English UK - Morgan Thermal Ceramics
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1. 1 Typical Welding Conditions for Stud Welding of Steel Thermal Ceramics i ThermalCeramics2s be sic a nstatation manuar PYRO FOLD M MODULE The most common method for testing the welds is the bend test This is carried out by striking the stud with a hammer or by using a bending tool such as a pipe Figure 14 In the case of a good weld the stud will break before the weld In either case the testing will damage the stud so shoot the test studs on a separate plate or be pre pared to grind smooth the area and reshoot li et RELER p L ee hae a r r x Z a al a Figure 14 Bend Test As with any welding process the operator should under stand the process properly maintain the equipment and ORE SEP EEE EEE Et follow proper safety precautions P Good stud weld with a good flash formation Stud wel in which plunge is too short Hang up Poor alignment Figure 13 Weld Inspection Good and Bad Welds December 2002 Thermal Ceramics Page 7 W Thermal Ceramics 2 INSTALLATION The Pyro Fold M Modules are typically installed soldier course with a folded batten strip between rows The Pyro Fold M Module requires a pre layed out stud pattern so the first step is to establish the layout Step 1 Measure the correct distance vertically and horizontally and mark with a chalk line Typically for walls the stud spacing is horizontally 12 805mm and 13 s 343mm vertically Ste2. Module lining is best installed using a soldier course pattern utilizing a folded batten strip Figure 4 shows how a typical Pyro Fold M Module lining would be installed on the walls and roof of a furnace In high temperature applications it is best to limit the length of the folded batten strips to 12 feet in order to minimize the effect of shrinkage The ends of the batten strips should be tightly compressed into the adjoining batten strip or preferably shiplapped as in Figure 5 In overhead applications the folded batten strip must also be pinned to the modules using the Thermal Ceramics T C 403 packing pin It is impor tant to insert this packing pin on an angle as shown in Figure 6 in order to ensure the legs of the packing pin do not fall in the fold of a module Prior to installing the Pyro Fold M Modules it is nec essary to lay out the necessary stud pattern and weld the studs in place At this point a stalastic coating can be applied to the steel casing followed by a layer of blanket for back up as well as a layer of stainless steel foil for a vapor barrier if required The specific operating condi tions for your particular furnace will determine the need for stalastic coatings back up blanket and vapor barriers Figure 5 Typical Installation Using Soldier Course Pattern with Batten Strip Fa iF rr fi r pin Figure 4 Typical Pyro Fold M Module Lining Once the studs and back up materials are in plac
3. i Thermal Ceramics PYRO FOLD M MODULE DESIGN AND INSTALLATION MANUAL i Thermal Ceramics TABLE OF CONTENTS A Preface Introduction 3 B Pyro Fold M Module 1 General 1 1 Lining Considerations 4 1 2 Site Preparation 6 1 3 Stud Welding Equipment 6 2 Installation 9 C Glossary of terms 12 List of Figures Figure 1 Pyro Fold M Module with Stud Gun and Control Box 2 Figure 2 Pyro Fold M Module Cutaway Displaying Internal Anchoring as well as Stud and Nut 3 Figure 3 Pyro Fold M Module with Anchor Hardware and Installation Equipment 4 Figure 4 Typical Pyro Fold M Module Lining 4 Figure 5 Typical Installation using Soldier Course Pattern with Batten Strip 5 Figure 6 Inserting Packing Pin into Batten Strip Overhead 5 Figure 7 Folded Module Cutting Detail 6 Figure 8 Pyro Fold M T Bar Module Corner Block 7 Figure 9 Equipment Set Up with Separate Power Source and Control Box 8 Figure 10 Equipment Set up with Power Source and Control Box Combined 8 Figure 11 The Welding Process Figure 12 Portable Stud Gun Figure 13 Weld Inspection Figure 14 Bend Test List of Tables Table 1 Typical Welding Conditions for Stud Welding of Steel Figure 1 Pyro Fold Y Module Stud Gun and Control Box Page 2 Thermal Ceramics W Thermal Ceramics s INTRODUCTION Over the past 80 years Thermal Ceramics has proven itself to be a world leader in solving problems for heat intensive industries The refractory ceramic fiber manufactured by Therma
4. stud off the plate and creates an arc The end of the stud and the plate are melted by the arc Upon completion of the preset arc period the welding current is automatically shut off The mainspring within the gun then plunges the stud into the molten pool on the plate to complete the weld The gun should then be lifted off the stud and the ferrule broken off Installation rates for welding studs in this manner will vary with the size of the stud and other working conditions However an average rate is approximately six studs per minute A Gun is properly positioned B Trigger is depressed and stud is lifted creating an arc C Arcing period is completed and stud is plunged into the molten pool of metal on the base metal D Gun is withdrawn from the welded stud and ferrule is removed Figure 11 The Welding Process Figure 12 Portable Stud Gun To set up the gun for shooting studs set the plunge length to approximately s inch 3 2mm Figure 12 The approximate settings for weld time and weld current is provided in Table 1 STUD Weld Base Diameter in mm Weld Time Cycles Weld Current Amperes 60 cycles 1 second The above settings may vary due to the power source con dition of the work piece age of equipment length of cable used between power source and the control unit and the alloy to be used After determination of proper settings the unit is ready to weld studs Table
5. at Thermal Ceramics in Augusta Georgia Any questions or comments regarding this manual should be addressed to your local Thermal Ceramics representative December 2002 Thermal Ceramics DESIGN amp INSTALLATION MANUAL PYRO FOLD M MODULE PYRO FOLD M MODULE The Pyro Fold M Module is a folded module system designed for industrial applications that require corrosion barriers a back up blanket layer or a pre layed out stud system The Pyro Fold M Module is composed of ceram ic fiber blanket accordion folded to form the module The folded blanket is precompressed in one direction and banded The anchor hardware consists of an internal M yoke in the center of the module and two support tubes The Pyro Fold M Modules are available in 8 pcf and 9 3 pcf densities 128 and 149 kg m and in thickness es from 4 to 12 inches 102 to 305 mm These modules can also be made using any of our standard blanket chemistries to suit the particular furnace application i e Kaowool S Cerablanket Cerachem and Cerachrome The internal anchor hardware is made of 3048S The necessary studs nuts and installation tools are purchased separately The installation equipment and tools described in this manual have been developed to ensure a quick reliable installation Figure 3 Pyro Fold M Module with Anchor Hardware and Installation Equipment Page 3 W Thermal Ceramics 1 GENERAL 1 1 Lining Considerations A Pyro Fold M
6. e the Pyro Fold M Modules can be installed The yoke in the Pyro Fold M Module has an offset to allow for the stud to be in the center of the module Figure 6 Inserting Packing Pin into Batten Strip Overhead Page 4 Thermal Ceramics i Thermal Ceramics 2s The Pyro Fold M Module can be cut or trimmed to allow for obstructions such as burners or peepsites Best results will be achieved if the module is trimmed equally from opposite sides of the module so that the stud will remain centered as closely as possible This point is out lined in the cutting detail in Figure 7 It is best to cut less than what is necessary and compress the module into place to ensure the tightest possible joint CINT WERE EIN ed AL LEBETE bunar ba H Figure 7 Typical Pyro Fold M Cutting Detail Bullnose areas present a challenge for folded module systems These areas are best accommodated by utiliz ing a Pyro Fold M T Bar corner block as shown in Figure 8 or astacked module of similar configuration These cor ner block modules can be specially designed to match the specific requirements of the furnace A Figure 8 Typical Pyro Fold M T Bar Corner Block December 2002 Thermal Ceramics DESIGN amp INSTALLATION MANUAL PYRO FOLD M MODULE 1 2 Site Preparation The steel surface to be lined should be free of heavy rust or scale non conductive paints dried refractory cements or oil Sandblasting wire brushing or grindi
7. e than 90 alumina giving a high use limit Mullite fiber is also used in high temperature applications High Purity HP Fiber A ceramic fiber produced from synthetic alumina and silica Hot Face Insulating Material The layer of lining insulating mater ial that has at least one surface exposed to the full temperature of the furnace gases Kaolin Fiber A ceramic fiber produced from calcined kaolin Laminar Flow The flow of a gas in which the gas stream moves in straight lines parallel to the direction of the flow Layered Lining Wallpaper Lining that is composed of several layers and thicknesses of refractory ceramic fiber Linear Shrinkage The amount of shrinkage which occurs along the length of a material after it has been subjected to elevat ed temperatures and then cooled measured in percent of original prefired length December 2002 Thermal Ceramics GLOSSARY OF TERMS Lock Washers Washers used in conjunction with Kao Lok studs They are slotted so that when pushed over the stud and then twist ed 90 the washer is locked into place other locking systems are available such as cone anchors Lock anchors come in ceramics or alloy metals to suit temperature requirements Maximum Temperature Rating The temperature which is used by the industry as a loose classification of different grades of ceramic fiber This is generally higher than the continuous use limit Module A prefabricated unit which can be applied a
8. esistivity The property of a material to resist the flow of heat the reciprocal of thermal conductivity Thermal Shock A failure mechanism wherein sudden changes in temperature bring sufficient thermal mechanical stress in a materi al to cause cracking or spalling As a general rule the thermal shock resistance of a material is greater as the strength and ther mal conductivity of a material increase and as the thermal expan sion and modulus of elasticity decrease Turbulent Flow Fluid flow in which the velocity of a given stream of gas changes constantly both in magnitude and direction Vacuum Forming A method of producing molded shapes and flat board by converting fibers into a slurry and vacuuming them onto a screen former Veneer Layer of ceramic fiber in either blanket or module form which is attached to the hot face of a brick module or monolithic lining Wallpaper Construction The term used to describe a ceramic fiber lining construction technique where the blanket is installed on a wall like a roll of wallpaper Page 11 For further information contact your nearest Thermal Ceramics technical sales office e mail tceramics thermalceramics com or visit us on the web at www thermalceramics com Global Headquarters Thermal Ceramics Global L Europeen Bat C 2 rue Joseph Monier 92859 Rueil Malmaison Cedex France T 33 0 1 47 16 22 23 F 33 0 1 47 16 22 40 E mail info tc global com Global Marketing Offices T
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10. l Ceramics is a highly versatile material It can be spun or blown into bulk air laid into a blanket folded into mod ules formed into monolithic modules Pyro Bloc con verted into boards and shapes die cut into gaskets twist ed into yarns woven into rope and cloth and blended into liquid binders for coatings and cements With this wide range of products Thermal Ceramics can provide exactly the right product or engineered system to fit your requirements Thermal Ceramics has an experienced staff of refractory specialists to assist you in product selection system design and installation techniques Thermal Ceramics has enjoyed great success with its ceramic fiber products due to their cost effectiveness and excellent insulating properties They are lightweight and have low thermal conductivities excellent resistance to thermal shock outstanding electrical resistivity and good acoustical properties This Design and Installation Manual is intended to give the designers installers and users of Thermal Ceramics ceramic fiber products a broad range of information on how to select the most appropriate fiber system for a par ticular application necessary design criteria and how to correctly install the selected system PLEASE NOTE This manual has been designed to eas ily accommodate new or revised information Holders of the manual are advised to keep their address current with the Advertising and Sales Promotion Department
11. ng will be required to clean the surface or at least the area where the stud is to be attached Set up good scaffolding so there will be easy access to the areas to be lined Also make arrangements for the material to be as close to the work area as possible with out being in the way so it can be efficiently delivered to the work crews The steel shell should preferably be 10 gage or thicker This will minimize difficulty with blowing holes in the steel while trying to weld the studs in place 1 3 Stud Welding The process of arc stud welding involves the same prin ciples as any other arc welding process 1 Creation of welding heat by developing an arc between the stud and the plate 2 Bringing the two pieces together when the proper temperature is reached The equipment needed includes a stud gun a control unit and an adequate DC welding current supply The stud is loaded into the properly sized chuck the ceramic ferrule is placed in position over the end of the stud and the gun is properly positioned for welding The gun control unit and welding machine are connected as shown in Figure 9 or 10 for welding Figure 9 Equipment Setup with Separate Power Source and Control Box Page 5 Page 6 i Thermal Ceramics Figure 10 Equipment Set up With Power Source and Control Box Combined The welding process is shown in Figure 11 A solenoid coil within the gun is energized when the trigger is pulled This lifts the
12. p 2 At the points where the chalk lines cross weld an M Module two step stud onto the steel casing Step 3 Install the plastic covers over the studs and coat the steel casing with stalastic If a coating is not being used plastic covers for the studs are not needed At this point back up layers of blanket and stainless steel foil vapor barriers should be installed if being incorporated into the lining of the furnace Step 4 To install the Pyro Fold M Module insert the guide rod through the hole in the yoke tab lift the module and guide rod into position and thread the guide rod onto the small tip on the M Module stud The module can now be pushed into place with the module yoke tab sliding onto the stud and against the steel casing A slide plate can be used against adjoining modules to ease the installation Thermal Ceramics Page 8 9 ThermalCeramics S pesien a insTALLATION MANUAL PYRO FOLD M MODULE Step 5 Step 8 Insert a hexnut into the end of the nut driver and slide Lay folded batten strip in place on top of installed row of onto the guide rod Thread the nut by hand onto the stud modules before installing the next row of modules Remove the guide rod Step 6 Using a ratchet or drill tighten the nut onto the stud Step 9 When all the Pyro Fold M Modules have been installed the banding strips should be cut and removed Step 7 Push the fiber together to eliminate the hole in the cen
13. s a lining block to the inner face of a furnace structure Mortar Cement A ceramic based adhesive for attaching ceramic fiber products to other surfaces Mullite A crystalline phase of alumina silica Overlap Construction A construction technique used to accom modate shrinkage in ceramic fiber or to improve velocity resistance in which one edge of a blanket is lapped over an adjacent blanket edge by 4 to 12 and shares a common anchor stud and washer Paper A roll product produced from ceramic fibers and organic binders on conventional paper making machinery Parquet A method of installing modular edge grained forms of ceramic fiber so that the edge grain of one module is perpendicular to the edge grain of the adjacent modules Rigidizing The practice of applying an inorganic hardening agent to the surface of ceramic fiber by spray or brush in order to improve its velocity resistance RCF Refractory Ceramic Fiber Shingled Joint A method of applying double layers of ceramic fiber blanket in such a way that half the width of each layer overlaps half the width of the adjacent layer Shot A glassy material formed during fiberization Textile Cloth tape sleeving tubing or other forms manufactured from ceramic fiber yarn Thermal Conductivity The property of material to conduct heat measured in Btu flow per hour through a square foot of area across one inch of thickness Btuein hrefte F w m C 9 Thermal R
14. s in the as produced state Butt Joint A ceramic fiber wallpaper construction joint where edges of adjacent blankets meet Cold Face Temperature Term used to denote the outside casing temperature Continuous Use Limit Long term continuous temperature limit for a product installed as a lining This temperature is based upon product shrinkage specifically what is considered to be a man ageable or controllable shrinkage This term is not to be confused with temperature rating Cristobalite A crystalline phase of silica which will begin to form above 1800 F Devitrification The phase transformation from glass to crystalline structure Edge grain The orientation of a fiber system in which strips of ceramic fiber blanket or felt are oriented perpendicular to the plane of the furnace casing Felt Pressed A flexible sheet product formed from ceramic fibers and bonded with an organic binder Heat Loss The term used to denote the amount of heat being lost through a lining construction over time measured in BT U sq ft min watts sq in Heat Storage The thermal property of a material wherein heat accumulates in the mass which in refractories is a function primar ily of the material s specific heat mass and temperature rise mea sured in Btu Ib F Cal g C Heat Transfer The study of heat flow mechanisms conduction convection and radiation High Alumina Fiber A ceramic fiber containing mor
15. ter of the module December 2002 Thermal Ceramics Page 9 W Thermal Ceramics Step 10 The final step should be to tamp out the lining to further tighten all joints and close any gaps that may exist Notice Some of the products described in this literature contain Refractory Ceramic Fiber RCF and or crystalline silica cristobalite or quartz Based on experimental animal data the International Agency for Research on Cancer IARC has classified RCF along with fibrous glasswool and mineral wool as a possible human carcinogen Group2B and respirable crystalline silica as a probable human carcinogen Group 2A To reduce the potential risk of health effects Thermal Ceramics recommends engineering controls and safe work practices be followed by product users Contact the Thermal Ceramics Product Stewardship Group i 800 722 5681 to request detailed information contained in its MSDSs and product literature and videos Page 10 Thermal Ceramics CERAMIC FIBER SYSTEMS DESIGN amp INSTALLATION MANUAL Amorphous Having no definite crystalline structure or form Back up Insulating Material The layer or layers of insulating material that are located between the hot face insulating layer and the outer casing Blanket A flexible unbonded ceramic fibrous insulating material of reasonably determinate dimensions Board A substantially rigid or semi rigid flat sheet produced by vacuum forming Bulk Fiber Ceramic fiber
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