 1.5mm
C . All expansion joints are to have been filled with ceramic fiber blanket.
12 REPAIRS
12-1 CASTABLE
1) Repair portion shall be cut out to steel plate of first layer, and made
the following shapes.
More than three(3) anchors are required at one repair portion.
2) Make the space around repair portion to become wet sufficiently prior to
castable insalltation.
3) Materials to be used for repair shall be same one installed previously.
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12-2 BRICK
1) Replace the damage brick with new brick of the same material.
2) Fill insufficient mortar joints with new mortar of the same material as original.
Where joint mortar is separated from a brick, remove applicable bricks and lay them again
with new mortar after removing old mortar.
13 DRY-OUT
1) Raise temperature to 110℃ at a rate of 30℃ per hour.
2) Hold at 110℃ for 8 hours.
3) Raise
to
R i
ttemperature
t
t 260℃ att a rate
t off 30℃ per hour.
h
4) Hold at 260℃ for 4 hours.
5) Lower to ambient temp slowly.
6) Thermocouple q'ty
q ty & Location (See the dryout sequence)
- one(1) thermocouple at refractory surface per each item.
7) Check outlet temperature per the 30 minutes interval during the holding time.
8) Visual inspection and hammering test shall be done after dry-out.
TEMP(℃)
4 Hrs Holding
260℃
Curing
30℃/Hr
8Hrs Holding
g
110℃
l
lower
temp. slowly
l l
30℃/Hr
3
11
16
20
Time(Hour)
CASTABLE INSPECTION REPORT
PROJECT NAME : INCINERATOR
P.O. NO. :
INSTALLATION COMPANY : CEAR ENGINEERING CO., LTD
INSTALLATION METHOD :
ITEM NAME :
ITEM NO. :
INSPECTION DATE :
NO.
INSPECTION POINT
1
Used Materials
2
g Thickness
c ess
Lining
3
Visual Examination After Installation
4
Check Of Dimension
5
Hammer Test Before Heat Dryout
6
Visual Examination After Heat Dryout
7
Hammer Test After Heat Dryout
8
Internal Clearing
RESULT
REMARKS
WITNESSED /
PREPARED BY
REVIEWED BY
APPROVED BY
REVIEWED BY
CERA ENGINEERING CO., LTD
BRICK INSPECTION REPORT
PROJECT NAME : INCINERATOR
P.O. NO. :
INSTALLATION COMPANY :
INSTALLATION METHOD :
ITEM NAME :
ITEM NO. :
N
N DATE :
INSPECTION
NO.
INSPECTION POINT
1
Used Materials
2
Surface Condition Before Installation
3
Lining Thickness
4
Mortar Condition
5
Visual Examination After Installation
6
Vi l Examination
Visual
E
i i
After
Af
H
Heat D
Dryout
RESULT
REMARKS
WITNESSED /
PREPARED BY
REVIEWED BY
APPROVED BY
REVIEWED BY
CERA ENGINEERING CO., LTD
REFRACTORY INSTALLATION LOG
PROJECT NAME : INCINERATOR
P.O. NO. :
ITEM NAME :
ITEM NO. :
MATERIALS USED :
Mix
NO
MFG.
Weight
Code
Of
(Pallet No.) Materials
( KG )
INSTALLER COMPANY : CEAR ENGINEERING CO., LTD
INSTALLATION METHOD :
LOCATION :
PAGE NO
DATE :
Amount
Water
Ambient
Temp.
Mix
Water
Temp.
Material
Temp.
Mixing
Time
( KG )
(℃)
(℃)
(℃)
( Minute )
Remarks
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
PREPARED BY
REVIEWED BY
CERA ENGINEERING CO., LTD
APPROVED BY
WITNESSED
/REVIEWED BY