PYRO-BLOC® M™ MODULE DESIGN AND INSTALLATION MANUAL
Contents
1. OF CORNER BLOC ROW CUT OFF OUTSIDE LEG TO AVOID INTERFERENCE WTH FURNACE STEEL Figure 9 Pyro Bloc T Bar Module Corner Bloc Page 6 ait Thermal Ceramics WEN GORGE gi WER SOURCE WELDING GUN UNIT CABLE 5 ABLE x be NEGATIVE amp 1 by N WORKPIECE POSITIVE Figure 10 Equipment Setup with Separate Power Source and Control Box 5 DISCONNECT SWITCH WELDING GUN NEGATIVE D tg WORKPIECE CABLE AND CLAMP 7 d POSITIVE amp WELDING CABLE Figure 11 Equipment Setup with Power Source and Control Box The welding process is shown in Figure 12 A solenoid coil within the gun is energized when the trigger is pulled This lifts the 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 To set up the gun for shooting studs set the plunge length to approximately 4 3 2 mm Figure 13 The approxi mate settings for weld time and weld current is provided in Table 1 December 2002 Thermal Ceramics D2. for heat intensive industries The refractory ceramic fiber manufactured by Thermal 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 exact ly 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 easily accommodate new or revised information Holders of the manual are advis
3. 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 ceram ic fiber This is generally higher than the continuous use limit Module A prefabricated unit which can be applied as 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 applyin
4. E e Pyro Bloc M Module Red Plastic Access Tube e Pyro Bloc Y Module Aluminum Tube December 2002 Close Tube Opening Thermal Ceramics Tamp Module in Accordance with Appropriate Installation Manual Page 11 ait Thermal Ceramics 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 fibers 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 manage able 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 perpendi
5. ESIGN amp INSTALLATION MANUAL PYRO BLOC M MODULE nr mii A Gun is properly positioned B Trigger is depressed and stud is lifted dreating 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 12 The Welding Process CHUCK ADAPTOR PLUNGE LENGTH CENTER STUD IN FERRULE FOOT SCREWS Figure 13 Portable Stud Gun Stud Weld Time Weld Base Diameter Cycles in mm Weld Current Amperes 60 cycles 1 second The above settings vary due to the power source condition o the work piece age of equipment length of cable used between power source and the control unit and the alloy to be used After determi nation of proper settings the unit is ready to weld studs Taole 1 Typical Welding Conditions for Stud Welding of Steel Page ait Thermal Ceramics 2 INSTALLATION The Pyro Bloc M Modules are typically installed soldier course on walls with a batten strip between rows while a parquet pattern is used when installing on a roof Figure 2 The Pyro Bloc 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 11 292mm horizontally and 12 305mm vertically while on roofs the spac
6. ai Thermal Ceramics PYRO BLOC M MODULE DESIGN AND INSTALLATION MANUAL aiit Thermal Ceramics IABLE OF CONTENTS A Preface Introduction B Pyro Bloc M Module 1 General 1 1 Lining Considerations 1 2 Site Preparation 1 3 Stud Welding 2 Installation C Glossary of terms List of Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 List of Tables Table 1 December 2002 Pyro Bloc M Module and Stud Welding System Pyro Bloc M Module Cutaway Displaying Internal Anchoring as well as Stud and Nut Pyro Bloc M Module with Anchor Hardware and Installation Equipment Typical Module Cutting Detail Typical Pyro Bloc M 12 x 12 Module Lining Typical Pyro Bloc M 12 x 16 Module Lining Typical Pyro Bloc M 16 x 16 Module Lining Pyro Bloc M Module Corner Bloc Pyro Bloc T Bar Module Corner Bloc Equipment Setup with Separate Power Source and Control Box Equipment Setup with Power Source and Control Box Combined The Welding Process Portable Stud Gun Weld Inspection Bend Test Typical Welding Conditions for Stud Welding of Steel Stud Welding System Thermal Ceramics Figure 1 Pyro Bloc M Module and Nc 00 A co OO 44 41 05 050101 HF BWW PY Page 2 ait Thermal Ceramics INTRODUCTION Over the past 81 years Thermal Ceramics has proven itself to be a world leader in solving problems
7. anket 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 12 For further information contact your nearest Thermal Ceramics technical sales office You may also fax us toll free at 1 800 KAOWOOL or write to Thermal Ceramics P O Box 923 Dept 140 Augusta GA 30903 E Mail tceramics thermalceramics com Global Headquarters Thermal Ceramics Global L Europ en 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 Thermal Ceramics Americas 2102 Old Savannah Road Augusta Georgia 30906 T 1 706 796 4200 F 1 706 796 4398 Thermal Ceramics Asia Pacific 28 Jalan Kilang Barat Kewalram House Singapore 159362 T 65 6273 1351 F 65 6273 0165 E mail thermalceramics tcasia com sg Thermal Ceramics Europe Tebay Road Bromborough Wirral CH62 3PH England T 44 0 151 334 4030 F 44 0 151 334 1684 E mail marketing thermalceramics co uk North America Canada T 1 905 335 3414 F 1 905 335 5145 Mexico T 452 555 576 6622 F 452 555 576 3060 Sales and Marketing Office Locations United States of America Southeastern Region T 1 800 338 9284 F 1 706 796 4324 Midwe
8. cular 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 BTU 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 more 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 lay ers 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 elevated tem peratures and
9. ed to keep their address current with the Advertising and Sales Promotion Department 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 BLOC M MODULE PYRO BLOC M MODULE The Pyro Bloc M Module is a monolithic edge grain ceramic fiber module designed for industrial furnaces that require corrosion barriers a back up blanket layer or a pre layed out stud system The Pyro Bloc M Module is a unique module composed of two monolithic pieces of edge grain ceramic fiber Pyro Log9 with an internal M yoke and two support tubes Pyro Bloc M Modules are available in densities ranging from 10 15 pcf 160 240 kg m and in thick nesses from 3 12 inches 76 305 mm Figure 2 Pyro Bloc M Module Cutaway Displaying Internal Anchoring as well as Stud and Nut The internal anchor hardware is made of 316SS which offers better corrosion resistance than 304SS 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 In addition to simplifying the attachment of the modules these installation tools allow you to achieve high degrees of compression between modules Figure 3 Pyro Bloc M Module with Anchor Hardware and Trt allation E
10. efractory cements or oil Sandblasting wire brushing or grinding 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 0 135 min 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 10 or 11 for welding HEX NUT T C 288 4 FULL YOKE T C 923 BETWEEN CORNER BL CS M MODULE STUD T C 350 HALF YOKE T C 924 BEGINNING AND END OF CORNER BLOC ROW SPLIT YOKE T C 925 BETWEEN CORNER BLOCS SPLIT YOKE T C 925 AT BEGINNING AND END
11. g 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 Btu in hr ft F w m C 9 Thermal Resistivity 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 bl
12. ical Pyro Bloc M 12 x 12 Module Lining December 2002 Thermal Ceramics Page 4 que Thermal Ceramics _C DESIGN amp INSTALLATION MANUAL PYRO BLOC M MODULE ARIES Note a a Te USE STANDARD aT d THERMAL CERAMICS There are a number of factors which 12 x 19 M MODULES i F CERAMIC FIBER must be considered when designing a OVERHEAD prd Sy 1 THE amp 6g DENSITY Thermal Ceramics Pyro Bloc Module Pa CUNPRESEEG TU 1 4 Lining The typical dimensions of Pyro PYRO BLOC MODULE Bloc Modules should be used only as a POBLOG guide when considering lining installa b ANCHOR HARDWARE tion and design Higher temperature applications may require greater com pression For assistance please call your nearest Thermal Ceramics repre X LINING THICKNESS sentative Figure 6 Typical Pyro Bloc M 12 x 16 Module Lining QUU TU QU WE QE Ta Z7 Note There are a number of factors which must be considered when designing a Thermal Ceramics Pyro Bloc Module Lining The typical dimensions of Pyro Bloc Modules should be used only as a guide when considering lining installa tion and design Higher temperature applications may require greater com pression For assistance please call your nearest Thermal Ceramics repre sentative THERMAL CERAMICS USE STAND 12 x 12 M NODULES OVERHEAD 1 THK 6 DENSITY COMPRESSED TO 1 7 YRO BLOC MODULE ZA Figure 7 Typical Pyro Bloc M 16 x 16 Module Li
13. ing will be 11 2 x 11 292mm x 292mm Step 2 At the points where the chalk lines cross weld an M Module two step stud onto the steel casing December 2002 Thermal Ceramics DESIGN amp INSTALLATION MANUAL PYRO BLOC M MODULE Step 3 Install the plastic covers over the studs and coat the steel casing with stalastic If a coating is not being used plas tic 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 The Pyro Bloc M Modules can be installed Insert the module hot face side down into a compression box using a compression funnel In this way the Pyro Bloc M Module is precompressed when it is installed Page 9 aiit Thermal Ceramics Step 5 Step 8 Insert the guide rod through the hole in the yoke tab Lift Remove the collapsible red access tube compression box with module and guide rod into position and thread the guide rod onto the small tip on the M Module stud The module and compression box can now be pushed into place with the module yoke tab sliding onto the stud and against the steel casing Step 9 Pinch the fiber closed over the stud to protect it from the heat Step 6 Insert a hexnut into the end of the nut driver and slide onto the guide rod Thread the nut by hand onto the stud Remove the guide rod Step 7 Using a ratchet o
14. ning December 2002 Thermal Ceramics Page 5 Thermal Ceramics Once the studs and back up materials are in place the Pyro Bloc M Modules can be installed The yoke in the Pyro Bloc M Module has an offset to allow for the stud to be in the center of the module The Pyro Bloc M Module is easy to cut or trim 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 outlined in the cutting detail in Figure 5 It is best to cut less than what is necessary and compress the module into place to ensure the tightest possible joint Bullnose areas which cause problems for other modular systems are easily accommodated by the Pyro Bloc Corner Bloc Module These Pyro Bloc Corner Bloc Modules can be installed using the same Pyro Bloc M Module anchor hardware Alternatively our Pyro Bloc T Bar anchoring system can be used where access Is limit ed Figures 8 and 9 illustrate these two Pyro Bloc Corner Bloc anchoring options FULL YOKE T C 592 M MODULE STUD T C 350 HEX NUT j T C 288 4 M MODULE STUD T C 350 HALF YOKE T C 593 HEX NUT T C 288 4 Figure 8 Pyro Bloc M Module Corner Bloc December 2002 Thermal Ceramics 1 2 Site Preparation The steel surface to be lined should be free of heavy rust or scale non conductive paints dried r
15. quipment Page 3 Thermal Ceramics L GENERAL 1 1 Lining Considerations A Pyro Bloc M Module lining can be installed in a soldier course fashion on vertical walls with batten strip or ina parquet pattern on a roof Figures 5 7 show how a typi cal Pyro Bloc M Module lining would be installed on the walls and roof of a furnace Prior to installing the Pyro Bloc M Modules it is necessary 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 conditions for your par ticular furnace will determine the need for stalastic coat ings back up blanket or vapor barriers F I d L l B 1 1 l l Figure 4 Typical Module Cutting Detal Ze LANL PYRO BLOC MODULE THERMAL CERAMICS CERAMIC FIBER 1 THK 64 DENSITY COMPRESSED TO 1 2 tl Note There are a number of factors which must be considered when designing a Thermal Ceramics Pyro Bloc Module Lining The ANCHOR HARDWARE typical dimensions of Pyro Bloc Modules should be used only as a guide when con sidering lining installation and design Higher temperature applications may require greater compression For assis tance please call your nearest Thermal Ceramics representative X UNING THICKNESS Figure 5 Typ
16. r drill tighten the nut onto the stud December 2002 Thermal Ceramics Page 10 ait Thermal Ceramics Step 10 After all the adjacent modules have been installed you can remove the compression box Step 11 When all the Pyro Bloc M Modules have been installed the lining should be tamped out to further tighten all joints and close any gaps that may exist DESIGN amp INSTALLATION MANUAL PYRO BLOC M MODULE 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 1 800 22 5681 to request detailed information contained in its MSDSs and product literature and videos IMPORTANT INSTALLATION INFORMATION Install Pyro Bloc Modules in Accordance with the Installation Manuals Pyro Bloc M Module Installation Manual M 143 Issued 12 02 or later Pyro Bloc Y Module Installation Manual M 142 Issued 7 01 or later After installation of the Module REMOVE TUB
17. st Region T 1 866 785 2738 F 1 866 785 2760 Eastern Region T 1 866 785 2763 F 1 866 785 2764 Western Region T 1 866 785 2765 F 1 866 785 2782 12 02 M 143 1 5M w w w thermalceramics com COPYRIGHT T 2002 South America Argentina T 54 11 4373 4439 F 54 11 4372 3331 Brazil T 55 11 4178 1999 F 55 11 4178 1675 Chile T 56 2 854 1064 F 56 2 854 1952 Colombia T 57 222 82935 82803 F 457 222 82935 82803 Guatemala T 50 2 4733 295 6 F 50 2 4730 601 Venezuela T 58 241 878 3164 F 58 241 878 6712 THERMAL CERAMICS INC dit Thermal Ceramics BENDING TOOL BUSHING TEST PLATE Figure 15 Bend Test 7772727277 Figure 14 Weld Inspection Good and Bad Welds 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 15 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 As with any welding process the operator should under stand the process properly maintain the equipment and follow proper safety precautions December 2002 Thermal Ceramics Page 8
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