Burner Pipe Sop

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Installation Guidelines : Supramon HS/ SUPRAMON HS SS 37/ SUPRAMON NS BW FOR

BURNER PIPE application only.

General Remarks: This installation instruction is dedicated to Supramon HS/ Supramon HS SS 37/
Supramon NS BW. These products consist of a dry powder mix and a liquid bonding agent
(Supramon HS/ Supramon HS SS 37) or water ( Supramon NS BW) that has to be mixed together
at site before use.

Storage : Though material supplied in water resistance packing, store the product in a cool & dry
place under the shed. Liquid binder has to be stored at temperature 50C -400C.

Preparation of Adjacent Surfaces & cleaning of mixer : Any equipment or tools coming into contact
with castable must be clean, loose material should be removed from the adjacent surfaces. The
mixer cleaning is the main requirement for any no cement castable by preferably using of water jet
to free it from any source of contamination. The bucket/mug with scale marks is to be provided in
order to measure liquid / water precisely.

Fixing setting time and shuttering removal time:


Make a test panel size of 250 x 250 x 250 mm. Prepare a batch and mix with liquid ( SUPRAMON
HS/ HS SS 37)/water( potable water ,pH around 7,SUPRAMON NS BW) then observe the setting
time of the material. Fix the setting time of the material and shuttering removal time. If material is not
getting set((set time>3 hrs), then as per instruction of QC department add additives ( refer table 1),
which will be provided by Calderys in small packets as per mixing quantity of material. Check for
setting of material. If setting is as per normal condition, then proceed casting otherwise further adjust
the additives to fix the setting as per site condition. Extra additives should not be used at site.

Table 1

Srl No Product Additives Name


1 Supramon NS BW Additive C
2 Supramon HS Additives HS
3 Supramon HS SS 37 Additives HS SS 37

Liquid Binder Addition/Mixing: Quantity of liquid binder ( SUPRAMON HS / HS SS 37)/ water(


SUPRAMON NS BW) that has to be used should be as per the test certificate of the product/in
consultation with plant QC person. The addition of the liquid/water takes place after dry mixing for 1
minute.Liquid should preferably be added in one go. Afterwards the mixing process has to be continued
(40 rpm) for 5 minutes. Like LC castable set time of this product (group of products) is sensitive to
temperatures. Supplied material will be used with minimum setting additive% (if required)which would
provide desirable set time in summer (250C - 500C). Additives will be supplied in smaller packs
proportional to 25 Kg packed material & has no significant effect on physical & chemical properties of the
product.

Tools and Tackles

1. Pan Mixer Machine should be located as close as possible to the installation site. Check the
mixer condition (RPM of min 40, gap between scraper and bottom plate should not be more
than 8 mm)

2. Check the working of Needle Vibrator and ensure the availability of adequate needle size
with spare. ( 25 mm dia electrical needle vibrator with 12000 VPM)

3. Welding machine, electrode etc - Welding electrodes should be proper grade ( MS to SS-
WS E309-16 & SS to SS- AWS E 310-16) as per requirement. Use only L&T make Strain
Rod D electrodes.

Panel Size / Casting position :

1. Casting should be done in the vertical position with two segments. Length of each segment
should not be more than 600 mm.

2. Plan staggered panels as far as possible to ensure staggered joints.

3. Shuttering materials can be either wooden or metal. But ensure shuttering has to be strong
enough to bear the load of material, vibration etc., if required give further support.

Anchor Welding :

1. Clean the surface of the shell thoroughly with a wire brush.

2. Put a punch mark in the anchor welding location as per drawing.

3. Grind the surface all around the punch mark. This will ensure the better welding of anchors
with shells.

4. After welding the anchors, check by hammer testing. (ensure good quality welding by
experienced welders only).

5. Anchos pitching should be as per approved/ reviewed drawing.

ILLUSTRATIVE REFRACTORY DESIGN FOR BURNER PIPE


Curing: Contrary to hydraulic bonded materials these chemically bonded products must not be
cured with water. However minimum 24 hrs air curing is recommended.

Drying and Heating Up:Each monolithic refractory lining has to be dried. Too rapid heating up can
cause bond disruption, spalling and cracking. For precise control use thermocouples placed on
the hot face. A standard curve applying to all situations does not exist, each lining being a
particular case.

However for a standard installation up to 100 mm thickness, following dryout schedule should be
followed :

Ambient to 150 0C @10 to 15 0C /hr.


Hold at 150 0C 1 hr per 10mm thickness
150-350 0C @15 0C /hr
Hold at 350 0C 1 hr per 10mm thickness

Please contact Calderys for specific drying instructions linked to your installation.

Safety : Protection measures indicated in our MSDS of all components should be observed.

Disclaimer:
These guidelines are intended for information purposes only.
Any technical advice, recommendations or information contained herein are given by Calderys in
good faith, based on Calderys’ current knowledge and experience of the products and are
deemed to accurate. However, Calderys undertakes no liability or responsibilities of any kind of
whether express or implied in respect thereof. Users are advised that these guidelines are
necessary conditions but may not be sufficient. Specific conditions such as the nature of the
surfaces, the thickness of the linings or their intended use should be taken into account when
installing the products.

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