Document KR28NNbZae8doeD1qGgKJRXK0

I, PAUL SCHERER, residing at 644 7th Avenue") Carlsoadt, New Jersey, hereby certifies as follows: 1. I am a former employee and estimator with the Robert A. Keasbey Company from April 15, 1948 to June 30, 1987 . 2. Exhibits A through S, attached hereto and referred to herein are true and accurate copies of the originals which were either created or received by Robert A. Keasbey during the course of my employment with Robert A. Keasbey. These exhibits were created or received at or about the time reflected therein, and were received by me in the normal course of Robert A. Keasbey business. Further, I was authorized by Robert A. Kejfasbey to either create or receive these exhibits. 3. Exhibit A is a standard Babcock & Wilcox type of specification, which is furnished with every job detailing insulation, refractory material, lagging materials, etc. While certain aspects of these specifications may change from job to job, the standard portions do not. 4. Exhibit B is a true and accurate copy of a Baldwin Ehret Hill 1964 catalogue received by me while I was working with Robert A. Keasbey. 5. Exhibit C is a true and accurate copy of a 1950 catalogue of Detrick Insulations. 6. Exhibit D is a true and accurate copy of a Ruberoid catalogue entitled, "Ruberoid Pressure Molded Calsilite." 7. Exhibit E is a true and accurate copy of a R & i catalogue entitled, "Super #3000 Refractory Cement." 8. Exhibit F is a true and accurate copy of a 1953 Refractories and Insulations catalogue for Refractory & Insulation Corporation. 9. Exhibit G is a true and accurate copy of a 19461947 catalogue of Philip Carey entitled, "Heat Insulation for Industry." This catalogue was handed to me when I first started working for Robert A. Keasbey in 1948. 10. Exhibit H is a true and accurate copy of a reference data brochure of The Philip Carey Mfg. Company used by me during the course of my employment at Robert A. Keasbey. 11. Exhibit I is a true and accurate copy of a Keasbey & Mattison catalogue entitled, "Fiberglas Pipe-Blanket-Duct Liner Insulations." 12. Exhibit J is a true and accurate copy of the Carey Industrial Insulation Manual of The Philip Carey Mfg. Company which I used during the course of my employment at Robert A. Keasbey. 13. Exhibit K is a true and accurate copy of the Johns-Manville catalogue entitled, "Thermobestos Pipe and Block Insulation," which I refered to during the course of my employment as an estimator for Robert A. Keasbey. 14. Exhibit L is a true and accurate copy of the 1983 edition of Commercial and Industrial Insulation Standards. -2- 15. Exhibit M is a true and accurate copy of the Carey brochure entitled, "Insulating Cements and Weatherproof Coating." 16. Exhibit N is a true and accurate copy of a Philip Carey brochure entitled, "Carey Asbestos Fiber and Shorts." 17. Exhibit 0 is a true and accurate copy of a portion of a Philip Carey brochure entitled, "Asbestos Paper and Rollboard." 18. `Exhibit P is a true and accurate copy of a portion of a Philip Carey brochure entitled, "Pipefittings and Flanges." 19. Exhibit Q is a true and accurate copy of a portion of an engineering data sheet, dated April, 1970 from Ovens Corning entitled, "Kaylo 10 and Kaylo 20 Thickness Standards, Nesting Sizes." 20. Exhibit R is a true and accurate copy of a Babcock & Wilcox September 1, 1956 catalogue of insulation instructions. 21. Exhibit S is a true and accurate copy of a brochure entitled, "Scale Model Powerplant." -3- I hereby certify that the foregoing statements made by me are true. I am aware that if any of the foregoing statements made by me are wilfully false, I am subject to punishment. DATED2 FEBRUARY -2j , 1990 PAUL SCH2RER -4- SPECIFICATIONS & DRAWINGS Contract 586-0447 (UPGD) 546-0881 (IPGD) Existing (PFI-2845) Customer P.O. No. 3-03497 for Consolidated Edison Co. of New York, Inc. 59th Street Station New York, New York KJK) K) M M THE BABCOCK k WILCOX COMPANY INDUSTRIAL POWER GENERATION DIVISION TAB INDEX INSULATION LAGGING EXISTING PFI-2845 586-0447 (UPGD) 546-0881 (IPGD) TAB NO. Page 1 Bril Specifications...................................................................................... 1 Page 2 Reference Drawings......................................................................................... 1 Page 3 Insulation Materials Specifications(Paragraph Designations and Special RequirementsPage).......................1 General Insulation Materials Specifications............................................... 1 Page 1 Insulation Labor Specifications....................................... ....1 Page 2 Insulation Labor Specifications (Paragraph Designations k Special RequirementsPage)........................... 1 General Insulation Labor Specifications......................................................... 1 Page 1 Lagging Materials Specifications......................... Page 2 Lagging Materials Specification (Paragraph Designations k Special Requirements Page) General Lagging Materials Specifications............................ Page 1 Lagging Labor Specifications.................................... Page 2 Lagging Labor Specifications (Paragraph Designations k Special Requirements Page) General Lagging Labor Specifications.................. ................... Page 1 Brickwork k Refractory, Material k Labor Spec's................. Page 2 Brickwork k Refractory, Material i Labor Spec...................... (Paragraph Designations k Special Requirements Pg.)... General Brickwork k Refractory, Material k Labor Spec's.................. Index to Drawings in Folder Page............................................................................3 Detail Section Drawings.................................................................................................. 4 Application Drawings, Design Temperature Page and 3Y3U2 k 3Y3U3 Insulation Thickness Chart for Tubes k Pipe............................5 Key Arrangement Drawings............................................................................................... 6 2 W WWW THE BABCOCK & WILCOX COMPANY INDUSTRIAL POWER GENERATION DIVISION ENGINEERING DEPARTMENT TO: CONSOLIDATED EDISON CO. OF NEW YORK/ INC. DATE: JULY 17, 19 84 BRIL SPECIFICATIONS for: One (1) B&W PFI-28-28, indoor installa tion, 775 PSI design, 750F S.H. outlet temperature. Existing PFI-2845 586-0447 (UPGD) Contract No.: 546-0881 (IPGD) Customer & Plant Location Consolidated Edison Co. New York, Inc. 59th St. Station New York, New York of Customer P.O. No. 3-03497 SCOPE: No Mat'l., No Labor These specifications cover the furnishing of material only by others for complete application of insulation for surfaces out lined on the following pages and in accordance with the reference cravings listed and represent The Babcock & Wilcox Company's standard and best recommendations. However, since this applica tion is not in B&W`s contract, these specifications are only intended as a guide to the Erection Superintendent. Page 1 SETTINGS 31011 IE 310U2E 310113E 310114E 310115E 310116E THE BABCOCK & WILCOX COMPANY INDUSTRIAL POWER GENERATION DIVISION EXISTING PEI-2845 586-0447 (UPGD) 546-0881 (IPGD) NOTE: For Key Ar Section an t i on Dvc s. NurJoe r s , Refer to Index to Drawings in Felder Pages. n. t Page 2 4 THE BABCOCK & WILCOX COMPANY INDUSTRIAL POWER GENERATION DIVISION INSULATION EXISTING PFI-2845 586-0447 (UPGD) 546-0881 (IPGD) MATERIALS SPECIFICATIONS For areas requiring materials to be considered in this specif cation, refer to attached prints of the drawings which const! a part of this specifi- cation. Attached hereto, as part of this requirement, are some genera material specifications marked "M" for all types of boilers. From this "M" speci- fication, only the paragraphs: 1M, 2M, 3M, 4M, 5M, 19M, 21M, 23M, 25M, 47M, 48M, 49M, 50M, 5SM, 59K, 60M, 61M, 6M, 7M, 9M, 10M, 12M, 12Ma, 14M, 25M, 16M 28M, 29M, 30M, 31M, 31Ma, 33M, 35M, 38M, 51M, 52M, 54M, 55M, 55Mb, 56M, 56Ma, 57M, 63M, and 65M. are to be considered applicable and required for this specifi iob. Page 3 5 RAECOCX & WILCOX INDUSTRIAL & MARINE DIVISION SPECIFICATIONS FOR INSULATION MATERIALS GENERAL 1M These specificatioas are to provide an economical and well designee insulation job. The Company will consider suggested changes it material offered for the purpose of improving or making the design more economical. The base specification as shown, should be quoted with changes quoted as alternates. The Company reserves the right to approve suggested changes before their inclusion in this contract The Contractor oust submit sketch showing attachment detail and pro cedure for approval before contract is awarded. CONTRACT 2M Questions concerning materials as specified in this contract are tc be resolved with the Company prior to the signing of tms contrac:. 3M The Contractor upon signing this contract, convenants and agrees to the requirements of this contract. 4M The Contractor shall not be entitled to any monetary compensation ever and above that stipulated in the contract as the result of not having fully understood the requirements as' defined in this contract. The Contractor shall at no time proceed to make changes to the specified requirements of this contract without written authority from the Com pany. MATERIAL 5M Where application drawings differ from contract drawings, written specificatioas drawings, key arrangement drawings, section number drawings, follow the Latter. 6M All insulating material shall be of such quality to be suitable for the purpose intended by the contract and of such durability as to be capable of giving effective and reliable service under normal oper3iing conditions. ~M Ho substitutions for material specified shall be made without approval of the Company. 8M It is not permitted to substitute medium temperature blocks for higt temperature blocks. 9M The Contractor shall provide weather protection and insurance for the storage of all insulation materials at the job site prior to applica tion of same where such protection is necessary. BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION SPECIFICATIONS FOR INSULATION MATERIALS 3T;I?'GD 1A5-I La/2-1- class siocx o* suxrrf TTR --------------------------mrjiU'itMi------------------------------------- - fwmiAi 7W Utt------------------- spicificaticbs UHTT - *T lu> aPPIotCi i 17B Mifk-Teapcracsn Block lW aijs-Teaperatwe Block 19H fledm Tcap. Block 2OH Bedrn Tm^. Block 2in Rediai Teap. Block 22B DELETED 23H Intermediate Tep. Block 23fta Intermediate 7o^. Block f24f! Blanket loanlatxoe (TJW) 251! Blanket Inaulatioo 26* Blanket Initiation 26fta DELETED PIPE IXSUUTIO* 27H teem 7^^. P/C 2BR Bedm Tnap. P/C r29fl Mia Ten*. P/C ' *3OH Bedm T^. P/C 30fta tow Top. P/C Diateanceowa Lank Bineral Fiber Calcm Silicate Expanded Perlite flittera 1 Tiber fltaeral liber lb/ft3 BOH Siaeral Fiber 3 ib/ftJ non Hloeral Fiber 1.OS/fv non Bittera1 Tiber 1 lb/fr KR BW Loewool i Lrpoaoed Perlite Calcm Silicate Rittcral Fiber (Preformed) Bitteral Fiber , (Hat faced) 12#/ft Claaa Fiber (Preformed) ASTB C-517 (Type 2) ASTB C*612 (Claaa 5) ASTB C-533 ASTB C-61C ASTB C-412 (Claaa 5) ASTB C-612 (Claaa 3! ASTB C-412 (Cloaa 3) TIV - Type I ASTB C-SB2 (Claaa II) bW \PmiVTl) ASTB C-O10 ASTB C-533 ASTB C-547 (Cloaa 3} ASTB C--592 (Claaa ID ASTB C-547 (Claaa I) 1900 100 1200 1200 1200 850 BSC 1000 1200 2300 1200 1200 1200 1200 370 , I "CDffXTS 2in Ki*o Taap. Plaatic ituulatmt Coant 31Ba !Mi Tnap. Lnaalatini aad F (.matted Cant Bitteral Fiber Kitten! Fiber ItW AFPKOVID ASTB C-1*5 ASTB C-**9 1600 1200 ? 3/4 ASTM classes and specifications taken from ASTM Pa * Maximum cold face use limit 300F | For Package Boilers 19? BABCOCK & WTLCOX INDUSTRIAL POWER generation division SPECIFICATIONS FOR INSULATION MATERIALS V' .AS a CLASS TYPE COVERINGS 40M Glass Cloth for Glass Fabric - Open Seal Coats Weave, 26x12 Lino Weave v/Syton Finish 41M Insulation Jacketing Fabrics for Piping Canvas -2M DELETED 43M DELETED 44M Mastic Coating Emulsion or Cutback Type 45M Mastic Coating Synthetic Type SPECIFICATIONS MAT'L SPECS. TEMP USE T 8 oz/sq. yd. Min. Wt. 50C ICC B&W Approved Material ISC ISO 46M Contractor shall list in detail the square foot quantities and sire of all materials necessary to insulate each specific area designated on the various section drawings. This is necessary to enable us to evaluate the bids, and the applicator to install the material on the areas designated by the materials. BABCOCK & VILCOX INDUSTRIAL POWER GENERATION DIVISION SPECIFICATIONS FOR INSULATION MATERIALS' T(IPCI' as-: .e-s-s: 47M All materials required for proper support and fastening of msulatroL to all surfaces shall be provided by the contractor. The fastener description oust be submitted with the quotation. 48M All damper frames integral with insulated flues or ducts, require in sulating. The damper bearing shall not be covered with insulation. 49M When flat insulation block has a compressive strength of less than 50 psi at 10 per cent deformation, (including all mineral wool base block), it is required that light sheet metal plates or angles snail be used under lacing wire, where the wire tends to cut into the block. 5QM Multiple layers of insulation block are required where so shown on drawings, or so specified by this contract. 51M When two layers of insulation block, as well as two layer sectional and/or segmental insulation of different temperature limits are usee on the same area, the material having the higher limit of temperature must be placed against the hottest surface so that the lower limit material is protected at all points, and the blocks of outer layer shall stagger vertically and longitudinally the blocks of the inner layer. If lacing wires are used for support of insulation block same are to be applied over outer layer of block only unless otherwise stated. 52M Inner insulation support for insulation shall be furnished by the insulation contractor. It shall be 22 M.S.G. cold rolled finished^ corrugated sheet steel (not galvanized) for temperatures up to 85C? and 22 M.S.G. stainless steel corrugated sheet of any 300, 400 or 500 alloy for temperatures above 850 7. Supports for inner insula tion support to be 6'**0" maximum centers. The inner insulation sup port shall be fastened with three (3) plug welds per width of sheet. An alternate system shall be Hilti-Fastener system or equivalent. Corrugated sheet shall have corrugations at a pitch of 2-1/2" and a depth of 1/2". 52M All surfaces of boiler flues, ducts, hopper, housings, etc. shall have clips welded studs or other suitable means, spaced on proper centers for attachment of the insulation and inner insulation sup ports. All materials required for proper support and fastening of the insulation and inner insulation supports shall be provided by the Contract. 54M Where insulating block is applied to inner insulation support over stiffeners, insulating block is also required to be applied at full depth back to the casing at expansion joints and all openings such as doors, etc. KJ F9 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION SPECIFICATIONS FOR INSULATION MATERIALS 5/:c-:s-s 56M All expansion joints integral with insulated flues and ducts shall be insulated. Except Non-Metallic Expansion Joints. 56Ma Thermal barriers are required in all open areas or voids, between insulation and hot surfaces, to limit any vertical height of the space to a maximum of 10'. Minimum vertical distance between ther mal barriers shall be 5'. Maximum vertical distance between thermal barriers shall be 10'. TUBES & PIPE 57M Refer to B&V charts 3Y-3U-2/ & 3/ for insulation to be applied on ex posed piping, tubes, valves, bend, flanges and fitting when this in formation is not shown on the insulation drawings. Pm studding to tube or pipe bend radii surface other than to the neutral axis is not permitted. 58M Where tubes or pipes are insulated as a group and vertical runs are 10'-0" or more, thermal barriers will be required on 1C maximum cen ters. Barriers will consist of blanket insulation packed tightly be tween and around all pipes and tubes and supported by lath, annealed carboQ steel wire or annealed wire, copper wash coated wire laced be tween and around the pipes or tubes. 59M Provide insulation for all Company connections to the Company termi nals including mountings, nozzles, valves, flanges, fittings, pipe bends and piping for lines or connections where temperature of such lines or connections require insulating. See attached prints of insulation drawings, setting drawings, reference drawings, etc., and/or this insulation contract for indication of lines and/or con nections with mountings, nozzles, valves, flanges, fittings and pip ing. Insulation shall be applied in two layers where so specified. Drum mountings: lines, valves, and instruments must be insulated as snovn on specific mounting drawings for proper function of instru ments, even if their location is beyond B&V Company's terminal Ref. 3Y-6A-1U. 60M Fittings, flanges and valves on pipe sizes 3-1/2" or less, are covered witn high temperature asbestos free insulating cement, bringing the total thickness to that of the insulation on the adja cent piping, Fittings, flanges and valves on pipe sizes A" or over are insulated with block or pipe insulation with a finish coat of hydraulic setting finishing cement to create a smooth finish. olM For IPS diameters up to and including 18" diameter, the block insu lation can be of the molded, sectional or segmental type. Above 18" IPS diameter, the block insulation can be of the flat type. V THE BABCOCK & WILCOX COMPANY INDUSTRIAL POWER GENERATION DIVISION ENGINEERING DEPARTMENT TO: CONSOLIDATED EDISON CO. OF NEW YORK, INC. DATE: JULY IT, 195^ BRIL SPECIFICATIONS for: One (1) g&W PF1-28-28, indoor installation, 775 PSI design, 750F S.H. outlet temperature. Existing PFI-2845 586-0447 (UPGD) Contract No.: 546-0881 (IPGD) Customer & Plant Location Consolidated Edison Co. of New York, Inc. 59th St. Station New York, New York Customer P.O. No. 3-034S7 SCOPE: No Mat*!., No Labor These specifications cover the furnishing of labor by others for complete application of insulation for surfaces outlined on the following pages and in accordance with the reference drawings listed and represent The Babcock & Wilcox Company's standard and best recommendations. However, since this application is not in B&W's contract, these specifications are only intended as a guide to the Erection Superintendent. Page 1 6 THE BABCOCK & WILCOX COMPANY INDUSTRIAL POWER GENERATION DIVISION INSULATION EXISTING PFI-2845 586-0447 (UPGD) 546-0881 (IPGD) LABOR SPECIFICATION Fcr areas requiring application labor to be considered in this specifics- tion, refer to attached prints of the drawings which constitute a part of this specification. Attached hereto, as part of this requirement, are some general labor speci- fications marked "L" for all types of boilers. From this "L" speci fica- tion , only the paragraphs : >o to m 1T t 2L, 3L, 4L , 5L, 6L, 7L, 8L, 9L , 10L, 11L, 12L, 11 ^, 16L, 17L, 19L, 20L, 21L, 22L, 23L, 24L, 25L, 26L, 27L 3 0L, 31L, 32L, 34L, 35L, 36L, 37L, 38L, 39L, 40L, 41L 44L, 45L, 47L, 49L, 50L, 51L, 53L, 54L, 56L, 57L, SSL 61L, 62L, 63L, and 64L are to be considered applicable and required for this specific job. Page 2 BABCOCX & WILCOX INDUSTRIAL POWER GENERATION DIVISION SPECIFICATIONS FOR INSULATION LABOR GENERAL XL These specifications are to provide for the economical application o: insulation material. The Company will consider suggested changes m application methods offered for the purpose of improving the design or making the application sore economical. The base specification as shown, should be quoted with the changes quoted as alternates. The Company reserves the right to approve suggested changes before their inclusion in this contract. The Contractor must submit sketch shown attachment detail and procedure for approval before contract is aware 21 Questions concerning application methods as specified in this contra: are to be resolved with the Company prior to the signing of this con tract. 3L The Contractor upon signing this contract, convenants and agrees to the requirements of this contract. 4L The Contractor shall not be entitled to any monetary compensation over and above that stipulated in the contract as the result of not having fully understood the requirements as defined in this contract. The Contractor shall at no time proceed to make changes to the speci fied requirements of this contract without written authority from the Company. 5L Where application drawings differ from contract drawings, written specification pages, key arrangement drawings, section number draw ings, follow the latter. 6L All materials required for proper support and fastening of the Insu lation shall be installed by the Contractor. This will include clips insulation pins, speed clips, welded studs, tie wire, or other suit able means. All attachments shall be on proper or specified centers for supporting insulation. 71 Inner insulation support for insulation shall be installed by the Contractor.. Side lap of corrugatons is not required, but sheets must be tightly butted. End laps, where required, should be a mini mum of 3". Inner insulation support should be plug welded three (3; times per width of sheet to supports installed on six foot maximum centers. An alterante system shall be the Hilti-Fasteaer system or equivalent based on fastener location same as above. 8L All fasteners and intermediate supports for mounting the inner insu lation support shall be installed by the insulation contractor. tbabcoct vncoz OTUSTRIAl & HARDfE DIVISIOK SPECIFICATIONS FOR INSULATION LABOR 3TCSS' iA5-:: 19L Insulation block next to flue, duct, and casing stiffeners or flange should be slotted to fit over and close up voids. To prevent breaka block over angle or channel stiffeners shall not be less than tii Block over bar stiffeners may be 1/2" thick. 20L All field velds on inner pressure casing (for boiler units vice pres sure furnace only) must remain uncovered creating a slot of approxi mately 2" vide full depth in insulation until after casing tightness test work is complete. Upon completion of casing test, this slot void is to be filled full depth with high temperature plastic insula tion or insulation of the same material as adjoining area. 21L All finished insulation block application and method of supporting same is required to be approved by B&W Co. representative before starting insulation block of finish coat, sealing compound, lagging, or casing. 221 All open joints, voids, holes or cracks appearing after application of insulation block must be filled full depth of opening, with insu lating cement made from the same material (or equal) as insulating block. 231 An outer metal lagging supplied and applied by others will cover the insulation in areas designated on the drawings. On all areas, excep boiler and furnace walls between buckstays and piping, this lagging will be supported by pins, studs, or other approved supports welded on appropriate centers for the loading requirements. The supports will be supplied and applied by others. The insulation is to be applied over the lagging supports so as to permit them to protrude for lagging attachment. BABCOCX & vncox INDUSTRIAL POWER GENERATION DIVISION SPECIFICATIONS FOR INSULATION LABOR 24L Where insulating block is applied over inner insulation support out side of stiffeners, insulating block is also required to be applied at full depth back to the casing at expansion joint and all openings, such as doors, etc. 25L The top surfaces of insulation on top of all horizontal flues and ducts, etc., on outdoor areas, where water can lay oust be sloped 1/4 inch per foot to permit drainage construction. This may be ac complished by maintaining minimus required thickness of insulation at the lowest points and increasing insulation thickness to provide a 1/4 inch per foot slope or by providing a built up inner insulation support under the insulation at a slope of 1/4 inch per foot and us ing a uniform thickness of insulation. When the top plates of flues and ducts are already sloped, no change occurs in the thickness of insulation blocks on same. 26L All stiffeners or flanges of casing, flues or ducts shall be covered with insulation. Outstanding legs of stiffeners, flanges or other metal parts projecting beyond the outside of the insulation face shall be covered with insulation of not less than 1 inch thickness at all points. For flues and ducts requiring 1 inch of insulation, see appropriate application drawing for approved installation. 27L For flues or ducts, 33 inch diameter and greater, the block insulation is to be applied the same as to flat flues and ducts. 281 For ducts, flues, etc., if insulation drawings do not specify exact areas for insulation next to plate, and exact areas for insulation on inner insulation support outside of stiffeners; then refer to details and arrangements of ducts and/or flues etc., (prints attached hereto) which clarify these two classifications. 29L All damper frames integral with insulated flues or ducts, require in sulating. The damper bearings shall not be covered with insulation. The insulation around the bearings shall be tapered away frost the bearing, packing gland or air seal thereby providing access to these components for maintenance or adjustment. 30L Insulation on headers is to cover over cup type welded handhole fit tings, level with adjacent insulation. The insulation shall be ar ranged to provide a removable plug or block of sufficient size to provide access for removal and rewelding of the handhole fittings. 31L Gasketed handholes in headers, and man holes in drums, are to be left uncovered. 31La Thermal barriers are required in all open areas or voids, between in sulation and hot surfaces, to limit any vertical height of the space to a maximum of 10'. .Minimum vertical distance between thermal bar riers shall be 5'. Maximum vertical distance between thermal barriers shall be 10'. BA8C0cr & WILCOX INDUSTRIAL POWER GENERATION DIVISION SPECIFICATIONS FOR INSULATION LABOR stops: ias-ii -a ' 12-1 - SI 38L Fittings, flanges, and valves on pipe si2es 3-1/2 inch or less, are covered vith high temperature insulating cement, bringing the total thickness to that of the insulation on the adjacent piping. Fittings flanges and valves on pipe si2es 4 inch or over are insulated vith block or pipe insulation with a finish coat of hydraulic setting finishing cement to create a smooth finish. 39L All rods, pipes or tubes piercing through enclosure casings of boiler are to be insulated at the casing such as to be air infiltration leakproof, or heat leak-proof, depending on which case applies to specific enclosure. 40L Where supply tubes are routed through insulation of boiler walls. square off around each tube with high temperature insulating cement. 41L When completed, the insulation on all piping shall be entirely protected, and shall be capable of accommodating any thermal movements without destruction or distortion of the insulation or weather pro tection. 42L For IPS diameters up to and including 18 inch diameter, the pipe in sulation can be of the molded, sectional or segmental type. Above 18 inch IPS diameter the pipe insulation can be of the flat type. 43L As far as possible all pipe or tube insulation shall be applied m sectional or segmental fora. Cracks 1/16 inch and over which occur after application shall be filled with high temperature plastic in sulation. 44L Covering on vertical pipes should be supported in such a manner as to prevent slipping or contraction. 45L For 10 inch IPS or over (pipe and/or tubes) there is required m the insulation proper heat leak-proof expansion joints for every 9 feet 0 inch of straight run and for each bend to correspond with 1 inch thermal expansion of tube or pipe. F;6 EABCOCT & WILCOX INDCSTRIAL POWER GENERATION DIVISION SPECmCATIONS FOR INSOLATION LABOR 46L There will be electric cable or steam pipe "tracing" on piping as specified. The contractor shall provide insulation having proper inside diameter to accoanodate same. 47L Permanent thermocouples must be insulated per Dvg. S7I01A. ALUMINUM METAL JACKETING FOR PIPING 48L Metal jacketing for all runs of tubes and pipes shall be corrosion resistant aluminum alloy .016" thick jacketing with a plain mill or smooth finish. The jacketing shall have a factory applied pol yethylene and kraft moisture barrier or an approved equal attached to the inside. 3/S" x #7 self-tapping aluminum sheet metal screws shall be used on 6" centers when attaching the metal jacketing. Bends, fittings and valves shall be covered with similar metal jacketing. SHEET METAL JACKETING FOR PIPING 49L Metal jacketing for all runs of tubes and pipes shall be corrosion resistant steel .010" thick jacketing with a plain mill or smooth finish. The jacketing shall have a factory applied polvethleae and kraft moisture barrier or an approved equal attached to the in side. 3/8" x #7 self-tapping cadmium plated carbon steel sheet metal screws shall be used on 6" centers when attaching the metal jacketing. Bends, fittings and valves shall be covered with simi lar metal jacketing. SOL All bundled piping and tubes are to have a metal lagging finish that will be supplied and applied by others. 51L A vapor barrier is required over insulation which will be covered by metal lagging less than .032" aluminum or #20 Msg galvanized steel. FINISH COATS 521 When finish cement coat is under lagging, grooving in finish cement is not required. COVERINGS 53L For exposed to weather rounds up to and including 14" CD, all joints in the covering shall be lapped at least 3" and all horizontal laps shall be turned downward to shed water. Side laps on vertical piping are to be sealed with cement. 54L All insulation shall be thoroughly dry prior to application of any weather protection material. BABCOCX & WILCOX INDUSTRIAL POWER GENERATION DIVISION SPECIFICATIONS FOR INSULATION LABOR ia5-i: 64L Boiler and other equipment to be covered may be hot at the time cf application; however, the following areas must be covered prior to initial firing and prior to continuous service as noted: 1. PRESSURE PARTS 1.1 Areas to be covered prior to initial firing of the unit. 1.1.1 All boilers - the principal factor to be consid ered for insulating boiler pressure parts prior to initial firing is personnel safety. Frog this standpoint, all pressure parts should be covered. Functional or thermal expansion requirements of the boiler pressure parts do not require the com pletion of insulation prior to initial firing. Accordingly, the Erection Contractor can be given some leeway in this requirement and the Erector can exercise his judgement. 1.2 Areas to be covered prior to continuous serv f the 1.2.1 All pressure parts are to be covered. 2. NON-PRESSURE PARTS 2.1 Areas to be covered prior to initial firing of the unit: 2.1.1 Entire penthouse 2.1.2 Entire plenums andvestibules 2.1.3 Entire windbox 2.1.4 All plate within three feet of pressure parts 2.1.5 All bellows seals, and plate seal areas 2.1.6 All flue and duct expansion joints, as specified. 2.1.7 Entire precipitator, including flue transitions or nozzles up to the first expansion joint. 2.1.8 Deleted. 2.1.9 Airheater tubular, entire periphery of exterior airheater casing. 2.2 Areas to be covered prior to continuous service of the 'unit 2.2.1 All non-pressureparts are to be covered. THE BABCOCK & WILCOX COMPANY INDUSTRIAL POWER GENERATION DIVISION ENGINEERING DEPARTMENT TO: CONSOLIDATED EDISON CO. OF NEW YORK, INC. DATE: JULY * BRIL SPECIFICATIONS for: One U) B&W PFI-28-28, indoor installation, 775 PSI design, 750F S.H. outlet temperature. Existing PFI-2845 586-0447 (UPGD) Contract No.: 546-0881 (IPGD) Customer & Plant Location Consolidated Edison Co. New York, Inc. 59th Street Station New York, New York of Customer P.O. No. 3-03497 SCOPE: No Mat1!., No Labor These specifications cover the furnishing of material only br others for complete application of lagging for surfaces outline on the following pages and in accordance with the reference drawings listed and represent The Babcock & Wilcox Company's standard and best.recommendations. However, since this appli cation is not in B&W's contract, these specifications are only intended as a guide to the Erection Superintendent. Page 1 THE BABCOCK & WILCOX COMPANY INDUSTRIAL POWER GENERATION DIVISION LAGGING EXISTING PFI-2845 586-0447 (UPGD) 546-0881 (IPGD) MATERIALS SPECIFICATIONS For areas requiring materials to be considered in this specifi cation, refer to attached prints of the drawings which constitute a part of this specifi- cation. Attached hereto, as part of this requirement, are some general material specifications marked "M" for all types of boilers. From this "M" specifi- cation, only the paragraphs: 101M, 102M, 103M, 104M, 107M, 108M, 110M, 114M, 115M. are to be considered applicable and required for this specific job. Page 2 9 BABCOCK & WILCOX INDUSTRIAL POWR GENERATION DIVISION SPECIFICATIONS FOR LAGGING MATERIALS - STEEL GENERAL 201M These specifications are to provide an economical and veil designed lagging job. The Company will consider suggested changes in material offered for the purpose of improving or Baking the design aore eco no! cal. The base specification as shown, should be quoted with changes quoted as alternates. The Company reserves the right to approve suggested changes before their inclusion in this contract. The Contractor Bust submit sketches shoving attachment detail and procedure for approval before the contract is awarded. CONTRACT 202M Questions concerning materials as specified in this contract are tc be resolved with the Company prior to the signing of this contract. 20311 The Contractor upon signing this contract, convenants and agrees to the requirements of this contract. 204M The Contractor shall not be entitled to any onetary cocpensation over and above that stipulated in the contract as the result of not having fully understood the requirement as defined in their contract. The Contractor shall at no time proceed to make changes to the speci fied requirements of this Contract without written authority from the Coopany. 205M Where application drawings differ fro* the contract drawings, written specification pages, key arrangement drawings or section numbered drawings, follow the latter. 206M All lagging material shall be of such quality to be suitable for the purpose intended by the Contract, and of such durability as to be capable of giving effective and reliable aervice under normal operat ing conditions. 20711 No substitutions for materials specified shall be made without approval of the Coapany. 208M The Contractor shall provide weather protection for the storage of all lagging materials at the jobsite prior to application of same where such protection is necessary. 209M Lagging materials are to be packed for shipment to jobsite in such a manner as to protect same against breakage and weather conditions un til actually applied. The Contractor shall be responsible.for the proper packing to afford this protection and safe arrival of the material in good condition as acceptable for use. BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION SPECIFICATIONS EOR LAGGING MATERIALS - STEEL 3TCIPGT' 3 / 2 -1 ** - S ^ PIPING - ''BUNDLES" STEEL 220M Piping in "bundles" shall be lagged of 20 Msg galvanized flat sheet. ATTACHMENTS 221M All attachments such as clips, bands, screws, etc. shall be supplied by the Contractor. The metal screws used shall be cadmium-plated c: stainless steel with Neoprene composite, Neoprene aluminum or vinyl washers. Sizes of attachments may be determined by the Contractor from drawings of the insulation to be covered which are supplied as part of this contract. PENTHOUSE ROOF 222M Outdoor Units The penthouse roof is to be covered with 18 Msg. galvanized steel lagging. (ASTM Specification A525-76) for a commercial zinc coating of 1.25 oz/ft. The lagging is to be installed in a manner that will keep the panels flat and provide water run-off at all points. Joints between roof panels and roof penetrations are to be sealed by welding and or soldering. Roof gutters, when required by customer, to be furnished by lagging contractor. Downspouts furnished by customer. 222Ma Indoor Units The penthouse roof is to be covered with ribbed lagging with subgirts and subgirt supports on 2,-0" maximum centers. Additional support should be added at penetrations or if the footing is spongy. PREPACKED PANELS - STEEL 223M The use of pre-insulated panels or "packed panels" lagging systems shall be of a design and support arrangement as approved by B&V. Id general, the above specifications for metal thickness and attachments shall be adhered to. Insulation material and thickness thereof shall be as approved by B&W. FLASHING - BOILER TO BUILDING 224M The flashing between building structure and boiler lagging shall be equivalent to "Expand-o-Flash" where applicable. All joints and changes of direction shall be suitably lapped and closed to prevent rain leakage. THE BABCOCK & WILCOX COMPANY INDUSTRIAL POWER GENERATION DIVISION ENGINEERING DEPARTMENT TO: CONSOLIDATED EDISON CO. OF NEW YORK, INC. DATE: JULY 17, 1984 BRIL SPECIFICATIONS for: One (1) B&W PFI-28-28, indoor installation, 775 PSI design, 750F S.H. outlet temperature. Existing PFI-2845 586-0447 (UPGD) Contract No.: 546-0881 (IPGD) Customer & Plant Location Consoldiated Edison Co. of New York, Inc. 59th Street Station New York, New York Customer P.0. No. 3-03497 SCOPE: No Mat'l., No Labor These specifications cover the furnishing of labor by others for complete application of lagging for surfaces outlined on the following pages and in accordance with the reference drawings listed and represent The Babcock & Wilcox Company's standard and best recommendations. However, since this application is not in B&W's contract, these specifications are only intended as a guide to the Erection Superintendent. Page 1 10 THE BABCOCK 6 WILCOX COMPANY INDUSTRIAL POWER GENERATION DIVISION LAGGING EXISTING PFI-2845 586-0447 (UPGD) 546-0881 (IPGD) LABOR SPECIFICATION For areas requiring application labor to be considered in this specification, refer to attached prints of the drawings which constitute a part of this specification. Attached hereto, as part of this requirement, are some general labor specifications marked "L" for all types of boilers. From this "L" specification, only the paragraphs: 101L, 102L, 103L, 104L, 105L, 106L are to be considered applicable and required for this specific job. Page 2 11 BABCOCX & WILCOX INDUSTRIAL POWER GENERATION DIVISION SPECIFICATIONS FOR LAGGING LABOR 3Y(IPGD) 1A5-V 1/12-i-s: DESIGN 101L It is not the intention to specify exact construction in all locations as this is the respoaibility of the contractor. However, the designs used by the contractor should have at least the equivalent provision for expansion, strength, and weather tightness as that shown on the drawings. The Contractor upon signing this contract, convenants and agrees to the requirements of this contract. The Contractor shall not be entitled to any monetary compensation over and above the stipulated in the contract as the result of not having fully understood the requirements as defined in this contract. The Contractor shall at no time proceed to sake changes to the specified requirements of this contract without the written authority from the Company. When application drawings differ from contract drawings, written specification pages, key arrangement drawings, numbered section drawings, follow the latter. Standard B&W drawings on metal lagging for various areas are included as a guide to the lagging contractor. In general, the insulation will present a flat unbroken surface except for wall openings and support rods. It should be recognized by the lagging contractor, however, that stiffeners will sometimes occur to break up the flat surfaces. The lagging must extend over these stiff eners if they are insulated. The necessary''provisions for expansion and contraction is to be pro vided in the design of the lagging. Small easily removed panels are to be provided in the metal lagging to allow the removal of handhole closure fittings in all headers that are to be lagged. Damper bearings shall not be covered with lagging. Lagging around damper bearings shall be arranged so that maintenance or adjustment to the bearing, packing gland or air seal can be accomplished with out removing any portion of the lagging. APPEARANCE 1021 It is the responsibility of the lagging contractor to arrange the flanges and ribs of the lagging in consistent vertical lines from top to bottom. BABCOCK & WILCOX INDUSTRIAL & MARINE DIVISION SPECIFICATIONS FOR LAGGING LABOR 3T(I&M) 1A5-V 3/10-8-8 It is the reponsAbility of the lagging contractor to maintain satis factory labor relations on the job. When instructed by the Company, the contractor shall proceed at the job site vith the performance of this contract. It is agreed by the contractor not to sublet any portion of this contract or assign the same for any money which may become due thereunder. GENERAL 106L Due to job scheduling, portions or all of the metal lagging may have to be installed vith the boiler in operation. 107L Welding to Non-pressure Parts. All welding shall meet minimum acceptable standards of quality work manship as determined by visual inspection, proper cleaning and/or slag removal should proceed inspection of velds. Welds may be con sidered unacceptable for any of the following reasons: A. Cracks in weld or base material caused by welding. B. Incomplete or non-fusion between veld and base metal. C. Craters not filled to the full cross section of the weld. D. Undercut exceeding 1/32". E. Any excessive porosity or spatter which will cause a probable reduction in the expected service life of the weldment. Welding to pressure parts is to be covered under pressure vessel codes. THE BABCOCK & WILCOX COMPANY INDUSTRIAL POWER GENERATION DIVISION ENGINEERING DEPARTMENT TO: CONSOLIDATED EDISON CO. OF NEW YORK, INC. DATE: JULY 17, 1984 BRIL SPECIFICATIONS for: One (1) B&W PFI-28-28, indoor installation, 775 PSI design, 750F S.H. outelt temperature. Existing PFI-2845 586-0447 (UPGD) Contract No.: 546-0881 (IPGD) Customer & Plant Location Consolidated Edison Co. of New York, Inc. 59th St. Station New York, New York Customers P.O. No. 3-03497 SCOPE: No Mat1!., No Labor These specifications cover the material and labor for brickwork and refractory for surfaces outlined on the following pages and in accordance with the reference drawings listed and represent The Babcock & Wilcox Company'.s standard and best recommendations. However, since this material application is not in B&W's contract, these specifications are only intended as a guide to the Erection Superintendent. Page 1 12 THE BABCOCK & WILCOX COMPANY INDUSTRIAL POWER GENERATION DIVISION EXISTING PFI-2845 586-0447 (UPGD) 546-0881 (IPGD) BRICKWORK AND REFRACTORY MATERIALS AND LABOR SPECIFICATIONS For areas requiring materials and application labor to be con sidered in this specification, refer to attached prints of the drawings which constitute a part of this specification. Attached hereto, as part of this requirement, are some general material and labor specifications marked "M* for all types of boilers. From this "M" specification, only the paragraphs: 301M, 302M, 303M, 304M, 305M, 306M, 307M, 308M, 309M, 311M. are to be considered applicable and required for this specific job. Page 2 13 INDOSTRIAl & MARINE DIVISIOV SPECIFICATIONS FOR BRICKWORK AND REFRACTORS' 1A5-VI 1/10-8-82 general 301M The Contractor shall perfora all phases of work and supply all materials in an acceptable Banner as shovn on the drawings subsitted with these specifications. The scope of work shall include that shown on revisions to these drawings or additional drawings supplied for clari fication or engineering detail. Where drawings are not complete as to detail and a complete closure is not shown because of the lack of such detail it shall be the Contractor responsibility to ascertain such de tailed information prior to his submission of a quotation. 302M Material furnished by the Contractor shall be unloaded, stored and protected by the Contractor until properly applied. 303M The Contractor shall furnish all supervision, labor, tools and equip ment including compressed air, scaffolding, dry storage, office and change roos facilities necessary to install all materials furnished under these specifications and drawings. 304M Water and electricity for construction purposes will be made available to the Contractor. The Contractor is to supply his own extension cords leaps, water hoses and other equipment needed to use these facilities. 305M The Contractor shall furnish all material and labor necessary to fabricate, install and remove any forms necessary to properly apply any materials covered under these specifications. 306M All materials furnished must be asbestos free. 307M The correct installation, inspection, curing, drying and repairing of the castable installation shall be the responsibility of the in stallation Contractor. 308M The approval or acceptance of the installation by a Company inspector or representative does not relieve the installation contractor of any responsibility, warranty, or guarantee. 309H be customer* s premises must be kept reasonably clean during construc tion and left broom clean prior to leaving the job at completion. 310M Export jobs are to receive special packing considerations to withstand extra handling necessary on these jobs. For packing instructions con tact the Company. 311M Rapid Fired Technology Castables are approved for initial installa tions as well as for installation for retrofit applications. % F33 THE BABCOCK & WILCOX COMPANY INDUSTRIAL POWER GENERATION DIVISION EXISTING PFI-2845 586-0447 (UPGD) 546-0881 (IPGD) TAB #4 DWG. NO. 28459A-3 28456A-8 44453A-1 28457A-4 77889A-2 3707A-10 28458A-3 28455A-5 28454A-4 23593A-5 23596A-7 28453A-2 23597A-2 3730A-4 63530A-0 23594A-2 28402A-4 23598A-2 28452A-5 28406A-4 29255A-2 29256A-2 39796A-2 201253A-0 INDEX OF DRAWINGS IN FOLDER Section A-A Section B-B Section Bl-Bl Section C-C Section Cl-Cl . Section D-D Section E-E Section F-F Section G-G Section H-H Section J-J Section K-K Section L-L Section M-M Section Ml-Ml Section N-N Section P-P Section Q-Q Section R-R Section S-S Section T-T Section U-U Section V-V Piping - Insul & Lagging INSUL. LAG. REFR. XX X XX XX XX XX X XX X XX X XX X XX XX X XX X XX X XX X XX X XX XX XX XX XX XX 14 _Cv f f> t*iM N t t. to III ,,I THS BABCOCK & WILCOX COMPANY &OILK DIVISION 1NTESRPI FVRvIBCE KM.ER-TNPB PFI msutM\0N IK 1V.I 2v REYJSfOW* BURNER WHOBtX JtiJBWIM. -CM+ *MXtnv*+ "* Tt L0+tr 101* 6 frorftDPP * NTTE ^imc ; / feywLgj^ - f. , _ y /r * i s - r. ft 12/ fcHSt. METAL L^T^i fViruscRitN t, | 4| CONSTRUCTION !> FIRST VlENvBPWNE TVS%fc OUTSTOS BORNEO WK wndbo* vfion m------------------------- fcAOCRFTt B (SWOP WUED) 3 TINE SELF-NLUaNG PIN SPACED WVWTTVCAlI \V UCftYtOvn^L ti"* IS GA LXP lAFTftL tPTW TOO: UJEtD TO TUBE U N in m p iih rD H R iM im ? ti f i t l h o t t o rn n *t t I ll* P *H (;(IC H A W IIC O H C O M fA H <> n iR N itH iN ii iu r o M T in H t o ?*. CI - kX I tf sS< i - CS i -- 2V\NTtewiEP',KTtTByip Block iusulhTioM Class3 -- WiETOl lAfeEm"- NELSON SCF SETLOCK STUD' WITH 2^ SQ. STAINLESS STEEL SPEEDNUT SETLOCK CAP. * FOR AIR TEMPERATURES UP TO SOO r USE 4M FOR AIR TEMPERATURES 601 F TO' 700 F > lA \ >' } ' t\s iC\ INSULATION bTU\L >C*LC NC SECltOU B-B *AT* a- ;e 2S^5E A- 8 i '1V 1N B M IM X B O n i u i m x ) M K I 4-"* eew ae Ui 0*0 i| ** Ul THE BABCOCK & WILCOX COMPANY BOILER DrVISlON N5ULATION PENT^OJSE >< G* *Z >' - a/a - n - 11 ktvisioms I; MMBM. 1 HIT ----iTitili i 1 81084^1, na. n j z KIOCAWN APC JT i VlC*iC St** Vvfci *** - ! ZVlNTRMEDiA- tlM = SLOCK IN^UL. CiA5f 5 2*3>*/5C yd. COPPER 6EAR.INC; EXPANOi" MTAL LATk TtK\P WtLT GLfc*5~ lNi^UUP^T\0>0 V^VvCs1 PE.SL 7059IA COw\PR^S TOVX^ Shop supply z t, nOUS`i*to' l dt;! i *1? 5 : S|c 5s. C r" -e > k,,c Z0U \ * * <S> BAR NOTCH METAL LATH AT 5UPP0RT l-J>> SECTION 2 2- " t rt i *c c* t. c SECTION C-C SECTION i-1 L. 2 l_3 m TT Wtllk*t*kV CMC'* fcS R6L INSULATION DETAILS eo 264.57 a-4. * eo I: ? Ill [s ii 229 *-B Oz -< ZV " I ,, =li :1l >- Z& CB - ft z& B THE BABCOCK & WllCOX COMPANY ftOllES DMBJON NS'JL AT l O Si i v" **-, 4REVISION* ^y' 1-^ Jr +' -- c.uys xsicri**.- 3-3* ?l>2 INTERMEDIATE TE^p BLOCK IWSUL. CLASS 3 ?.S*/$G YD. COPIES 5E an jn'C EXPANDED METAl LftTn. TE>AP-TAJAT GUNS'- \NSUL-ACV\ON :'V/:"xi"! PE_P TOS\A COtAP^-VS TO'a'Tak.; b L W sHO^ >UPPO WUCOK COMPAUr T ^T T f-rr ^1 uc :z o5 4l* \ * G>\ BAR M NOTCH metal lath c !--. *|c e c2< AT SUPPORT LUGS ~ :> SECTION 2" - 2" ! !*! I f 5! i -ut SECTION C-C )------------------------------- SECT ION "l1*' L-2' Uj- ,T ^A * IN SUL AT ION DETAILS so fcT *i-t- W Tses a. p H A n C O C K ft W it C O * C O M P A N Y *>*(> THE BABCOCK & WILCOX COMPANY TOW OPERATION OtOUF 3Y THE BABCOCK & WILCOX COMPANY *04L* WVtfcO* lNTSfc*l fUPWftCi BOUEE-TJR-Pfi 5C Mt *Tf S tVC-.\^ > \ * 5 )NEA)tPfUOVJ **. CSi ^ V \** 4^ -*v w RrYlftOMS TUtn V ttTTt'v ***''** t4 2i* >nE*W*D*ATB TtKV. SlKA IM*AAtlOk' ClASS 3 STUOOEfc VUftlL KMtSnfc-'B FIRST &(& Utt: Ofcjtf V&M&RftME (6&U.EB (FIRST Gt*S Egi^----------------- ^ | i i t r rfiecfcCTB-B e* A w bet** N>tcprrtO z cncv IH * m w 'lt f K ft W M C O X C O M P A N Y - 5>J0CX 1^0C"K C zI c -I t c CGik>G ViET&viPG&iWG ,c tii -r [A<- !1,` mmm w ^ C.5 1 i Mil CK 1 *^B t tPCCVTf*-* vk *t&&* kjdcvict>-2 bpoc^s ow QRDu? (TUIRW 6P* PfcBB, KQOCttTE^ in W?WG PJ^CF~fcv * cfei o4u/ 2i' WJT3?VvE.t^TE. TEw*,= HCOC. lUaOLfkTlON C*3S INtAJlAnON DETAILS L SECnoo - Pr ItrtM zr* -* X m i -- ' -- at * ' * CP ze^es a-S ---- . . U l\j u i THI ftAfcCOCK A WILCOX COMPANY tOlkit DIVISION KZ1[Z \ > R 6/2 -5-r^. INTEGRAL FURNACE BOILER * TYPE PF INSULATION f* FURNACE FLOOR INSULATION 1 note. 4 T-CT DES i D 2 iACtfC Str ? **' *->w' : m*? *** st~ U*A*r ^ 'ZrifTCZ: *5/**<*' *oc 4y t<o to ru>c$ wtm t* wwe. tc c* MVfcx e* cnc.. 1 .frWUUMS 11 * 12 (5 64 ffltTKOO OF ROAD mESM ATTBCWMfcNT DWfcRt "TURES AR AOPt TWAN 1%" ftPAPT. SECTION 1-2 | an Els 1 mmm. KCl INSULATION DETAILS SUPPLY g-g SECTION mu* wTS mm-- - 28454 ] j THI IACOCK Ml WILCOX COMPANY IOILIK DIVISION k:s. Xv INTEGRAL -uRNACE BCklER * TYPE INSULATION furnace floor ) 'AVgj *T+u - <tamz ^xx tn ro*^ ***.. w , y; - C. r> ! >rr- -ig-.A *- *: ;sy n-' S 2>. - <** _ >-*- OJ XOJUM * |!|i iS'Hij gj hit 1 * *1^.111 "Milip i iliil n FWii* 61DCI. t-'ETV JOINT S1W 3-S" *aoc*m s k.irf5 o'tj pmt i r-t4 u* o*t itk joim's $t*se: >------------ flWNSlOK JOMUTS Cvt 3-0* o>. ax SECTION THROUGH FLOOR flOGR AT FRONT WAIL n. r CJS om ;2 m &| ; r*. CBS ! *n-. INSULATION DETAILS i. SECHOTJ H- H M HTJ mm - . mm 23593 A- 5 >r>> ***%;* w w F* WiiCOX COMrANT tOUH DIVISION 6 -^cD rO*Fflc 10*HL'L'CtS 32-fc7 ser/mjg 2 \2>trr<rjCcr 5/*^. " integral eJ~NAGE B0;^R * Tycr INSULATION pci WISJON5 niti:> jc;t ** J` *C. HI i T; it?* * 5* i s c liil IlSIl | r|s 1 f5 S'- ; ti|?s : MsU* Hm5 fl;S! i|*i *8|SSi:*5*J*J * |; * X S 51 < FURNACE CLOSURi RtFRA; AT LOWER 'ORY DRUM 10 6* X 2 i _ f'-- 1 4 <*-c*e" stc .<vr ?----L! 6 ! y>. Mrvi 5?r > :- l SCA-.OOC: Ki'n TACK WtLC TC TU8S (R0 AOILCWS WlTNCC* 5^'*<i*C-S US 22 6* SHT' M? T A. -f -i ^ h--.- L I :/' c^DSC-if-: txRihSiOK .'Ois's y-c- c^n^s Tw* to r Y o ft wncox ro. rxti ttrr-m m* * 1 siot Cu lues: SECTION l-I boiler with Superheater NK r tfi : tMTt i< j i ewo. EES ' PL section i*i boiler without superheater insulation details SECTION 2-2 SECTION Ctp(TT,r>nrr> t nft * If, V- THE IA&COCK A WILCOX COMPANY ftOlLft CIVtSlON "2;* INTEGRAL FURNACE BOILER - TYPE PFi INSULATION merer See' gg/.V'g-; a/> r- >. 2 i^s.-'r-r i> FURNACE CLOSURE AT STEAM DRUM REFRACTOR r SECTION 1 SECTION 2*2 M. rr Ctl Ml It 14 Wi tu mm%. tti. INSULATION DETAILS SECTION t-L 23597 A- AwLOCKED DRn\vLr; DR 'K ' ' . THE -BABCOCK & WILCOX COMPANY BOilEt DIVISION IK Zlll c- Y . 3 a*/ 3-24-6*7 TMK EAiCOCK A WILCOX COMPANY lOlLlt DIVISION INTEGRAL FURNACE BOitEF INSULATION upper furnace closure at SIDEWALLS TYPE PFI __ i. 2 i*. 5ft" i j i >i\Xn 4. ViJli. ^ z*.^ 0A'.* T'V&SJS PFI 22 6 28 k THE tAtCOCK & WILCOX COMPANY ftOHU DIVISION i? /2 INTEGRAL fuRNAC BOILER INSULATION TYPE PP| MM W0TT0I omc me^rt rr" jt.fi r ? ?r e: closure at saturated connecting tubes detail a rrlli Mn 12 1} >1 CM Ml INSULATION DETAILS SECTION! O-Q 23598 A- 2 iNTcaAL-rvmAGZ to*. Eft type *n N?.JL*^*0W REAR MU CAVITY AT LOWER D*UM > */7-. S---7 C toe* m*v*z MCTAi i AT,CMC -- 3' M(*4. CX> A.AMCET WtUiTlOk fACEL *- .* "C w* KV- A li* CT*^ LATH. HE* MCV AAAMCT plate Kft?flCT* ft SICTO* i-1 M CIS ?*'** ' c*s IWSULATlOK DETAILS SECTION R-R-- T| 2B<02 5. s*s*c if:!* eist 55XCI 1:3*1 t({fi llsii *OIlfI DIVISION INTEGRAL "URNACE BOILER * type PFi :NS--A":0N penthouse sidewall at UPPER HEADERS 2.S*/s$.rv. ct>PPse eeopio CJCWi.KPEfr tTK. LATU - I nt-C-l'S p. j. i . iSrf.s-.Vc i!r :5 m' I V ; LOCS MIWRAL WOOL INSUl6T;0* TA^Ptti TK5HT TC PPC-V6N1 SfcTTLlNG i | ct""*- rr eS O.TT 2- 20* 59 tBS n RZL in Sul at ion de tail S SECTION c - c ClyJ K T S IHO -- - ' *COT 2 S^ 06 A--4- CCW C0 tli(te 1. i1e gg? , -z,, :i -t CI THE BABCOCK & WILCOX COMPANY ROilER DIVISION INTEGRAL-FURNACE 90SLER-TYPE PFi INSULATION 'kZI 2 3Y REVISION* ^!RDRA^TB.a"F JU. 77. 7c ,, A ^ 5 c UJ o5 NITOKM40 K ro H H o l 'i t r <411 H A flC O C K > W IL C O X C O M T 4 N V , AMO t o w>> w W j o*r- C> i a^ IP6L INSULATION DETAILS SECTION U-U c - T'29256 a H THE &ABCOCK t WILCOX COMPANY lOtLEK DIVISION ihtcg^av. PuHACe eot.tff-TvPr prV INFLATION UCNTP WND0X Z.Styse/yp. coeorr ieo*iw6 exp. meTfic wrtw Z. IK 23 ; -V 25,X- REVISIONS IMTI -0l-- !W- "5*XsCBfe W^ *=%> Tt t<* * 6.t//'orrv' Dc/'A' ft 'Un/nZ*srrrDo~r''~m3s.: I < ^XJ 5 ^.5- ;I i% s f2 ilOTzRmfcD'STe^mP.BlOCfc INSVL FI6UP APPUED SWO ftPDUffD ON' AU. UNITS 2 z MJTeRmgPiATE TEmP, block HJSv/LATroW 12 mg?W GftLYAWlteO FUVSCPCeKJ 2.5^ coppek Basing up. hncrfti uATH (PlGVTEKE*S UTO*) : sf t- rif :| El HI 6 r" ee tz t e. i - 6 _c XU0 k. 1. oK0 :L *?k fc C 5C a t t* 2?" T^mp *LO(X IWSULCniONJ .CLAS33 S.5*/SG.Y0. COPPEJ? &EAI?IW6 EXP mETAt LC\TH------------------- lOtPntOlATP T&W fcOCt IMSOL fitLD OPt>C/cD INSULATE to BACK Gt CWAWkJEL ^UOP ftPOuieP ^'iNTTPrvieDiATE TfcrrtP BlCCX m$vtTit.w class 3 ww. FT S.P r i ** J J & >MU T L.WC !*-* 12 r*e$H ^alvawi2EP PLvrceee^ 25*C0PPE SEGUING EVP. METGL LPTHCPiRElEPee IftTlQ INSULATION DETAILS SECTION V-V lc ..3S7SKL A- Z. esa. *aer t~\ THE MKQa ft WLCOX COMPANY TOWS V P\P^_ *ASTA\_ V.*&G\UG ^\U\SV\ 11$ H 5* ** :* ttl I ** *s V-KGGAUG N\T \HSV3V_KT\OV4 n f* g? < 11 W ILC O X CO M TA M Y ?5 f e9 *1 t 1c 3- c6 X* ue l_iVjJ.'. YvlAO>_,^. COLUfA^ P\P\KC> -- V t^/A" \NKMS, CSl S Z" P\?\uCr-Z -------------------- 3 1 VTC \UVOU! \': y^KW V Kwa \_~LM\- \ND\9lC\c.^.- Z" Vrt \KS0V V SiOnI-OPT PxPvSiQ, - 'Z11 *K\ \^yo\_ V'COMT Sv0MO>0'Mt4 $ Vs/SCX^St Sf^APUNS- Z." W\T IM^UL Uc" \U'wV^-6vjr^vj^ \o" P\Pvs^-4'` va z ~J cW kK {*11 S"Fttt T5\P\S5 t-^Si TCs JgLfr^cMPEKlttoX.mES P\P\V4G - S>` Cgos^ove-g. P\Pfc. % ^?QS.D E-Cot^ 'D^OSA- Z" K\T U'H, -- \"_ NAT. \Y4S\JV. Ml \mvjl g r * ^USt DouB\.t \_iK'rtF5. UfvQ,Q\KiQ> x>OT ^.^15 Ok* PvPWiCa T.V BOR. 0-C^'JiL ..Vom.g.1.-. 0 as&c, IHSOl>T\OH DtTAW-S 295..3\9&-\0 s-y-t. ~t M7-1U S"- 2017.53 <-Q THE BABCOCK & WILCOX COMPANY INDUSTRIAL POWER GENERATION DIVISION EXISTING PFI-2845 586-044? (UPGD) 546-0881 (IPGD) TAB #5 DWG. NO. APPLICATION DRAWINGS INSUL. uA^. RE. 3729A-8 Insul. - Applic. barriers X 3731A-4 Insul. - Applic. over stiffeners X 23579A-3 Insul. - Applic. tubes and pipes X 28405A-3 Insul. - Applic. blanket 26438A-5 Lagging - Applic. over tubes & pipe 28445A-2 Lagging - Applic. over drum ends X 2S091A-0 Arrangement removable type air vents 29092A-0 Arrangement permanent type air vents 39732A-2 Lagging - Arrangement around access doors 39734A-9 Lagging attachments 39738A-5 Applic. of inner lagging X 44433A-3 Lagging - Applic. handhole covers X 64419A-4 Insul. - Applic. over safety valve X 77804A-10 Insul. - Applic. I.T. block X 97085A-2 Insul. - Applic access door X 970S8A-2 Lagging - Buckstay end conn's X 97091A-3 Applic. horiz. barrier and inner X lagging conrner constr. 97101A-0 Insul. - ApDlic. over thermocouples X 101955A-0 Applic. refractory in access doors 101956A-2 Applic. refractory in access doors 101957A-0 Insul. - Applic. 8 access door X 101960A-C Insul. - Applic. sootblower wallboxes X 101963A-1 Insul. - Applic buckstay X 101964A-0 Insul. - Applic $ buckstay X 1C1965A-2 Insul. - Applic. I.T. block inside X vestibules etc. 1C1997A-2 Insul. - Applic. 2 15" x 21" access X door 200007A-C Lagging - Applic. buckstay conn. X 2C3C22A-C Insul. - Applic. inter, temp, block on inner casing, membrane wail, flue or duct & inner insul. support X 3Y3U2 Insul. thickness chart for tubes & pipe 3Y3U3 Insul. thickness chart for tubes & pipe >: X X j; >: X X X XX .* X X XX XX XX XX XX X X TAB #6 DWG. NO. INSUL. LAG. REEK. 20795IA-0 Insul. Key Arrangement Boiler xXX THE ftAftCOCK & WILCOX COMPANY fOWB GiNSJtATlON D(VISION 3Y &A hr INSULATION APPLICATION FLUES,DUCTS PRECIPITATORS AND OTHER HOT EQUIPMENT EXTEND INGUL SUPPT. TO CORNER REVISIONS 7 **/*' VZ>kAuj TBfl $ W^*~iU c: **> lUVlt lO^t. Vf4CS c vtr~,t.A* ;; t- 2*< INNP INS'JL c. ;3p- STIFFENER PULL INSULATION F}RWLT AGAINST INNER NSUL. SUPPT. AT BARRIER ELEV. TO PREVENT STACK EFFECT AT THE OUTSIDE AND INSIDE WAVES OF THE INNER INSULATION SUPPT.--------------------- OUTER LAGGING It ~ Ra r A?R I v A S !J p p 0 R AS REQUIR ED HC- SURFACE INSULATED BARRIER-IQ-Q MAX VERTICA. CTRS. VERT. THK. EQUAL T0 OUTER INSUL. ! i . T HK. I-NSULATION <2 0 5 i t c ?"s v1; tZ i 1 < ^c cc 2f -o ill <!; :c !!!s l: , - ,; s: r5 i ; :3 c w- Barrier suppt. e< SECTION A-A l. USE THERMAL BARRIERS ON VERTICAL HOT SURFACES WHOSE SIDES ARE 10*0" OR MORE in HEIGHT. 2.THERMAL BARRIERS ARE REQUIRED ON ALL TOP AND BOTTOM SURFACES WITH 15c RISE OR GREATER-SPACE ON1 APPROX. 0^0" VERTICAL CTRS.* BARRIERS MUST FORM CONTINUOUS BAND AROUND HOT SURFACEJNCLUDING closure of ALL CORNERS. Ji I I V ; ; t x * ea l. . immune inn* 1 i PUT, tES 1 | >.M(I * EB$ e k5 TKUfcMAL BA^EIERS ON IklSULCiTcrj QgipMENT r~- -- -- D HOT K.ALf me : D l^ 1 1 ^1^ ^ *** *t !2 3T2.9 5f ; *- p f *>' **- *** t5 SM- ** ! in (;s M| * VI =li si l ei tc x u THE BABCOCK k WH.COX COMPANY SOW OtYtftOM iMSDLFtttOVi 3F*LCW\ON ?LU6S L OOCTS UK. , f e-'-rs 2 twsu- ' "THtcg**^; j^g <U^ ~ TITJ f^-ju^r -^j UJ..W Rtl.n *.!.> > _*_ AWli OK CHANNEL **e St\FTENEfc WEAGWT SnE*TUWN AWBCgNrt IUSUUTOM TWtCiCNtSS Kvsrq ANCLE OK CHANNEL STffTENtt. UEStfT ESOWl "O PfcU&CSKT \USULWT\ON TH\CKMESS UNimvau cum vau u j m j u i ------- quvqnujs------- ANCLE OK CHANNEL RAE STmHK ?\WT LESS TUAN. ADJACENT IViSUVKTVOK 7M\CWESS MOTES- Ajcnc cd*t5 ** ver to *e conooueed wet of \KSUL*moW TWICCNESS S^VP\eD. %'JOCK 0\J* ST\PTUe*S SMALL We ?*STSUD UMEE, OE ?IVJ STU^S. *Tct.S CS.t kel BLOCK INSUITTOU OfcK S^FEDJEES 1TX 5T^\ f- . THE BABCOCK A WILCOX COMPANY ftOILER DIVISION integral furnace boiler 'Ypr insulation pfi 21 , ? - *1 - 2 hh;c ; r; P!w wuc rrr r>- ^ rv: ? I cm; -c. ' IggP;;;;Tie>. :k.?: '.w BLPiMkfcT 0PPLICRT10W $ULATiON htyST be SECURELY FASTENED ON 12* CENTERS 0* OvRna> c?s S? TH BABCOCK k WILCOX COMPANY 04L* tfY&OK 'NSwu^'rtC^ u ic^ KACTfti. LtnC^iMG iWaGHO >K|S'JLh*T\OKj Oft T'JKS RTVlSiOKS ruj fckTT aln. 7 -Q8C mj.- . p* i Tt ?$ ?>r/wWr *3^ v_v>iij *i~ iT . t ^**' C fy 1 Dfc V. t ^ k ft jTbs; A ^us*cr accti+r. **' v. s 5 JtfVO sw Hoc. : Tor Sie&m* * | 2"^hj o^ftLftft uonw CftvMO^c. CCTSft fcOGS HO - - - - - - - - STANDARD- - - - - - - - - DCKFD DPAMI? ni?AW!lir 5: X* * ;i C1 S! i2 I * ?*? t t e 32 o" CfcNTtES t3C 0t~> KflCt SCfcfcU-'S IK CVtftL^~ :'\ I r*r< *7 SELF TAPPING i ALL*rt>ML>Vl OC COfcMIfcA* PLOTtP *" cnsujow vrett swevt meiai 50tiwi 7"T . OUft\.ftP 2* *rt^. OOSPvW* VJIT* ceii^Peo cxrree toG*. im fltWwLeuLHSt" r>OSJT K>K VORilOVTTUU *\M Wfm StSS\tt=t> ovKW> iu r r= ;} s *I * I YERT\CW_ RUMS 0 k: tts TUBES AKJD PlPfcS t.e l i- T 2*^23 ^-S THI ftAftCOCK A WJICOX COMPANY totut orvuiew insulation AAPUCATO* octal lagging 3Y A 3v 33 s/s-k-e; A * r o r * m o o < roI cur ocf m immk T9 *urr O^ttoMC FO* OMum ruw. CUWT t to c mcmmili ro* MOrcCTCM ', VTiHCTlTO cd % < TXU DtAWJNO K THE PtOPttTT Of THE BABCOCK & WILCOX CO. AHO IS IOAKTT UfON GOtOmOH THAT If IS NOT TO II ItPtOOUCED 01 COPIEO. IN WHOU Ot IN PAO. Ot USES K>t PVt*:s*lNC INPOlMATiON 70 C'txm. 0* POt ANT 0JMI1 PWIPOSE emiMfNlAi TO THE INTEttSTS OP THE lAtCOCY l WUCCX CO*PANT, AN? IS '0 > uovcrr.tnuiNt? uhoi; the pouipwnt shown keieon is tiotected t patents wnc? o coNTtouiS it tn: iaicock. t WUCOZ COMSAJ4T APO AKT INPtINOlt OP SUCH PATENTS IS UAftU TO P10SECVTI0K. -AVShIC'*' l.lr*tkAKL r" 1 ' TWJ BIAWNO ts TXI ftOfftIT Of THE BABCOCK & WILCOX CO. ANO B IOAKO VTON CO*mON THAT ft B NOT TO 61 tVlODVOO Ot COflE6, IV WKOU Ct IN fATT. Ot USR> K>* K/IX3K1NO IKJCtMATJON TO OTXEU. 06 Ml ANT OTXU fUlFOSI DFTXIfAINTAi TO TKt INTOUTS OF Hit 6A6COOX * WUCCX COttFANT. ANP JJ TC 6i trrjxKte noTicno 6Titfon uouer. thi wujfmwt shown kouon u patents owkcd o* contiouip it tks uacoc: i WUTOX COMPACT AND ANT INHHNCa OF SUCH PATENTS IS UA6U TO PtOSECVTTOK, lt !- c. i * f'^ c n nortu/rd w im m * Sl .1 ti r <McSs f! :ni! -t cV * h; II .- C t2 * -c Il 5v lil m :x i iy * hi j cs ,, W UA p * TUPwiCATX THE lAftCOOC & WICOX COMPANY mot* IWSULATIOKI APPLICATION METAL LAGOiHO ^OlA. SLF WELDING ANURLtD STUD/ORrVf PLATE ASSCM- Jv vA 3/23 Jii* .- *rvt*lKS _ ,'R--H----7--S---7- l IS APPROX. 2" S^. r ALUMINUM CAP NOTES- 1.STOPS POR lAG&imO SHOU-0 Sr APPLIED TO THE CASiHO BE^crr APPLICATION O? THE INSUwATiO*. K5M, NELSON (SETLOCK) OR tq\JVALENT FASTENER 2-ALL SElP WELDIWOSTUD devices Should BcSUC* THAT SuRn THROUGH OP CAGHKi. P*.AT,ETC. tS IMPOSWSu&.TH'B MAYfc ACCOMPLISHED STCURRENT limiting devices*}*equivalent. r' STANDING punch OH SEAM, BUTTON 6h CENTERS 3. ON OUTDOOR ALUMIUUM LAGGED JOBS ANY PORTION Of THE FA5TEMER that IS EXPOSED TO THE WEATHER SHALL BE MADE OF A MATERIAL TH AT VA WILL NOT STAINTHE LAGGING. MIN. PITTSBURGH LOCK 4. WHEN SOBGtRTS ARE USED OVER HARD IH AULATtON.BEND l/fc" FLANGES fiat AGAINST SOBGIRT WCB TO ALLOW LAGGING TO BElN CONTACT L/lTHTHE INSULATI ON -s?" SSUSGIRTSCWHEN USED) SHOULD BE 18 MSG ALUMINIZED STEEL or panted per dissimilar BUND RIVET OPEN-ENO TYPE SHOWN, USE CtOSED'ENO FOR outdoor areas metals SPECIFICATIONS WHERE AL U M i HUM LAGGING iS USED AND C S WHERE Galvanized STEEL lagging IS USED- C* TH S/Me* Di A. SELF WELDING KNURLED STUD/DRiVE PLATE AS5EK-SHOULD hi A$ MPG'DBY H. a. jonES co. Dayton Ohio OR EQUIVALENT- 7. *14 SHEET METAL SCREWS Should &E USED whew attaching subgirt to DRwe Plate assem. CD SCREWS are REQUIRED For OVERHEAO SURFACES. J J.l. TYPICAL E.R-S. METHODS OP FASTENING ______ ________________ tc g - ? - fel ; S" 39 734 *. S I LOiT <&7 TW lAftCOCK A WICOX COMPANY IO&X DfVt&ON INSULATION i OUTER LAGGING APPUCATION METAL INNER INSULATION SUPPORT ? IR lA \ 1 !EV**>gf7 C,fa{v l*3rrf ;M**-Urlltk TVLgSS*- cutirtw. i**-'1 ^/u^c i; '?L vC- u.i. --^ k'<1' JV*e< W /AT* 7i *7^ it 1 RE V. APPLICATION _ j 1. -2 C-C i s< 58S |e| nr \ ft*n S-13-^ Jj * 3 5 ScCHONTUSU CMAKJGt IKi STlFFEUfcB DtPTM I A /,!/' * *r> : iVWi riPA-A'i^G 35T3S W" KM-ieCTIi A-S m nh n p n w j n h r a w in h ell vv > ; 5t !0 ff f2 ;I . *I * 0C' ;i -j * !* J I5 * }i -l Ai [e * V :*t is6 !t S< s :S iv e ?'I j ue 2 ! 5t 5l ; i>i *vc j;* [iZ* > THE &A5COCK & WUCOX COMPANY WWH GENERATION DIVISION APP L ' C ^ ~T ! Q NJ C. : i-t:- : ^ fL&USET> __ WZVJl JOINT (>AE\UEO LETT Or THIS LIUS) UJLIOEO NCZ2LS 0Q\ttT OP This UNE) T H f A C O C K A W tL C O * C O M T A fir. AMD ^ l P. 1 -*are a ik- O- 0 CMC-V '- Vfc* `p ?,C. AZvt^K35Ew\E>0T Of LSS&ttOS PD Sf'f&T^' VALUcS n^'T * r /. > rs V-, -- W i Jy in i ir >h> aer 6c BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION srcipsr 6A TVCTTT ITTfW 3T* t WfcULKT \ OU ftSVt**ON APPLICATION OF Sfc TS^PEfSxruRE blocs; \usulwioh FF^jig&PS^AJ. 2. 2SSL piaster urrvac * /C 1^ PIKA STUDS TO BE. SPACED OKi \E mll. CEKIT EPS OVERHEAD AMD \6" MAL. TESTERS OA VERTICAL OR HORVICUTM. SUR-ACES 5ECT\0K1 Av-Av ttETlAL LLGGAMGj--------- J V 50?EWS WITH UEOPPEUE OP. VlUYt WASHERS I BLOCKS BUTTED TIGHTLY TOGETHER TO AVO\D CRACKS 4TEMP MAT (AS MvPLO. SY PITTSBURGH CORKUKIG OP. EQUAL") STlPPEKiER L-CASWJGj rt Z. GaA P\U STUD r \utejemed\ate WITH SPEED CUP.- TEMPERATURE BLOCK. PI U STUD BE.UT OVER. \USULAT\OKl 131 A.FTER APPUCXHOU SPEED CL/P OF LOCKED DRAWER DRAWING ioll -S.BP I^L-WP TYP\CAL fcPPUC. WHEfcfe .. A.O.D R.C.H 'X.T. SLOCK. SPe-OFSP n L-- t * L"7 sr- nnsoc* a-io .c? THE BA&CCCJC & WECOX COWANT POWBt GB0tATtOH PIVBtON im5 jlaton 35$ic<.jJoe< ck v?tf DOQi'S 4v c?* r 8U 2/12- \9- ?2 *TVt*IONS IIM I I M * 1 --11^11' { "C2 I^ i *"** -r ^/ufuvO tuyCCf'-e - rxact.i -U 4 a^ec ? A UVlk 6TKJ* Ju iffiocct<t *: \ c&ocr^" ; 1 t 5 \NSUlACT\ON AKj ; t OOTcH C2VEE1M * I .AS SPEC\?\eS c .c l. PiLL ASEA EtTUJEEKi TUBES AtUD C^SlKi WITH KAOCAST PUJSH VttTH TOP PLATE. APPLIED \kj field bv b^icc u>oac COUTRftCTO*. &sxe G t S ei-e u i_w ^ A-B ft 6 SMALL A--CaSS LOCKED DRAWER DRAWING J-w. STOSS * 2 ;Z THE KAftCOOC & WACOX COMPANY POW* thwmtkw wvsiom IN9ULRTOK APPLICATION N\SAl LAPSING 2 "F-- rrn 3/3- RCV[S1CW* TTST _U_ |visc> TP if^rr /^A-y SfLTCC Jm, Tr. 2 9m t ie S r&WALL Stir TMWH 5QSV3S SUCKSW END COMNECHOKi VJTTUOUT OWES ze _ 46. 5* k 52 s it '5 t _ 0 Jrt oI t- * fy ! 5i . '; I51 v*o 52* lei i z ox 11 1 1 8* i fll 'll I-1 '1 d! 1 f fcJ rj !i ll SECTION C-C II III ill j U 1 1 ' !' - !; : w 1 '. i ! TT-7 1 1 B*1 ~c^k.=i B-J SECTION B-B ' saskcocncB surrorr SRftce B\X*ST sv IA6SIMS C&*JTRC\CTOE to BUC<STAX END CONNECTION WffH -CONES. .T t t * tMa tGES. c-c ,, UuJ.F, ^b A B P. gOCKSTPN 3Nt> CONNECTIONS bQGKEQ. DRAWER DRWWtiG. 1fcCAt Un 9-Z3--II 97088 11 ca {o ri ce; -lize,, ST. ru)fc OR. our *2 s; THE ftAKCOOC & WfcCOX COMPAMT PO*m OMKATIOM OCVISION IN^ULftTtOM APPLICATION METAw 3r &A 'A- / =- e--r* Rcvmiot< j L**? /oy^ w.y] 7*r r^-i-4acsr^ /**>nr ^ -`X.rj?^*wO n/iw^'fD l ****!< i+sttfA . i TS | f vrr f S. 166&CI wUt '^6 EXTEND IKiSUL. SUPPORT TO CORNIER OUTER lASGiNS INSULATION !kss\jl. support PLUG UiElPEO TO STlFFEUWS !4 b-wKL W SELF WELD STUD SEE i DWG. 39734A SECTION 1. FOR THERMAL BARRIERS ON VERTICAL FLUES AND DUCTS WHOSE SIDES ARE 10-0" OR MORE IN HEIGHT SEE DWG. 3729A i e * 2. SUPPORTS FOR INUE* INSULATION SUPPORT TOSE OW '*0" MS* CTt&. P105 UJc'J^THRee CD times tREH S*K~ VNIOTK. ns 3. AN ALTERNATE SYSTEM FOR SECURING the INNER INSULATION 5sS SUPPORT TO EXTERNAL STIFFENERS FOR PLUES, DUCTS AND ih OTHER AREAS WHERE the inner SUPPORT REST AGAINST THE EXTERNAL STIFFENERS SHALL BE * HILT I FASTENER SYSTEM * OR EQUIVALENT. 3-EDn IDP8 PINS PER SHEET WIDTH . PINS SHOULD BE PLACED AGAINST THE LOW SIDE OF CORRUGATION, tHAT iS THE CORRUGATION N DIRECT CONTACT WITH THE SUPPORTING ktMBEP. DM 3 5 P oG a LCM C UJ , P *-. Di.3P INNER- NSULATtOH SUPPCX' OVER STIrPEWEi2S *z5. - 7* 37091 ' k eo z ec I ?c 0 s e< zc c e v-; *a X I. rC foc Z0 Cis %S 41 \ ZZ r\i. TK BABCOCK WUCOX COWANT powh osksxadon wvis>ON INSULA ! ION EXPLICATION PERMANENT THERMOCOUfltS INSULftTE THERMOCOUPLE. OT MOT JUNCTION FOR ft LEMG-TH ^ WHEN TUBES, WDR OR DRUM ART MOT COMPLETE^ INSULATED, ADD \ Vz MED TEMP PREFORMED 1MSUL. IN THE AREA SHOWN. "HE 3L0CK to TO BE TIED INi TWO PtfiCES WITH STAINLESS STEEL BANDS OR WISE BV iMSULTiON contractor .v 20 _ c SECTION A-A ix i8 -u :5 5>P let**-* L Uj a*cb my LGS--^g-S j TSP. THEEWOOOUPL 97 IC\ rc tc 2 c*L * c * w* Cc c * \ !r I INSULATION AS SPECIFIED THE BABCOCK t WILCOX COMPANY POWER OENEftATION DfVlSlON C > . , t *< > A S>-'3 ; / \ - ,9 -n INSULATION APPLICATION QOOR3 [^>K lOUFE. iHACHPr.*: IOC-- 2: _ 1-* c EXPANDED METAL LATA sc SHOP APPLIED ACCESS DOOR INI FLUE, DUCT 03 PENTHOUSE. Czf * ' INSiDE OR OUTSIDE INSULATED NO REFRACTORY. PINS AND EXPANDED METAL -ACri REQUIRED FOR TEMP. isC' AND BELOW NT AX . TE. M P. WITH REFRACTORY UNIiNO SS2 . S I l ce ^x K* % vX L C c Cc f si ic ?: rl0 it?" INSULATION AS SPECIFIED ACCE55 DOOR MAX. TEMP. 1500 >.u , -c j } ACCESS DOOR5 01^5 C1 > z 5j; k 0 l 3ta ::I 23 -* - 2 I " 3,, :i-c2 < VC C THE BABCOCK 4 WILCOX COMPANY POWBt OBiBUDON DfVISION INSULATION APPLICAT ION DOORS 3> :L N; OA U3 \-//r*B-Sl !7vibiOJS OMSK ort o**Jt\pr ** rium , OIL. 52 i.3CCO*P faC* AUJf* INlA ms plastic chko**o*r1 icwgo roo* co MP INSULATION At SPECIFIED i* KAOCRETE & FIELD APPLIED z' >* i Yn t i ;; - .c INSULATION. SHOP APPLIED EXPANDED .METAl LATH SHOP APPLIED ACCE.5S DOOR-REFRACTORY LINED : c MAX. TEMP. 2200 3PICK JN OPENING 3 . c5 * SEE DWG I0/997A ;ic jor ;c KAOCRETE B FIELD APPLIED INSULATION AS SPECIFIED ( (,i ii i i . T '' i p n r ,M tw p L (w i* i 8 INSULATION o I SHOP APPLIED EXPANDED M7*L LATH SHOP APPLIED * 0 ACCESS DOOR - REFRACTORY' LINED -. a< ca FOR TEMP. OVER 2200 H z- c 5*2/ WATER COOLED ACCESS_DOOR DWG 32D39E OPTIONAL u* S.A-5* eMK-e mscs M-e ACCESS DOORS cm otw#; mo C..TT 1 * 1 2 " 7 *2. IOI <5 5C. re ID. <*' THH KAftCOQC 4 WILCOX COMPANY POWB OOIBUTION WVWON IM3ULAT1QNA_______ APPLICATION ACCESS DOOR oY O* m , is A C t/ !--.S-l rscr* REVISIONS ^- 30w *0* Sr 111 insulation AMD OUTER COVE.RING A* SPECIFIED FILL Af?EA BETWEEN WALL SO* AND TUBES WITH KAOCRETE S FLUSH WITH TOP PLATS. H I O * IV tN IN lm tll M O J n 4 V IH IO IH * >* 2< k20u. 0 2 0k X0 u;e iS5 i5* 5s c IJ t2. c" : *,, *0 ? 5W k ** s m ** l ol ` S* in i I ** wr ** ACCESS DOOR meh&rane WALL * *CAkX mo l*s p* kATw i " i &7 1018 5 7 a- C THE BABCOCK & WILCOX COMPANY POWEK OWttATlON DIVISION INSULATION application boot Blowers &A* # L=>A I2RI REVISIONS WcmriM c- Hi INSULATION AND OUTER COVERING AS SPECIFIED .z ;'? -r c | !I Zoi il5 *! 5 is 8 Is 52. (I * > 2 i ,, c : 5u k JU l oi , J`* I;* Xu0 c o ki ; t 0I S- ADVM If 5. 'Hie y CMK'O * FOR PRESSURE OR SUCTION SOILED soot slowed MEMBRANE WALL U>0 DVW MG ) o, M ATT i -- 7-7 2 ! O 1 S G C * o r^v/ root* kOo im> CKID DRAWtK UKAWiWu ^ C6- cc v If1 lJ2 i,, -cc Zt lJ l, o5 TH *A*COCK l WILCOX COMPANY POWIft efNfKATON OrVtSION SY -/ tM IN SUL ATI ON APPLICATION AT SUCKSTAY REVISIONS MC . 1 ! r,tl. ! *,; >Z ;0 0o le * * scw :(i ei:e *2 is 5c l3 : : r<l . cJ CV l ;. *0 ;x m l i tf cC c < h M S.A FOP PRESSURE OR SUCT\ON 5>LR. C*0 INSULATION at 5UCKSTAY STUDDED WALL :-2fe-7 101 904 A- 0 rO* tMt 4.} THE kA&COa & WILCOX COMPANY POWM MNSATtON DfVWON iNit>UlATiOM appli cation INTERMEDIATE TEMP. >LOC< 2 3Y GA tM 7/= REVISIONS TTCJRr nr1 l_*TH X *,ft~fc' -- <15 t.af - u ;:i SLOCKS JAMMED TOGETHER *s TO AVOID ANY CRACKS i W IIC O * C O M P A N Y tu li i OCKIr j.f ;v,Lf: OHA /VI? 1 ' OP LATH SHEETS SECURELY TIE EDGES OP - LATH SHEETS TOGETHER cfTc < t WITH DOUBLE STRANDS Of TIE WtCE ON Gv MAE. CENTERS. ADEQUATE LACING op LATH SHOULD BE PROVIDED AT LATH CORNERS AND EDGE* TO prevent CURuNG. VIEW **A - A* * tc ` ;c 0u 2 i 5x `*-- SV ran *t S A S ewc'O i.rr vr AP^p PIN STUDS TO E 3' = i?ofi EDGES AND ON \Z'1 *. W MAX. CENTERS ON overhead SUR FACES AND On MAX. CENTERS On all other Surfaces, 12 GA 5WG Pin STUD INSULATION FASTENERS BENT OVER AFTER APPLICATION OF LATH AND SPEED CUP Z.5 /SQ.YD. syp plasterers lath SPEED CUP INSIDE INSULATED VESTIBULE, PENTHOUSE < +cm*x AREAS WITHOUT OUTER lA&iiWG Of FINISH IT* i v tin 2- 2'7 2. 101^65 *-Z 6*0 s2o :em .zo o:i i;i " * 0 0* 0 2 1t tS 3'air coo OBSER. WH&NJ RBO THE BABCOQC ft WILCOX COMPANY POWSt GWHUTION DIVISION INSULATION APPLICATION DOORS 3Y Qe*) G>A &J3 / //o~q.&z REVISIONS feiCR&> we. oat 1 J | eeacetmow oeie I"' | | 1| . it OM t i. ASiQVfiL THIS '/KEN S" Ai R. CQQCSD OE5E^. Dggg. TNCLUDEU. U? \ riRE5R.lCK ^SOT REQ'd. OKI I3LATESR COOLED COOf^.) . 3 z Vl-EW "FROM NSIDE. FURMACE. s^ct\om"A-A' ^Z.\8>54G shown) is* >r2.rM access door wLTH:^ErR..R^i-wsK:C)W(5;3^Al t ! j; WHEN l5x 2.T DOOR. LoCAT\OM OVERLAPS STD. AOCATIOM FOR. 3k OB5ER. DOOR - USE ARRC^T. 21&54-&E. em *T.P.S. dirt (.no A R-*< *we w"' lEuau: Access >O.Ll ddo.el w i r.H &suc&.w op&mimq- eewe: we. lOISSl A-2 4 wicox com*" INSOLATION APtUCtmoN METAL LA&0 ST (1*0 6A 3733 1/ 3-7-77 f ni ii SeLF-U^tWfr STUDS u it HHV6 04 &TTftCVlMEVJr !h if subsist INTESMENPiTS SUPPORTS SECT) VDHEU i; PvBHED SWEET FTC6ED5 MAXIMUM ;; euw>oer spaw it i4xisap*upwM& sc*ew evtrr CtwtP BUCKSTW LUG fi! Ll'WOMNG *aI t? h'4 TOLERAMCE BOCXSTW n.t&UV4BS MUST-1 BG FABRCKT& TO WEEP s 3* mon pace Sfcue tS? TV|E TCP 4 BOTTOM OP EAQ* s;i BXtTTAV PLAUOE TO FACtUWTE TUE COfeVIES if! PLASmUG*. stn\ou B-B /ECA.x a" X 7" Clips ^A^kCWlO '+fO PZ-2 Sntrr Sl&PZD 3E.H1MD 3DCHSTAY. DO MOT WELD Clip MOST SLIP 5tHiMD 3DCXSTAy TO AllOn^ FOR xPAtOSlOM. CO c_ < J.E.&. BUC<STAT CONNECTION 100007 A O CODE. fc>0 THE BABCOCK B WILCOX COMPANY UlON INSULATION APPUCATION INTER. TEMP BLOCK APPLlCATION 3Y (ICM) (o A 3Y/. IO/^g-79 INTER. TEMP BLOCK MAY BE APPLIED USING "R GA. BWG PIN STUDS AND SFSED NUTS. STUDS TO BE OH lB*\8T MAX.CENTERS OH VERTICAL AND Top SURFACES AND \?*\V MAX. CENTERS OH OVERHEAD SURFACES. ALL BLOCK MUST BE BUTTEDTl&HTLY AGAINST ADJACENT BLOCK TO AVOID ANY CRACK. ON PRESSURE F\RED UNITS. CASING, FLUES. AND DUCTS WILL BE AIR TESTED. SOME OR ALL FIELD WELDS MAY BE LEFT UNCOVERED UHTlC AFTER THIS *2s TEST IS COMPLETE. AFTER TEST, FTLL VOIDS WITH INSUt. REQUIRED.- *V e .S* < r^.v, sc ta t4 e ! ! STJD TO BE BENT OVER i i AFTER APPLICATION OF Hi SPEED NUT. o;: w I oil 3s: >i{ ;i! " INTER. TEMP BLOCK ON CASING -INTER. TEMP BLOCK ON MEMBRANE WAU M.*. i < OUTER LAGGING ( .o !rS,`s=oy ?Si ei: S x I0.2I P1NNER msUL- suPPoRT FLUE OR DUCT inner, temp block on inker insui.support ^TRL TPS - ___NJM CAS'MG JkND INKIER INSUL SUPPT <bO te*u * 2*20*7S =" ZOiO'dZ*-0 D I\A U tK U ) HRAWFR DRAWING l & M M at MO. 1* THE BABCOCK & WILCOX COMPANY INDUSTRIAL POWER GENERATION DIVISION EXISTING PFI-2845 586-0447 (UPGD) 546-0881 (IPGD) The following are design temperatures to permit determination from .3Y3U2 and 3Y3U3 insulation thickness charts (attached hereto) the minimum thick- nesses and layers required for exposed pressure part lines, drains, vents, etc., and connections, when insulation thickness and layers are not already specified on this job's insulation drawings. Saturated Steam at Boiler Pressure Parts Steam at Superheater Inlet Steam at Superheater Outlet 501F 501F 750F Table 3Y3U2 for "Continuous Service" does not include soot blower lines or drain lines, etc., after first valve nearest supply connection at header, tube, pipe, or drum. Connections included are for exposed valves, fittings, nozzles, piping and tubes. Table 3Y3U3 for "Intermittent Service" includes soot blower lines, or drain lines, etc., after first valve nearest supply connection at header, tube, pipe, or drum. Connections included are for exposed valves, fittings, nozzles, piping and tubes. INDUSTRIAL & UARZKE EEPT. INSULATION 5U 2/1-10-72 tubes a pipe INSULATION THICKNESS -HO*'1 HAL '*1 lilt o-i-i/r 2 2-1/2 3 3-1/2 4 *-U2 5 t 7 6 9 10 n u 1* & 0VR 0-300. T 301-400 K? 1 1 1 1 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2 MT 1 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2 2 2 2-1/2 2-1/2 2-1/2 2-1/2 401-500 KT 1-1/2 1-1/2 2 2 2 2 2 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 3 3 3 501-550 MT 1-1/2 2 2 2 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 3 3 3 3 3 3-1/2 551-700 701-400 01-900 901-1000 1001-1100 1101-1200 MT 2 2-1/2 2-1/2 2-1/2 2-1/2 3 3 3 3 3-1/2 3-1/2 3-1/2 3-1/2 3-1/2 3-1/2 3-1/2 MT 2 2-1/2 2-1/2 3 3 3 3 3 3-1/2 3-1/2 3-1/2 3-1/2 * MT 2-1/2 2-1/2 2-1/2 3 3 3 3-1/2 3-1/2 3-1/2 4 4 4 *4 u KT 2-1/2 2-1/2 3 3 >-1/2 3-1/2 3-1/2 >-1/2 4 4 *-i/2 -1/2 4-1/2 -1/2 -1/2 . MT 2-1/2 3 3 >-1/2 >-i/2 3-1/2 3-1/2 4 4 1 -1/2 -1/2 -1/2 5 5 5 MT 3 3 3-1/2 3-1/2 >-1/2 4 4 4 -1/2 -1/2 5 5 5 5 5-1/2 NOTE: USE DOU3L2 LAYER CONSTRUCTION FOR THICKNESS TO RIGHT OF HEAV7 LINE. MT MEDIUM TEMPERATURE INSULATION When tubes are insulated in bundles, use the maximum inside dimension of the bundle to determine the required insulation thietoess. For instance, if the bundle cross section dimension is 2" x 14", use the insulation thictoess specified for 14" pipe. Where KT Insulation is specified on the job drawings for bundled piping, double layer construction is required. M f IflC wwa wvw^ni POWER GENERATION DIVISION iNDusmAi ft UAKXNE DCPT. INSULATION TUBES ft FIFE INSULATION THICKNESS 3Y(IJ) 3U 3/1-10-7 On intermittently used lines the insulation may be reduoed as shown in the able below. For soot blower systems that are continuously in service indoors, /" oust be added to the thicknesses shown in the table below. On all inter mittently used lines, full insulation as shown in this section oust be used up to the first valve. FIFE .SIZE 0"-4" TEMP. THICKNESS OF USD. TEMP. INSULATION (INCHES) 150-500 551-800 801-1200 1 1-1/2 2 {in two layers) 717Z SI2E OVER 4" IEUP. THICKNESS OF USD. TEMP. INSULATION 150-500 501-800 801-1200 1-1/2 2 3 (in two lavers) I 6 Babcock & Wilcox i McOtnrwtt company S'EG^AU Fu--N\ct BOILER -TYPE *=Fl INSULATION key ARRANGEMENT REVISIONS miCaM*O ii 1? 85 `sI: SI Sr Si !? I It t* t fwz i Oo Is 8< If ir fi! esSJ n BEC'r PR it e c -.agging reqd to form closure II AROUND BOTTOM OF UNIT if ft 5S<o-OAAl (u PCs p ) 5A<s *&8l Cl ^Gr D ) situs ^ ^ CMS t VMl, nSulATiON details ~'*2.0T=i5l a.O fpS* |D * * MAC MO * CATALOG OF INSULATION INSTRUCTIONS In order to consolidate instructions regarding the general subject of insulation, refractories and their application, a ' Cat alog of Insulation Instructions" has been prepared, a cotv z: which is attached. We would appreciate comments or. any phase of these instructions that are not clear to you, and any other questions on insulation about which you may be in doubt. This catalog does not supersede any job drawings but is designed as a guide to help interpret the meaning of the drawings and to supply information on insulation and its application which may be missing on the drawings. PART I APPLICATION TABLE OF CONTENTS Introduction............................................................................................................................... Erector's Responsibility in Supervising Insulation.................................. Insulation Fasteners............................................................................................................ Reinforcement tor Refractories.............................................................................. Refractory ........................................................................................................................... Block Insulation.................................................................................................................... Lacing Wires........................................................................................................................... Blanket Type Insulation................................................................................................. Lagging.......................................................................................................................................... Finish Coats and Reinforcement........................................................................... a. l/2" High Temperature Plastic Insulation on Expanded Metal Lath ......................................................................... b. 1-1/2" High Temperature Plastic Insulation on Expanded Metal Lath.............................................................................. c. l/2"High TemperaturePlasticInsulation on Hex Wire Mesh......................................................................................... d. 1/2" Asbe stos Cementon HexWire Mesh............................ e. Canvas ................................................................................................................ f. Asbestos Cloth.............................................................................................. Sealing Coats........................................................................................................................ 1. Emulsion Type............................................................................................. 2. Cut-Back Type............................................................................................. Grooving.................................................................................................................................. Approved Insulating Materials.............................................................................. List of Approved Insulating Materials............................................................ 2 4 ;14 37 39 45 48 54 54 54 55 56 56 56 61 61 61 66 71 72 % CATION INTRODUCTION Insulation on all boilers over 350,000 pounds of steam per hour will be installed in accordance with two sets of crav ings. One set will be a series of drawings showing material, thickness, and details of construction which will be made to individual job specifications. Another set of drawings will be issued to cover the procedures to be used in applying the ma terial shown in the first set. The following discussions are designed to help the interpretation of the insulation drawings received for the individual job. These drawings will take the place of the itemized list of material which has been previouslyincluded in the insulation contract and the drawings shall be noted to show the extent of the boiler covered by the B&W insu lation contract. This procedure became effective on insulation contracts placed after January 1, 1955. On boilers below 350,000 pounds of steam per hour the same procedure that has been followed for the past few years will remain in effect until further notice. ERECTOR'S RESPONSIBILITY IN SUPERVISING INSULATION All insulation work which is done by vendors for the Boiler Divi sion of the Company is under the supervision of the Erector assigned to the job. The various vendors have been notified of this, and in the future all orders for application of insulation will carry a clause stating that the workmanship must be acceptable to Erection. When an Erector is on a job where insulation work is being done under B&W contract, he will inspect the progress of the insulation work to see that it is according to specifications. When other work on the ;cb has been finished, the Erector will advise the District Erector of his opinion as to whether the insulation work should have additional part-time or full-time supervision. It will be the function of the District Erector to decide what type of supervision will be used for each particular insulation contract. When an Erector is assigned to a job solely for the inspection of insulation, his time and expense will be charged to the contract number with the subscript I (for example OP-321), and this charge number should be shown on time sheets and expense envelopes. If an Erector is on a jco for any other purpose whatsoever, there is no time to be charred t: the insulation inspection account. When an Erector is assigned to a ;oc tor inspection of insulation, he should be advised by the District Erector how long he is to remain on the job or what phase of the insulation work he is to cover. When insulation work is sublet by the Purchasing Department, the vendor is given insulation drawings, complete as to detail, which des cribe how the insulation is to be applied and which types of materia: are to be used in the various areas. Copies of the drawings are sent to the n-rector, along with other job drawings and special instructions where necessary. This insulation catalog should also be considered as part of the insulation intructions for the job. On certain contracts the Company does not furnish insulation, and it is handled by the Purchaser directly with a sub-contractor. These jobs may be divided into three groups: 1. Contracts on which the Company is obligated to furnish specifications for insulation and supervision for its ap plication. 2. Contracts on which the Company is obligated to furnish specifications for insulation but not obligated to furnish supervision. 3. Contracts on which the Company is obligated to furnish neither supervision nor specifications. If conditions 1 or 2 above prevail, this will be noted in the C. I. sheets. Under condition 1, the supervision of insulation will be handled very much in accordance with instructions above applying to jobs where the insulation -2- contractor is the Company's own sub-contractor. Under condition 2. ve are not "obligated to furnish supervision, but we do have a moral obliga tion to see that the customer's sub-contractor fully understands our specifications. The Company is obligated to advise the customer if the sub-contractor is not following B&cW specifications. In effect this means that as long as the Erector is assigned to the job, he will supervise in sulation and advise the customer's local office or representative and the Erection office in Barberton when sub-contractor is no: following 3&v. specifications. Under condition 3, we have no definite obligation to fel low insulation in any detail. It must be remembered, however, that Erectors at all times should be definitely interested in seeing that the entire boiler unit is completed in a workmanlike manner that will be a credit to the Company. As long as the Erector is on ihe job he should be interested in customer's insulation work on the boiler and advise the customer's representative of insulation work that he feels will cause dif ficulty in the future. He should also advise this office in writing o: such circumstances. -c- INSULATION' FASTENERS There are many ways of attaching insulation to the ob;ec: which is to be insulated. The type of fastener depends on the location, :voe c: insulation, type of finish, etc. It is common to see several types of fasteners on the same job. The job drawings will designate wha: type of fastener is to be used at various locations on the individual job. The main object of the fastener is of course to support the inso lation and secure it tightly against the boiler, duct, or supporting frame work. It is difficult for every condition to be shown on the drawings sc additional fasteners should be added where deemed necessary to obtain a tight construction. This situation will be encountered mainly around doors, soot blower openings, etc. It should be noted that the insulation fasteners in certain constructions have several functions. The proper support of all phases of the insulation construction and often the final job appearance result from the initial fastener application. Before beginning to install listeners, the entire insulation construction should be reviewed to make sure the fasteners are applied in a manner that will serve all phases of the job. It is desirable to make the layout for fasteners as uniform as possible; however, a change in the plane surface, plane interruptions, and openings affect the requirements. Each area should be investigated for special requirements and the best general layout selected. This is of the utmost importance when grooving is required. On flues, ducts, airheaters and skin casing, the fasteners will be shop applied. Where no skin casing is used, the fasteners shall be field welded to the tubes on spacing shown, in Table I. In the case of a brick setting on small boilers, the strip fasteners shall be placed in the horizontal mortar joints between firebrick with bent ends against tubes at approximately 24''horizontal and vertical centers. The bent ends are sufficiently displaced from rube centerline to permit firebrick to bear against the tube. Standard drawings SSO-267988, attached, tabulates the round studs which are encountered. It should be noted that all even numbered studs are alloy. Drawings SSD-267989 tabulates the strip studs to be used in brick settings. These studs are all of alloy material. Drawing SSD-290883 illustrates tube reinforcement pads which are used on all boilers below 1050 psi. pressure. -4 - TABLE I TABLE 5HOWING SPACING OF FIELD WELDED STUDS TOR VARIOUS LOCATIONS vert wall 4 Roor LORfZ. SPACej VERT SPACE is" MAX. j BAILEY BLOCK 24" , WOPPER BOTTOM t, FLOOR MORIZ. SPACE ! VERT SPACE i IZ | 1 IB PARTIAL i FULL STUD is' MAX. flat stud 1' MAX, ' TANGEMT TUBB l" MAX. I zzi' 22 r 12" 12." iz- | iZ" 1 i | IZ11 1 i j 1 z" tube: 4 brjck ieT max. 2zi" TUBE 4 BRICK (ROOF) IZ" MAX. IZ" -- -- i c. i ~, 2 ,I > * .= .T * ^ y :c x 3 5 5 _ 2 -< ~, & S -1 = 5 :^a '? c x c cv *r rl ix iti .* ?* S * >*<.5 \ f C ?X 5 S3 ( 0 `'J S* I / !"' 'I 1 It'V' A015M) 6 11* . r !=: hi S a 5~ *" icSrsl_tf=i| iJljJ: w- jJ = * ; > ! 2 IT 5 I S:.-*2 *i!i!i :I;=. 5i| - "c1 l!! = n-i :5s-' Is ' llll s; =!H= * V-S < '* ^V- <c n'~* ? '<i. 5 $ --' rD w > ? sr- 5 <; x r-~ s ? X X ,r X X5 > X X cd CD CJ --- -- r_ X 'v X X X .n X _X :r> x> x X X r>. *- XX ~ o-- 2 ^-- 5c *X' i -d <x -- x x o -- x> o 7- '>- ^' REINFORCEMENT FOR REFRACTORIES In some types of construction there is a layer of refrac against the tubes which is reinforced with expanded metal lath. See Fig. 1). This lath is tack welded to the wall tubes on 18" center :. ve cal and horizontal. The lath must overlap 3" at its edges to ins- r e the reinforcement is continuous throughout the refractory. The laps should be held together tightly either by welding or tying with r 4 c a wire on 12" maximum centers. This applies to lath imbedded ir fractory. Lath in plastic insulation will be discussed later ir. tf instructions. The lath should be anchored firmly at its edges, wher-. doors, soot blower wall boxes, etc., by tack welding. The aim : a firm reinforcement for the refractory which will keep it from ing loose when minor furnace puffs occur. On vertical surface: advantageous to install the metal lath so that the slope of the It toward the tube surface (see Fig. 2). c. Where refractory is used between tubes to form a gas seal, ladder type reinforcement is used to hold the refractory in place. T is shown on drawing SSD-310309. It should be noted that where inner casing is used, the ladders are used only on wide spaced tubes. -9- FIG. 1 SKETCH SHOWING K-20 CONCRETE REINFORCED WITH EXP METAL LATH ri l-! l' NOTE : EDGES OP LATH DIAMONDS SLOPE DOWN AkJD TOW.ARD BOILER WALL FIG- 2 SKETCH SMOWING PROPER APPLICATION OP EXPANDED METAL LATH 10 B iy 2v 5 f c 05 e U x z c iU0 ig 1 $ ! 1= !*s "51 i;* I 81 e? E = < <. zs. S = iJ c o o 111 ? w2 c s zr c 5- ? 'S= ?z- --p 3**-j *< t **~ orO 1 CO cj m s A. Ltt CD,1 rl:z O $>>-i'\i cO UJ < 1 <S> --t :i uj co ij O' oo uj s ac - w Oc: o -- c* LU <o 12 CQ -- d\ r&> .'S', <PQ c*' ^UJ 9= _J Tfcfc'coi O t-- -- '-- 5xUJ diCD- ^ vP -- J = r --*. -O ^ -k> Z c 5s odd 5 UJ UU CO" ' LU :} bD-PP 2 ui o- t3^LL5 5 ?uiC^ Oc.^ CTO- cO 2^- DC l^-CC . r uJ O _,h^ CP tl! CO I a:o UJ UJ Sujt8 oot: * "; zz. ~~ CO pi UJ oJ '_L > UJ H- ^C^UJ O-S CO l_J -r > `4{=z.o ;0 CO uO "T -- <r~ OcO cc/0d>_ =H5 co 2u-lU uj Uii9 LU -dfv. - </> Pc LL) lP rz c H ^ 13 co 75 =5 O o i*. v2Q ^ 'i -- =>--;-l--l--Z-- r-- N-f cdO _ -- cr: 2 ' i-- < CL Uj gt ; < o .-- :so o < <CLl. O o., 2T C s?c5 *e* Uj O -j ^ Lu 5 ' O - cD ^ 1^. u- od g_ `x* r\ o jS rz^^ s^ o" dd - --- .- r *>_ U- c <=: .--i Cil oc v.o . _ vr rt \. . -- \D LU;! UJ H1! r-- 3 CL o i: X' 2>' )! ; >y~7 ARR'G'T o r M-ICHOR. WIRES ^ k r r R A d o R Y OH WALL TUBES\'Z ': l\ FIG. 3 SKETCH SHOWING EXAMPLE OF DEPTH GAGE EOF CHECKING K~2Q THICKNESS FIG. A 5KETCH SHOWING STEPS INJ APPLICATION OF REFRACTORY SEALS % sfeip a wo REFRACTORY The refractories most commonly used in boiler erecticr. work Kaolite 20, Kaocrete B, Hydrochrome and Plastic Chrome Ore. The Kaolite 20, Kaocrete B and Hydrochrome may be applied by hand or bv "Gunniting." For either method, the refractory should be packed behind tie bars and similar structural attachments before the ma;cr portion o: the wall is done. It is advantageous to install refractory behind thess tachments before the metal lath is applied. When gunniting, the material should be built up tc sufficient thick ness to bury the metal lath and then struck off to a smooth surface. Care should be taken to insure that the specified thickness is not exceed ed. A depth gage as shown in Fig. 3 may be used to check thickness When hand applied the refractory must be thrown through the with enough force to fill all voids behind the lath, the materia; bemo bui.: out until the lath is covered and the desired thickness is reaches. Y clock insulation is to be applied to this surface the refractory cho_.lt ctrowelled straight and smooth. If plastic insulation is to be applied, the surface should be made straight but left somewhat roughened. At the junction of some walls, a mound of refractory is _?ed seal against gas by-passing. This seal must be applied in two layers, the first being applied before the remainder of the area is covered. See Fig. 4, Step 1. After this first layer is thoroughly dry, the second layer should be installed making it part of the refractory covering the remaining portion of the surface as shown in Fig. 4, Step 2. All refractory should be stored in a dry place to prevent the various binders in it from setting up. Proper application of "Plastic Chrome Ore" or P.C.D. is highiv important to its successful performance as a furnace lining. The pamphle: "Instructions for Installing and Maintaining B&W Plastic Chrome Ore m Hearths and Furnace Bottoms" points out the peculiar features of this refractory. In applying PCO to studded tubes care should be :aken to fol-ow the drawings carefully with respect to thickness, contour, etc. The refractory must be applied in such a way that it will grip the studs and tubes tightly, for only by doing this will the wall be of any value. The studs act not only as a support for the PCO but also to carry heat away from it thereby cooling it and greatly prolonging its life. PCO is shipped to the job in cans containing 200 pounds of material and has exactly the correct consistency upon leaving the factory so that it is not necessary to add water or anv other substance to the material in the field. Lnder no circumstances should water be added to the material to increase its workability. The plasticizing liquid airsets quickly so the cans should not be opened until the PCO is to be used. I: the material has partially airset it is not fit for use and cannot be utilized by adding water to it. Each can of PCO represents a considerable amount of money and 14 - therefore when shipment is received it shove Id be r.ar.dlec with cors T cans are sealed with a rubber gasket tc Keep the mixture from, air :r-. and rough treatment will cfter. spring the cans enough tc allow the PTC inside..to dry out. If any cans are punctured or damaged so that this air seal is not sealing, the number of the damaged cans should be reported t: 3arberton unless the material is to be used right away. When rlacing the cans in storage a warm dry place should be selected and the cans stereo lid downwards so that any leakage through the lid seal may be detected The cans should not be subjected to high or freezing temperatures, ho: s.:r. rain or moisture. If in-transit or storage any of the material is unavoid ably frozen, it must be thawed out slowly, preferably before removing cover. There are several special tools available in Barberton that will aid in the application of P.C.O. These include mallets, tampers, vent board and spade as shown on the sketch included with the pamphlet on P.C.O. Be fore opening the can of P.C.O. it is advantageous to roll the can or. the floor so that the material within will pack slightly.This will make :: come out o: the can easier and will mix it with any liquid which may have separatee :r storage. The P.C.O. should be dumped on a clean surface, preferably .. steel plate or a liquid tight mortar box. If a wooden box is used :: shoe.: be soaked with water prior to use, then drained. The box is particula: .\ handy if any remixing is required where the liquid has separated from the chrome ore. This liquid must be thoroughly mixed in the material since it is not only a plasticizing agent but is aiso an air setting bine-or w-.:ll. and is an absolutely necessary ingredient in the material. Mixing a s.ipm- ly l!dryM can with a ':wetM one will often be necessary to make a uniform product. The material should be chopped up into 1" particles or smaller, to assure thorough mixing. If the material in the cans is of the correct consistency, the remixing is not necessary and may be shaved off in pieces of correct size and applied. The pieces used should be of sufficient size so that when pounded into place the required thickness will be achieved in one iayer. If P.C.O. is applied in several layers, they do not bond to each other readily segregation takes place - and the outer layer will probably drop off. In consolidating the material into lumps by hand, it should not be worked to a point where it becomes too plastic as it is then impossible to drive it with mallets into proper position. In general a much better job of application can oe obtained if the material is quite stiff and used just as i: comes from tne can. In using P.C.O. on a fully studded wall the best procedure is to first apply the material to the outside of the furnace between the tubes to a thickness just covering the first row of studs. This material should then be backed up by a heavy wooden (oak preferred) form cut to the exact shape that the finished surface should assume. The wall should then be finished by driving the material in from the furnace side of the tube to the exact thickness shown on the drawing. To properly bond the material, it must be driven in hard with a mallet. .Light taps do not force the P.C.O. into bond and serve only to bring the liquid to the surface where- it will air harden preventing proper drying of the material underneath. The above procedure must take place as a continuous process; it is not possible t.o obtain a good job by putting P.C.O. or. one side of the tubes and men later on applying P.C.O. to the other side. Further, it is not feasible to put P.C.O. on both sides simultaneously, since it is impossible to exact ly synchronize the mallet blovrs and the last blow will force the material awav from the studs-or. the opposite side of the tube. Where materia! .? applied to partially studded tubes the best plan is to make a term, tha: ~:1. give the proper contour on one side of the tube, then pound PCC through the studs against the form from the other side. Where material is eitner too stiff or too plastic to do this, the procedure for fully studded tubes mav be followed. Applying PCO to a floor is somewhat different than tc a wall. In this case the material should be applied in smali lumps to the desire! depth. Before tamping, the PCO should be chopped into a homogeneous mass with a tool similar to a lawn trimmer. This tool is shown tn the attached pamphlet. After chopping, the mass of PCO should be lamru solidly into place. To assist in levelling the PCO it is sometimes advantageous to use a heavy plank and drop it, edgewise, on the floor I: order to speed the drying of the PCO the mass should be pricked with closely spaced holes to a depth of 1-1/2" to 2". A useful tool for this job is shown in the attached pamphlet or. PCO, entitled "Instructions For Apply ing and Maintaining B&W Plastic Chrome Ore." Sine?..new PCO is relatively soft, it must not be walked or. until :: has been fired. Therefore as soon as work has been comrlerc-f e: :: " C boards should be provided for the necessary walkways over in-. . All contours must be as shown on the drawings. Sketches SSK232299"! and SSK-232300-1 as shown on pages 17 and If she- t:.t contours normally used. When PCO must be applied in freezing weather it is essential to use salamanders or some other type of heater, placed close enough to keep the PCO surface above freezing temperature. Another good method is to fill the wall with warm water after connecting hydrokineters (steam in jectors) in the drain nozzles or in one or two handhole openings in the wall headers. These steam injectors which are available in Barberton will keep the wall warm (60F to 100F) for any required length of time. If after the PCO installation is completed freezing weather continues, the temperature of the tubes should be increased to 150"200F and held at this temperature until the PCO is thoroughly dry. If the material is allowed to freeze at the time of application it will crack and disintegrate rapidly when put into normal service. The photographs on pages 19, 20, 21 and 22 show various stages of application of PCO. It should be noted that the surface is never ' slicked" down or trowelled since this brings the liquids to the surface. The surface should be stippiec with a course flat bristle brush to give the desired finish. It is sometimes desired to build up a PCO floor that has been in service. In such cases the slag and iron sulfide deposits should be cut out making sure the PCO remaining is not contaminated. The PCO should then be cleaned and roughened. A caste of Kromepatch cement is ther. made by thinning with water until it reaches the consistency of cream. This paste should then be applied to the PCO with a brush or broom. The PCO should not be wet with water prior to the application of the paste. PCO snouid then be applied in the manner described above. The following photographs show how typical applications should look on various types of wall constructions. -id- 4 ROWS Ufe LG. STUDS 6.46 5 ROWS I " LG. STUDS l0.3*/j5 P.C O. REQUIRED ACTUAL 19.14* PER SQ. FT. PROJ. AREA 1. GOCiCQ uhvlk Ti_ ^ */$ W,H. M mHaAKc1kD. APPULD i ST/sNCARO FULLY STUDDED WAUL TUBES 4- ECW5 i LG STUDS U H3 ~ P.C.O. EEQUISED ACTUAL 9.16* PER, SC FT RCJ. A.TS cr\ STANDARD PARTIALLYSTUD DD WAUL TUBES 4- ROWS |fe LG. STUDS &4> /tf 6 ROWS 1" LG. STUDS 10.3*/^ P.C.O. S2EQUIPED ACTUAL 30-70* PER SO- FT PROJ AREA mncn f WHckl HAU10 APPUED WUtH \_40 */^ " MAC*-*. ' STANDARD fully studded FLOOR TUBES 4- ROWS 1^' LG. STUDS 6.46*/^ P.C.O. KEOUIG.ED ACTUAL 24.76# PEP; SO FT. PROJ AREA nncn ( 2.7.25 */? wwgvj HALC applied 0RX*l3l.S */$ * MACH -. STAKJOARD PARTIALLY STUDDED FLOOR TUBES PLASTIC CHROME ORE REQUIREMENTS 3i O. D. TUBDS ON 6" CEnITECRS SHOP STUDDED WITH DlA. STUDS DWG SSK -2382S3 w/ E.i eTt 4 Rows L<3 Stuos 4.9z*//f 4 Rows ,5/i<o"LG 5rc-rr /ORows / " Lg. Studs /2.8>S*/f RC.O Raou/R e a RC.O. ReoU/PED /9c tual /9.04?Re* Sq FtP/toj.Arca Actual S. <38 *Per 5c t- - hroj Are': ' ORDER f 2l*/r.WHK/ HAS/D APPLfEO orOE(, {%sf// ^~L,SZ i l 25*// " MACH. S^AN/OARD FUi.LV 5TUODED STAISJOARD PARTIALLY STUDDED WALL. TU85 WALL TUSE5 /fov/5 % Z<S\ 57"c/^j 492*/P,, 4 (Rows '5/<c*Lg. Studs 4 92V/ /O Rows / * Lc. Studs /Z.66 */R PC. O. REOUHREO RC.O. Required ^ Actual Z6 76*'FkpSs. Ft Proj Arc* Actual 2/ 84 * Rex Sq. ft: Prcj. Ate 0RO.r(^Z */rWHW HAUO APPLIED l 37-5*/P " MACH. 24*/* V/rt W WA WD AARL. t ED 2&.S/*/? STANDARD FULLY STUDDED STANDARD PARTIALLV STUDDED FLOOR TUBBS F L OCR TUBES PLASTIC CHROME ORE REQUIREMENTS 4"O.D.TUBE3 ON 6" CENTERS Shop studded with i/z " Di AM. STUDS Dwg. SSX-cZ'300-1 wZe&e -l"7 .M l.- 'r i ? - 25 ! I INSTRUCTIONS FOR APPLYING AND MAINTAINING B&W PLASTIC CHROME ORE Method of B&W Plastic Chrcme Ore is shipped in Application ready-to-use condition . . . never add port* land cement, water, or any other materials, Open only sufficient drums to keep installation crews sup plied as needed. Remove the lid, turn the drum on its side, rc'i it back and forth a few times before turning the crurr. upside down and lifting it cff of the contents. B&W' P.C.O. should be dumped on a surface free from con taminating materials, and then cut into small pieces. Chopped material should be covered with wet buriap sacks if there are any delays. It should never be left ex posed to the air for a longer period than is required for proper cutting. For hearth work, use a minimum thickness of 4 in. B&W Plastic Chrome Ore. First clean away all iccse material and shovel on the small pieces to cover an e-ee 2 or 3 Tt. wide along one side or end of the furnace c a thictness I to 2 in. greater than the final thickness desired. Do not attempt to Install a layer of B&W P.C.O. on too of a layer that has been previously rammed. In applications where the thickness is too great to pack prcpeny, it is necessary to apply in layers 4 to 5 in. thick, but in all such cases the previously rammed surface must be thoroughly and deeply roughened with shovels or a heavy sharp tool. After working tre plastic into place with the edge of a space C-' similar sharp tool, ram it down as evenly as Dos sier to withir in. of the fnal thickness. Apply many snar- blows, ratner than light tamping, using a heavy ramming tool having a large face. Do not ram the entire covei-ed area; leave a minimum of 6 in. unrammed at the edge. The rammed area is now ready for the final treatment. Lay a smooth plank, 2 in. thick, about a foot wide, and from 4 to 8 ft. ior.g (depending upon the size of tne fur nace;, along the furnace wail and sledge it down until the desired hearth thickness has been obtained. Lav a similar clank alongside the frst and sledge the plastic down. Tner move the first plank forward and proceed as before, buJ do not ram until the moisture comes to the surface, and never slick the surface after ramrvng. if me stick, sand them with fne chrome ore. and as tne are moved forward, make vent holes abcui 1 m. c-:-:r p- 3 or 4 In. centers with a stiff too! nc* larger than 1 in diameter. An ice pick is goes for inls pu-pcse c- us-, a board about 12 by 16 *:*- e:cL*-re-"- -a : driven through it sc naiis extend i - in. *".*c_-p" ;. After the final ramming, high and low mas re present. To level off a low area, reuene- me stoc- s.-- face thoroughly and fill in with small p-s-ce. o4 B&W F;a:* ; Chrome Ore. After tamping (light.y rr'; rime! ft-,Is." O'- sledging the plank. Remove high spots with a s.narr shovel and refinish these areas, too, with the sledge arc plank. After B&W P.C.O. has started to set, it must r.ct be disturbed. If the whole job cannot be done at one time spread well-dampened burlap sacks over the unfinished edge of the work. When work is resumed, cut several inches of the installed material away :rc.~ tne edoe be fore adding more plastic. Due to tne nature c* B&W P.C.O., expansion joints are usualiv nor required. B&W P.C.O. wifi air.set and the top su`face will dry in a comparative^ sner* time afte' installation but the pc -- io.o oenea" the surface will remain plastic for quite some time. Wall ing or resting tools, ladders, etc., on the dried surface while in this condition, will produce cracks and depressions in the upper surface which will permit slag penetration and shorten the life of the installation, in addition to closing vent holes and causing the surface to pee' upon heating. Ever, the placing of boards on the hearth wil; not protect it if traffic over the hearth is permitted before it has deeply air-set. It has been found to be of advantage tc sp-reac i ;/r thickness of dry cinders over a B&W P.C.O, heartn to pre vent rapid drying before firing. A lave* of cinder; wi!, a:so protect the hearth from direct heat during the drying out process. - 2b - Firing a B &W dr.Lr.Ur\. \Ins.taIl.lat.i.on Provided that a hearth or bottom h.a.s. be. en, th,orough.l/y v.e,,nted,, ,as indicated above, it will not be damaged by the immediate application of heat, provided it is not concentrated and flame impingement is avoided. Fire at low rate or intermittently until all moisture is out of the B&W P.C.O. If air-setting has taken place for a few days or weeks, use greater precautions to dry the bottom very slowly. To obtain maximum slag and wear resistance, a B&W P.C.O. installation should then be fired to as high a temperature as possible before slag flow occurs. Burn ing in the material at 2,450 F to 2,500 F for 7 or 8 hours will Insure good results, but if the furnace cannot be heated to this temperature, hold at the maximum safe temperature for 8 hours or longer. Ir, drying out the floor of large bciie-s where B&W P.C.O. has been applied to floor tubes, it has been found to be of advantage to use 5-minute firing periods about every 45 minutes until the steam pressure just begins to -ise: then the boiler should be allowed to stand for 8 hcu's and tired for 5 minutes, and this procedure con tinued for 24 hours or as long as necessary, making inspec tions of the floor during this period. This will result In a tho-ojghiy dried out P.C.O. floor, and the application of hard tiring after the drying out has been accomplished will nor damage the P.C.O. Small cracks often develop during this burning in proc ess, but these usually close when the furnace is heated to -operating temperature. Should any such cracks fall to dose after a few heatings, fill them with B&W P.C.O. or a high-bond chrome mortar to prevent slag from working under and floating the hearth. Method of Sl<3 and scaie accumulate sm hearnr.-, ka . , or floors should be removed t o p-ever- contamination c* me su-race. pma,. ee- posits are more readiiv removed m*- -eavy accu ---j. tions: in fact, removing heavy siac wimow* in hearth is very difficult. In removing slag it is best to scrape i; off the 5&W P.C.O. while the furnace is hot. If a heavy decosi* has been allowed to accumulate, it mus* be careful criseiec or barred and in the latter case, always hcic the tool at an angle with the hearth. Allow some siag tc remain rathethan gouge the surface of the plastic in an effort to remove the slag completely. If the surface does oecome chipped during cleaning, patch it immediate!', (pefere tne furnace is put into production; in oroe* *o eleven- siac from entering the openinc. Do not allow a hearth to wea- too thin be*cre pa'chmg it, as there is danger that the thin section mav crack and come out, thus necessitating a mum li'ge* ca'ch. Tc patch old work, remove siac ant scaie from, trie sumsce and cut around the edge of tne area to a oepth ot not less than 1 in. This is important; shallow patches are net satisfactory. Be sure that the oic work is not hot enough to set the fresh plastic before it can be properly rammed. The surface should also be roughened and coaled with a batter of air-setting cfvome bonding mortar just before ramming in the patch and providing rhs usual vents. Never spray water on a Hearth to cool it: this will pro duce cracks and spalls . . . not oniv ir. the hearth itself, but also ir. other parts of the furnace lining. The required burning-in time for a patch depends upon its thickness, but in any case, raise the temperature gradually. THE BABCOCK & WILCOX COMPANY Refractories Division S. j - 29 - P,lMd in U l. * THE BABCOCK & WILCOX COMPANY Refractories Division , New York, N. Y. INSTRUCTIONS FOR INSTALLING & MAINTAINING B&W PLASTIC CHROME ORE IN HEARTHS AND FURNACE BOTTOMS These instructions for installing and maintaining furnace structure? c: B&W Plastic Chrome Ore are the result of years of experience. Ir. the light of this experience, it may be said that the manner in which B&W P.C.O. is applied is probably as important in its effect on the results obtained as the material itself. The homogeneity and compactness of the P.C.O. mass has a c;rec: relationship to its resistance to slag and its ability to stay in place. Due to ihe nature of the natural material from which the plastic is made it has not been found possible to develop a mix which can be applied with greater ease vithcu: sacrificing the ultimate quality of the finished job. Therefore, it may be said that care exercised in installing B&W P.C.O., according to the experienceproven methods set forth below, is at least as essential as the material itstT. ar.c well repays the effort required. Due to its nature, there are several fundamental principles which must be followed to obtain best results with B&W P.C.O. (1) BfcW P.C.O. is shipped in the proper consistency for use without the addition of any other ingredients. Water, Portland Cement or other mater ials will destroy the properties of P.C.O. and must not be added to it. (2) It is not necessary to allow for expansion joints when installing. (3) For a successful installation of B&W P.C.O. a jointless, dense, and perfectly uniform mass is desirable. Do not install it in layers. (4) Tho rough ramming and tamping into place is necessary and the mass should not be touched after final tamping and venting. Do not attempt to trowel B8*W P.C.O. into place or to slick it smooth. (5) Do not disturb B&W P.C.O. after air-setting has started. (6) As B&W P.C.O. is heavy and wall sag under its own weight if in stalled as a vertical or steeply sloped section, do not expect it to remain in place without adequate support and always build sloping sections on a gentle grade. (7) Do not use or work B&W P.C.O. which shows any sign of having a hardened crust. Throw- it aw-ay. Any excess P.C.O. which cannot be promptly used should be replaced into drum, covered over with a damp bag and the lid tigntiy sealed. Should the contents of a drum appear to be less plastic and less moist than usual upon opening, add it in shovel-size lumps to the contents of a "good" drum and chop and w-ork together with a spade on a clear, floor or ether clean surface. (8) Avoid freezing B&W P.C.O. in winter both before and after it has been installed and until it has been fired in. - 30 - (9) Due to its rapid air-setting properties, B8cW P.C.C. cannot be al lowed to stand very long after removing from drums without this action taking place. At ordinary room temperatures in still air, one hour is the maximum time unused P.C.O. or unfinished parts of an installation should be allowed to stand without covering with damp bags. In furnaces which are warm or ir. which there is a strong draft, air-setting may begin in a very few minutes. Under these circumstances, unworked P.C.O,, unfinished sections, etc., should be kept constantly covered with damp bags. STORING: Do not store B&W Plastic Chrome Ore in a hot place as heat will cause steaming which may build up pressure enough to cause air leakage w:;n consequent drying and air-setting. Drums should be kept under cover in a cool place but not allowed to freeze. HANDLING: B&W P.C.O. drums are rugged and every effort has been made to make them air-tight by gasketing the lids and attaching the lids by a number of crimped-on lugs. Air leakage or loss of liquid will cause drying and setting. On receipt of shipment, inspect for damage, particularly arouzc tn-t .:i joint. If leakage is suspected, store the drum upside down and if seepage o: the liquid occurs, tighten the lugs with a dull cold chisel and hammer. TOOLS REQUIRED FOR BOTTOM OR HEARTH INSTALLATION: Provide tools shown on drawing RS-208 in sufficient quantities to suit the size of the installation. They should be strong and well made. Also provide hardwood planks 2" thick and 12" wide in suitable lengths for finish-tamping. Several other boards not less than 1" thick should also be provided to cover the P.C.O. after installation for protection against damage to the surface from walking on it or resting tools or equipment on it. OPENING DRUMS: To open a drum, pry up the "ears" with a sharp instrument or screwdriver inserted in the holes in the lugs on the lid and then knock the lid off. Roll the opened drum back and forth a few times to loosen the material which may then be dumped upon a clean space close to the point of installation by turning the drum upside down and lifting it from its contents. Do not open drums of B&W P.C.O, until the material is needed for actual use. If a delay or interruption of the work should occur after drums have been opened, or the P.C.O. dumped, such drums or dumped material snouid be covered with damp bags to prevent the plastic from drying or setting before it can be installed. For large installations, drums can be handled into the furnace and emptied close to the point of actual installation. For small jobs where this cannot be done, the drums should be dumped onto a clean space near the furnace and the P.C.O. cut into lumps to facilitate handling through an excess door. - 31 BOTTOM OR HEARTH INSTALLATION INSTALLATION: For hearth or furnace bottom work, use a minimum thick* ness of 4" of BS:W Plastic Chrome Ore. Clean the surface on which the P.C.O. bottom is to be installed c: ah dirt and dust and install the material in sections about 30" wide. Cut the P.C.O. into convenient shovel-size lumps and place ever.lv ever an area about 30" wide to a depth somewhat greater than the finished application desired (5" to 5-1/2" for a 41' floor) beginning along the wall farthest from me access door. Ram or cut-in the lumps with the tool shown in drawing using a chopping action. Thoroughness and the use of force in chopping with the spade produces for a complete mixing of the lumps and produces a uniform and well-bedded mass. Do not smooth or walk upon the resulting rough, chopped surface. L the foregoing instructions have been followed a final thickness of 4" of P.C C. will be provided. If a greater thickness is desired, additional lumps should be added or. top and chopped into the material already in place, using deep strokes with the spade to tie it into the material beneath. Continue this procedure until a ness from 1" to 2" greater than the desired thickness is obtained. Try heaw blows with the tamper on a small area and check for depth to see if the ccrrec: level is obtained. After the proper thickness is obtained, tamp down the chopped P.C.O with heavy blows using the tamper shown in drawing RS-20S. Sharp blows, r&tner than light tamping, are necessary. Tamp the entire area covered but leave at feast 6" of chopped but un tamped material as an unfinished edge into which the next section of plasticmay be chopped, thus insuring a jointless bottom. As tamping progresses, cover this unfinished edge with damp bags to prevent air-setting before the next section is chopped into it. For final treatment, lay a 2" hardwood plant 12" wide upon the install ed P.C.O. section and tamp it with hard blows of the tamper to insure a smooth, even suriace. A'hen the entire area has been evenly tamped, lay a second plank similar to the first against the plank just tamped and tamp it firmly as before. This will finish off a 2" section and leave the remaining 6" strip of the 30" section un-tamped for ramming in the next section to it. Care should be taker, to smooth out ridges which may be raised between plank positions. Lay the plank over such ridges and tamp lightly or, if the ridges be slight, light tamping without the plank will remove them. As each area of several square feet has been tamped and rammed, check for depth, using a small diameter rod; for level, using a level board; or for slope, using a string. Always check level and slope with reference to previously-checked areas so that the entire floor will be uniform. After the final ramming, high or low spots may be present. Slag pools 32 - will form if they are not leveled. To level off low spots, the tamped r.Z.Z should be thoroughly chopped and more material added in small lumps wh;c are chopped into the underlying bed and tamped as before. Areas which arc too thick may be shaved off with a sharp shovel and lightly tamoed. If additional thickness is desired after final tamping, do no*, add mcr P.C.O. until the existing material has been chopped up. Additional materia should be chopped deeply into the installed mass to obtain a thorough :ie-:r. and to prevent layers. Be sure that the stroke of the tool carries :: we.; :r. the underlying material. When an area has been satisfactorily completed, vent it by pricking : with small holes on approximately 3'' centers, using the ventboard shown or. drawing RS-208. Additional sections of hearth or furnace bottom are laid ir. similar manner next to the tamped and vented sections by shoveling materia: along side the untamped edge of the previously laid section and chopping it into place, tamping and venting as described above. l.eep off of hearths or furnace bottoms of unfired P.C.O. 1 sr.ou.c be necessary to walk upon them, lay tools upon or stand ladders on such su faces, even when air-set, cover the necessary area with l'1 boards tc protec it from damage. Do not delay packing and tamping after the P.C.O. has been shoveled into place and do not leave an unfinished surface or edge without covering with damp bags to prevent air-setting. Do not attempt to rework B&W P.C.O. after installation when air setting has begun to take place. If the face of an installed section should be come air-set before the next section can be laid, remove the air-set portio or surface and discard it before thoroughly chopping in newly applied mater LABOR: It has been our observation that in hearths or furnace bottoms it requires from one to two man hours per cubic foot of material for a firstclass job (i.e., one to two man hours per drum of material). This includes labor in connection with handling, opening drums, application, etc. Care 3efore Firing: 3kW P.C.O. will air-set and the top surface will dry in a compara tively short time alter installation but the portion beneath the surface will remain plastic for quite some time. Walking or resting tools, ladders, etc. on the dried surface while in this condition w'ill produce cracks and depres sions in the upper surface which will permit slag penetration and shorten the lift of the installation, in addition to closing vent holes and causing the surface to peel upon heating. Ever, the placing of boards on the hearth will not protect it if traffic over the hearth is permitted before it has deeply air-set. Firing a B&W P.C.O. Installation: Provided that a hearth or bottom has been thoroughly vented as indicated above, the best installation will result if heat is applied immediat ly upon completion. If it is impossible to apply heat immediately after installation anc th r/u hearth or bottom is allowed to stand for a considerable length o: time, shrinkage cracks will develop. If these cracks are large .over 1 S :: ii necessary to fill them before applying heat with a chrome bonding mortar having good air-setting qualities. Smaller cracks (under 1, g": car. be r.eglecte because they will close up when heat is applied to the hearth. The furnace temperature should not be increased too rapidly, k t:.-; moisture in the B&W P.C.O. changes into steam too rapidly, it will r.ct li able to escape through the vent holes quickly enough, resulting in a blister-:-:, or bloated surface of the hearth or bottom. Generally, 5kV>' F.C.C v.k r dried out satisfactorily if the same time-temperature cycle is followed that is used for drying out other refractories in the furnace setting. For the average furnace job, if the temperature is brought up to about 500eF and held for 6 to 8 hours and then raised to about 12Q0*F and heLd for 3 to 4 hours, thv material should be thoroughly dried out. After the drying out period, the B&W P.C.O. must be burned ir. a: :ne final operating temperature of the furnace. The length of time which a hear:.-, should be held at the maximum temperature varies with its sice and thicknes; A minimum for small or medium size hearths (4" thick' would be five Tne time required for larger and thicker hearths should be increased acccrdingiy so that the heat will penetrate to a greater depth. 1 ou cannot injure B&W P.C.O. by increasing the burnms-in tempera ture, in fact it improves the structure. Therefore, where other refractories and equipment in the furnace permit, it is advisable to raise the burning-ir. temperature somewhat above the maximum operating temperature of the fur nace. MAINTENANCE: Except in slag tap furnaces, slag and scale accumuiatin hearths or furnace bottoms should be removed to prevent contamination o: tne surface. Small deposits are more readily removed than heavy accumulations m fact, removing heavy slag without injuring the P.C.O. is very difficult. Ir. slag tap furnaces, the slag surface is best left alone except in cases where 2 r.eavy accumulation of iron or iron suLfide finally dictates removal in which case considerable replacement or repair will be found necessary. The "best way of removing slag is to scrape it off of the B&W P.C.O. at frequent intervals while the furnace is hot. If a heavy deposit has been allowed to accumulate, the furnace will have to be cooled down and the slag carefully chiseled or barred. Ir. barring the slagged surface, always hold the tool at an angle to the hearth and allow some slag to remain rather than gouge the surface of the plastic in an effort to remove it completely. Do not allow a hearth or bottom to wear too thin before patching, as there is danger that the thin section may crack and come out and therefore require a much larger patch. To patch old hearths or furnace bottoms, remove the slag and scale from the surface and cut around the edge of the area to a depth of not less tnar. 1" below- the existing surface This is important: Patches less than 1 thick are not satisfactory. Lens-shaped or tapered patches are worthless. All patches should be of uniform thickness laid in the existing hearth and joined to it at vertical or slightly undercut edges. Be sure that the old work 34 is no: ho: enough to set the fresh plastic before it can be chopped ir. arc Apply a wash coating of a chrome bonding mortar having good air-settir... qualities to the roughened surface of the old P.C.C. to provide a good bond be tween it and the new P.C.O. applied as a patch. Apply this mortar over a srr.ah area at a time, immediately before putting the new P.C.C. into oiace, sc as :c prevent its having time to air-set before the P.C.O. is applied. The P C .C placed in the patch should be rammed and vented in the same manner as r.ev P.C.O. hearths described above. Never spray water on a hearth or furnace bottom to cool it This v. ill produce cracks and spalls not only in the hearth but also in other parts o: the furnace lining. The required burning-in time for a patch depends upon its thickness. When patches are relatively thick they should be burned in as rapidly as pos sible after installation. REBUILDING BOTTOMS: It is better to patch or completely re-install dearths or furnace bottoms of B&tW P.C.O. rather than attempt extensive rebuilding. Hearths and bottoms should preferably be allowed to wear thir. and be retraced with new hearths altogether. However, should a hearth of sufficient criminal depth wear thin, it may be rebuilt when it is possible to add 3" to 4 of mater ial to the entire surface. All slag and spalled or cracked portions of the bottom should be cut away and removed to a level where the bottom, is m a sound condition. Provide the tools which are required for laying a bottom as described above and as shown on drawing RS-208. Apply a coating of a chrome bonding mortar having good air-setting qualities to the surface of the old P.C.O. to provide a bond between it and the new plastic. Apply this wash coat over a small area at a time, rust before in stalling the new P.C.O., so that it will not have time to air dry and air-set before the new P.C.O. is put in place. Proceed with the installation of the new P.C.O. in the manner prescribed for installing a new bottom. - 35 - THIS WAWWC IS THE FWOPEKTY Of THE BABCOCK & WILCOX CO. AND IS LOANED UPON CONDITION THAT IT IS NOT TO BE REPRODUCED OR COP1EO. IN WHOLE OR IN PART. OR USED FOR FURNISKIK INFORA.'-: TO OTHERS. OR FOR ANY OTHER PURPOSE DETRIMENTAL TO THE INTERESTS OF THE BABCOCK A WILCOX CC. AND IS TO BE RETUMEO REQUEST. THE EQUIPMENT SHOWN HEREON IS PROTECTED BY PATENTS OWNED OR CONTROLLED BY THE BABCOCK 4 WILCOX CC. A*.: INFRINGER OF SUCH PATENTS IS LIABLE TO PROSECUTION. DO NOT SCALE. BSE DIMENSIONS ONLY. h- 5n--| -4% SPADE FOR PACKING B&W PLASTIC CHROME ORE (T) YENT BOARD It |j 1______ LJ (T) HARDWOOD TAMPER (?) HARDWOOD MALLET (Dogwood or H ickory) DRAW* BT i-_r CWt'D ,e c o TOOLS FOR INSTALLING B&W PLASTIC CHROME ORE IN BOTTOMS OF BOILERS AND FURNACES THE BABCOCK & WILCOX CO. j aFPSirrap m biviciqi_._ -----J scale i*. = s rr R$ - 2C8 BLOCK INSULATION After fasteners have been applied to the wall, block is applied. The main object is to have the block fit tightly against the object being insulated and against the neighboring block. There are several operations in the application of block which will give trouble if not done properly. When using layers of block having different temperature limits, the block having the higher limit should naturally be placed against the hot surface. Fig. 5 shows a typical example where this might be encountered. To reduce leakage through the insulation to a minimum, the blocks should be closely butted together with the joints staggered. Where :wc layers of block are used, the joints of the inner and outer layer should be staggered. All joints and holes in the blocks must be filled with an in sulating cement of the same temperature limit as the block. - 37 - FIG. 5 SKETCH SHOWING METHOD OF APPLYING BLOCK OE DIFFERENT TEMP LIMITS Hi^M TEMP. LOCK HOT OBJECT NOTE l-OW TEMP. ^LOCK AGAINST HOT SURF -CE INCORRECT METTHOC NOTE THAT NO LOW TEMP BLOCK IS IN CONTACT WITH HOT SURFACE CORRECT METHOD - 38 - LACING WIRES As block is applied it is necessary to secure it to the fasteners. The most common method used is a network of 14 gage lacing wires which attach to the fasteners and cross over the block holding it firmly against the object being insulated. On all flat surfaces and flues and ducts over 53 in diameter, a diamond shaped pattern is required. When two layers of block are used, it is not necessary to use lacing wires on the inner layer rig. 6 (a), (b), & (c) illustrate typical lacing wire constructions. As in the case of insulation fasteners, there will be places where additional wires must be used to properly secure the blocks, such as around doors, soo: blowers, etc. In some instances a soft block is used which must be protected from the cutting action of the wires. In such cases, metal washers ar.c corner beads will be supplied to fit under the lacing wires as protection for the block. (See Fig. 7). The lacing wires on tubes, pipe, or ducts of less than 33': C.D. shall be in bands around the block. Figure 8 shows a typical example of this type of construction. - 39 - PIG. 6 AMD TWISTED TO GET TENSION) (a) SKETCH SHOWING LACING WIRE APPLICATION! - -10 - a & O "Z i ,;L ( 5rrv:: , s: . , i g*R -. 5~'*rE-M5- ,,S (H S'0 1 se&,q^ CORNR W"ES e* 5t\v SP.KNS 'N A&JA&SK'T ~v,. _* ARE CN p^rERir -gxZTKTtOK' .! C- C s % '.X* r^ u Section s-s 4l: <'ONfM- WfATHEJ. ih 12 f:~ 14- GAGE! LACING WIRES mtoo OIA. STUD BLOCK INSULATION INNER LAVER WEED NOT BE LACED NOTE TO GAIN ADDITIONAL. TENSION IN WIRES AND FORCE BLOCK. AGAINST SURFACE OF CASING, NUTS SHOULD BE SCREWED DOWN FLUSH WITH BLOCK AFTER LACING WIRES ARE TIED. Cb) - 41 - EXTRA. WIRES FOR HEX. WIRE MESH IF SPeX^FtEO LACING WIRES SLOCK INSULATION CASINO, TUBE,ETC. FILL VOID WITH IKISUL. CEMENT OF THE SAME mat'l as block. CO - 42 FIG. 7 SKETCH SHOWING PROTECTIVE PADS FOR LOW STRENGTH BLOCK - 43 - FIG. 8 SKETCH 5HOWIKK3 LACING WIRE APPLICATION FOR PIPE , FLUE, E^C. UNDER 33w O.P. INSULATION--\ L 9" . 9* *-- LACING WIRE SPACING LAj >1 n 1i | ___1____ ____ 1 / / V ^________ u -----LACING WIRE BANDS PIPE, FLUE, DUCT, ETC. UNDER 33" O. D. FIG. D SKETCH SHOWING METMC D OF SFCUR\KH3 BLANKET IMSULATlQN VVH H WIRE STUDS - 44 - BLANKET TYPE INSULATION Although block type insulation is most widely used on boilers, there are occasions where blanket type is used. The installation of the blanket is relatively simple since it carries its own reinforcement in the form of expanded metal lath and chicken wire. The blanket is impaled over #9 gage wire studs and secured by bending the stud over the lath. (See Fig. 9). To prevent gas leakage and casing hot spots, special care must be taken where blankets join. Adjacent edges of blankets must be forced to gether and the metal lath laced to achieve maximum sealing. At casing flanges, the blanket ends should be wrapped with its mesh and lath. Both of these conditions are shown in Fig. 10. The studs holding the blanket may be shop or field applied. When field applied, the studs should be spaced on approximately 12" centers vertically and horizontally with outer rows of studs 3" from the edge of each panel. (See Fig. 11). The blanket should always be installed with the metal lath on the outside face of the blanket. The material making up the blanket may be mineral wool, glass wool, Kaowool, etc. All these may be installed as described above. % - 45 - FIG- IO .SKETCH SHOWING? METHOD OF JOINING AND ENDING BLANKET INSULATION STEP 1 H4 xx XX STEP 2 COMPRESS F*IORES STEP 3 AMO Tie TO EXR NlETAL LATH WITH WIRES ON lZ*`CENTERS METHOD OF MAKING BUTT JOINT 46 FIG. 11 SKETCH SHOWING SPACING OF FIELD WELDED STUDS FOR BLANKET INSULATION - 47 - LAGGING Lagging is a sheet metal covering placed over block insulation to protect it from the elements and physical abuse, and to give the boiler neat, finished appearance. The lagging takes the place of the high temperature plastic insulation finish coat and sealing compounds, a Lagging will be sublet by the B&W Co. Purchasing Dept, to a sheetmetal contractor who will supply the material and erect it. The lagging will not be designed or engineered except as shown on drawings 32034E, 32049E, 32038E, 23114E, and 32046E, copies of which are attached here with. The details will be left up to the contractors who usually fabricate the panels on the job to fit the individual boiler being covered. It must be neat in appearance and arranged so that it will prevent water from getting into the insulation. The contractor will be required to furnish all necessary fasteners, covers supports, clamps, clips and any other such items required to make a finished job. The lagging ribs should line up vertically from top to bottom wherever possible to give a neat appearance. It is particularly important that the ribs line up between buckstays. The lagging must be completely drainable and must not contain places where water can collect, either on panels, flashing, or stiffeners. It must be installed in direct con tact with the insulation so that "oil canning" will be held to a minimum. - 48 - FINISH COATS ANT R Z INF OR C Z.\ '.Z N T "Finish coats" are coverings over block and certain z 1 ar.c: irsulations to provide a continuous outer coating which covers a, th:. ;c:r.:cracks, reinforcing material, lacing wires, and uneven spaces romrmw; when the block or blanket is applied. The coat also minimizes w~ mfiltration to the setting. The material most commonly used for the finish coat m Hig:. Temperature Plastic Cement, although flues and ducts sometimes no-.-.hard smooth coat of asbestos cement or canvas finish. The ; er.stru ::i. m using these materials are listed below: (a) 1 /Z'1 High Temperature Plastic on Expanded Ntetai math. In this type of finish 16 gage expanded metal lath is usee us tu-. reinforcement for the plastic. Full sheets of lath are apcT.-c -gam block and tied back firmly by lacing wires which are attach', c ;; :ht insulation fasteners. (See Drawing SSD-310334). The sheen- snoul:. be placed so that a space of 1/4" to 1/2" will exist between adicir.in: sbvm o: latn. They must not be tied together but should be allowe: t: ms-r w cividually when the boiler expands. The edges of the lath sz:u.u. msecurelv tied to the lacing wires to prevent curling. The spaces between tne lath should iine up vertically and horizontally. After the lath is securely tied down the plastic should :e aprime in one 1/2" coat making sure that it keys well around the lain The plastic should be soaked in water at least eight hours to insure the.: the water has completely saturated the plastic. When properiv soaked tne plastic is easier to apply and will trowel smooth. Grooves, as shown later in these instructions, snou.c rrmae in tne space between the sheets of lath. The spaces should oe maru.ee witn a wooden peg or welding rod to aid in finding them after the plastic is applied. It is important to see that a full 1/2" is applied to tne lath since, in drying, the plastic will shrink anc if a thin coat has been applied, :n?. .am wil. show through, The clastic sneuie be aopliec while tne * coic. After at least one heating and cooling cvcie, all crac:.: cxceni at the grooves should be cu: out and refilled with plastic. (b) 1-1/2" High Temperature Plastic on Zxpancec Nfetal hath. "" ~ * The correct installation of the lath is particularly imtmrian: to revent cracking, bulging, anc peeling. The lath, as shewn Fig. (ai, age 58, is supported on studs which are welded to tne tune- cr casing. It is applied in full sheets with boiler cold and is held awav :rom the blocks with plate nuts. These plate nuts should be c-n.y har.c tigr.t, m allow the mesh to slide when the boiler gets hot. Tne application c: mo metal lath should start with the application of the filler sheets beninc tne buckstays. These filler sheets should be applied between tne buckstay spacers and lap the adjacent rows of studs above and below the bucKstav See Fig. 12 (b), page 58. .After the filler sheets are installed. :uh sue tl. Cl. 54 sneets of lain. wnicn are 4 Xx : . sncuid be s:ar:ec a: :r.e r: a buckstav, lapping over the cttside c: *.he filler pieces 7r lapped at least three inches a.- shown on Fig. 12 (cl, page 5 zcnt'a,! and vertical laps between backstays should be :r. a ct line as shown on Fig. 13, page 59. Each lap must be sec-rs weided to the casing. Where = lap does not fall or. a line c: studs, additional studs must be added to hold the laps tore:: bulging. At the junction of four thicknesses of lath, the inr.t be eliminated and the lath pushed tight against the block to showing through the finish coai. The finish coat is applied in two layers, the firs: .ivt: teim . If possible, this first coat should be applied with the boiler cola. Hi--;, temperature plastic should be soaked in water at least eight rears ; - applying. This allows the water to completely saturate the plastic makim it easier to apply and trowel smooth. The plastic should be thrown tr.r.-..; the lath with enough force to completely fill the space behir.c the let". . built out to cover the lath to the specified thickness. The firs: lav-.-r . . plastic should be grooved at the laps and in between as reces-ar- to :m 4' x 4' panels. The details of the grooving are under the section title c: '`Grooving." After the first layer of plastic is thorough!'-- :r. ' 1.. . . : r :. cracks except those in the grooves are to be cut out, peened _ :.:.mr . and filled in with Elastic insulation. The second layer should be approximately 1/2' true : or.: rm .. ' should be applied with the boiler cold. If job scheduling recv.ttvs tu-- u:tf to be in service before applicati >n of the second layer, it mav oe upp-icc with the boiler hot. In no case s \ould the studs show through tms secor.c coat. If the studs show, they she ild be clipped off so that thev art- buried under the plastic. The grooving >f the second coat must coincide with the grooves in the first coat. Small >egs, short pieces of wire, or the hue srt.u into the grooves of the first laye aid in the location of the grooves m the second layer. After the second c rat has thoroughly dried and the boiler gone through at least one heating and cooling cycle, all shrinkage cracks other than those in the grooves s ould be cut out, peened with a hammer, and filled with plastic insulation. (c) 1/2" High Temper.-ture Plastic on Hexwjre Mesh. Another type of finish coat utilizes 1/2" of High Temperature piastre w:*u hex wire mesh, chicken wire, or poultry netting as trie reinforcement cne application o: the wire mesh is the most particular oar: o: this "-'p- o: iinisn. The mesn must oe tied .-ecurelv to the lacing over the mock and also directly to the insulation fastener. This mesh must be installed with the boiler cold Since the mesh must act as a reinforcement for the plastic, it is important that the mesh be held away from the block occasionally so that the plastic ma bond itself into the mesh. To accomplish this, small daubs of plastic 3" in diameter and 1/4'' thick snouic oe applied to the block before the rr.esh is installed. The daubs should oe placed between the spots where the mesh is to be tied down. Vvhen apply- ing the mesh, the adjacent sheets should lap by at least 3" and be ties to gether with wire on 12" maximum centers. The mesh must be wired covr. at eacn insulation fastener and at ea :h cross point of the --ting w;ro_ At each opening or stopping point of the mesh, additional vires must ov installed to tie the mesh down to prevent it from pulling away from the block. (See drawing 23043D, page 60 In no case should the use of stap.es be allowed for holding down the mesr . _ .he 1/2" of plastic should be applied in one cor. with trcold, caking care to trowel the plastic in through the mesh c: ten plastic and the reinforcing mesh. The plastic should be grooved into panels approximate! 1 hori zontal by 5' vertical. Additional grooves around doers, etc. a--.- :c m made as shown in section on grooving. After the plastic has cr.ec ..m. preferably after the boiler has gone through a heating am c:.; long o all shrinkage cracks in the plastic should be filled in. (d) 1/2" Asbestos Cement on Hex Wire Mesh The type of finish commonly used on flues and duces .2 Asbestos Cement on Hex Wire Mesh. The wire mesh ruh; at:or. i: same as that for the "plastic finish" only using the cement ::: the cams to hold the mesh away from the block. Tne cement is applied in two layers. The first layer .s 1 tme and should be troweled through the mesh to bond the cement am! mess. After this first layer is thoroughly dry, the shrinkage emern most os filled in. The second layer should be 1/8" thick tro-welec om.roto: 7. . tinish coat should be grooved into approximately 3' horizon:., i vertical panels, with additional grooves around doors, etc., as s. ac-vr. tr section on grooving. (e) Car.vas. A canvas covering is used in some cases as a finish covering over block. Although it is used sometimes on flues and ducts the mom ccmmor application is piping such as downcomers, steam piping, etc. The canvas covering is applied over block, resin-sized paper, or asbestos cerne-m depending on location and job specifications. It may be apr.V.ec b'/ g.uta; or by sewing. The glued method is more in common practice than im sewn type of application. The job drawings will specify whicz methoc is to be used. m applying the glued canvas, it should be thorough!'/ smuratec tr. the glue, wrung out, and securely shrunk over the insulation. I: is high ly desirable to apply this canvas when the boiler and piping are cold. If appliec while the boiler is hot, the canvas will wrinkle when the roller is All canvas should oe starred 1-1/2" short of arm ho*. to prevent the canvas from burning. surtam (f) Asbestos Cloth. On areas which are too hot for the use of canvas, asbestos cloth is substituted for the canvas. The application is the same as for canvas except that asbestos paper is substituted for the resir.-sizec rarer where srecified. e ne use of the asbestos moth or canvas will be ;oc drawings. } 5 6- r im i u im ii .j u iv m i h t r .i i n`iii'> i, .' r m>< i i't n in iM C m r is HM i-w i. t o t ih . in d n r::rs > W -t t i> n r v a t i m u ; >>i ow Tin: RAfc n it * o r <k t io n t 4 h w iu 'o o iij ii x <u am ay the m ii is ik y to xi FIG. 12 SKETCH SHOWING? APPUCATION OF EXP. MTTAa LATH FOR I PLASTIC riNlSM (a) ( d) Cc> FIG. 13 5KETCH SHOWING? CONTINUOUS LA' LINES BETWEEN BUCKSTAY5 BUCKSTAY / p tXP METAL L-ATH( -4' X S* SHEETS 3* MSNi - 6"!VSAX LA? // ! [ / 1 BUCKSTAV i *1 -- -- *{I ,Njir V.:- 9NI*C"3 v z asfmS *s?r :_ nv;-;?^ : NO^hl.2*1*!" t XZmd'z : 3 1'cli -*SrHOii.yOC"3di-v- 3_ N23*. .:- a" o , `G3NIV13S 99 C_ 9'. 9" "ft'bl X\`- 3>v99 . 'S^fNiG /CiGd-: '933-9'X G "OidAX 01? NOUOlSbGl' ^ .-----SNIO>n C_ G3-_ u9? XCb--A 39/ '.IN- , Z _ c z - Vi; * e! XVi- .? _- ViC^,, "3Vj! - XOOO^ gO 3DG3 01 "BTIVV*:- SWNtvriV 9b * 9K:0b" -Sll' Xv,- 2 1" NXO'" 03 _ 39 01 993;'. 38'X v; 1 *- *l - - n't**. * \ i* * |C 1 <<i* | * W>~ 7V* = i-.:- <9 kt5- i* ns^><kk<iS VKUri O ' ' ,-v ' ./9'> : -- A_IT\ ; realms coats are requ'.rec over rirusn coats ir. certain spclic uncr. 5 ar.d are supplied as an. extra coating m other applications us-slx- or. soeeial request. On all outdoor units without outer casing or ~agg-_n: sealing coat is required to weatherproof the insulation. Or. sootier m having a plastic finish coat, the sealing coat serves to reduce the a: infiltration into the setting. There are two types of sealing gener al use *. 'nmuision type'1 wnicn is aspnait witn an asoestos ar.d emulsified with water. This type is mere ess.htroweled than sprayed. When this type is specifier 1: is usually used for major portions of the surface me me 'cutback'1 type supplements for sealing to meta. surr-oes 2. 'Out Back Type" which is asphalt with an asbesto: :i..e: blended with castor oil that may have naphtha adc.ec. Thutype is usually sprayed on to give a smooth limer The application of these sealing coats are as follows: 1. Emulsion Tvoe Seal Coat The emulsion type is best applied by trowelling it on :r one coat c: 1,4" thickness. When ary, this coat will shrink to 1/8". It should be applied after all shrinkage cracks have been filled in the finish coat Re inforcement with hex wire mesh is used only on overhead application or wr.ere emulsion seal coat is used outdoors by special request. When nex wire mesh is used, it must be tied tightly on 12" centers to the finish coat by tie wires from lacing wires, metal lath and/or ins-la non fasten ers. The mesh should be formed into all grooves. The grooves in the finish coat may be filled completely with this type of sealing compound since when it shrinks, the groove pattern will show up. (See Brewings 333-3 103 15, 3SD-3 1 03 16i. 2. Cut Back Type Seal Coat The cut back type seal coat is b'est appliec by spraying. It is applied in two layers with a glass cloth reinforcement between the layers Tne first layer is applied to a 1 IS" thickness after all the cracks in the plastic finish coat have been repaired. Care must be taken to spray, for a distance of 2", the edges of door frames, buckstays and other metal surfaces which meet the finish coat. At the grooves, the seal coat should lollow the contour of the groove. While the first layer is still wet, a layer of glass cloth is applied to the surface taking care to lap the steel previously sprayed. The glasscloth should follow the contour of the first layer of seal coat in the grooves, and adjacent sheets of glass cloth should overlap a: leas: 3" with overlaps bonded by sealing compound. After the surface has been covered with glass cloth, the final 1/8" layer of sealing compound should be sprayed on covering the entiresurface including the steel and following the contour of the grooves. f-rm - o1 drawing 5SD-310314). It is well tc remember cha: this r-tt c. compound is highly inflammable during the process c: application. so that-pro per fire extinguishing equipment should be or. hand, and all burning or welding forbidden in the immediate area of the scraving operation, Although the cut back type of sealing compound mu-- be trowelled on, it is usually specified to be SDrayed. / t- 62 Vf-, {. 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X * X to tou; < x Vi o w > X to * o < c w z z c X to V x x X c to o o* to toV*.i c to X wX to toc x c C c <J s K a z z<c o Ow c z c z X < u v. x _,*> w x 6<t to c UJ x to w % tou w Xc toVi Vi V) o to tow a o X uc>z to tok- x o oz Zo ft. toUJ o o O X Xw w 4J s m_ d, < > tox > o < c O < * O vi _/ tfe < X O to xx to to to c Xx to to >c> sr X c n_ 3 to [l_ MJ X X to < X X to <X< x to X V 0 VJ X to 0> < < * Vi o < X Ui z to to > X o * c o p5 X to O X 2 x to toc to vo to too x X o z to z< -- to to --zw < to V) toto KTi < w to X < to X < 3 u VO O VO x < w to X wWO to > X-- to <w o z to tzo to <ttoo 2 txo to ottoo V) to I - Ul > h- tZtoo < n X X tco z 2to c o o < tco x x to to U' * C x to X o to > < X X vo to X z < to < to o z <to vo 65 i's. r I <}".) t;< ti V GROOVING Since insulation does net expand readily when heated, it be. obvious that as the boiler expands, cracks will develop in the clas finish coat which surrounds the boiler. In order to make the crac objectionable, the finish coat is purposely cracked or grooved to c trol the location of these cracks. The grooving should be done wh finish coat material is still wet. Drawings SSD-310330 and SSI'-: shows the details of the grooves. It should be noted that the groo'. the 1-1/2" metal lath reinforced plastic come at the edge e: the oi layer of lath at the lap joint. Drawing 23039D illustrates the grooving pattern-to be used w: the 1-1/2" plastic finish on boiler walls. Fig. 14 shows a typical gre pattern for flues and ducts. Since the grooves will be in constant vie care should be taken to make them uniform, straight, and level. Tne should be laid out so that they are continuous within open areas suer, between buckstays on boiler walls. Special grooving locations will o shown on the drawings. - 66 - U U IJAHCO CK & W IL C O X CO . 67 I M l. U AH C O C K & W IL CO X CO . A N !* IS lo A N I 't ) U l`> K l '< iN O H Ic 'N TH A T IT IS N O T T il III: H TPlN iM H I . l* O K c o n n * IN W I I O I I ' O K IN 1'AHT i> U S Ill lo R (H R N IM IIM V f ' l t n i l l rJ N IO H M A T IO N TO o lllC H S O K l o l l A N T I ) T tl! H I'llH IM S i: l ' !.THIM IvH T A I. T o T U I. IN TI.K I.S TS <>l T ill. B A B lO il A W I I J O I i s . AHI> I I t HI. R tm iH N V H t io IN R t.Q U IS T T ill'. U jU IV U t.H T SHO W N H C H to N IS V lf H A T I.H 1S O W H U > O H I'O N T R l 111 1.11 H I T ill, B A N " & W IL C O X 1 .0 ANI> A N Y |H I B l MCILH O l S U t.lt I'A T IIN T S IS U A B U : T O HMOKI < U T IO N H O N O T S C A IJJ USC IU M I.N S IO N S U N IT o` c Ji - 68 - .M'P U < f\ MOM fiKO O VlUO r **- ? fM I) FIG. 14 SKETCH SHOWING GROOVIMG PATTERNS FOR FLUES t DUCTS -69" J| 6tOti jascsviS ts' fcOCCifiO iC 9i' e i X> X0311M 7 XD03WI &U Oi N^OHS SV .00^5 OiN! GBHSHo 3t- S : " ' -:.QQ,. D3S tv AC~B St *'.=213 . 0\jTOt Tjt: n d\Htf3A: ,,3 .1* 5 3_32r.3 "_31 d^l^AC .t Kii.* SnB BT Cr ""i't S3AC0 Oi 0 `3n'""3SN: d ,,t:: 5Nn\f=9 =3'-?2dS X2? ?7W" A NiC" C_ 2_; SBOOC it JC> -N^ C -.$ S- K'SSil'ic s" c^OS Oi SiBaHS oix~ =!C>SiO:S:_t Q3CC- 3*t \OCBt _iS' ^NCiCCr 92K ` _* = ' ? 2^0- iNC: B1S)N;S tv - _ ' r '. _~B"9 '/-- I'ifN w.cIBr .;/tiSHDP='?.:r!3? -2r-' ?! i ?>:?- e? 5a_ .m ~ r <js^ y ^ > .* ' ' 1 /i ** APPROVED INSULATING MATER / The following list gives approved insulation substitutions whic! may be used in place of that which is called for on the contract. Theftsubstitutions .should be made only in small quantities and when ttme do:. ; not permit checking with Barberton. If an insulation contractor w_h-;i to substitute large quantities, the change should be checked through the sponsor in Barberton. Only blocks of the same material and temperature limitutirr mat be substituted for each other. For example: If the contract called for Owens Hlinois-,!K.ayic' block. John: * Manville-"Thermobestos," Ruberoid-!'Calsilite,': or Philip Carev Co.- "Alltemp': could be used as a substitute since they are ail medium tem perature block of a lime silica base. The other medium temperature blocks of mineral wool and medium diatomaceous earth base could no: be.substituted since their base is not the same even though the tempera ture limit is correct. - 71 LIST OF APPROVED INSULATING' MATERIALS HIGH TEMPERATURE BLOCK - Terrmerature Use Limit - 1300T Manufacturer Johns Manville Phillip Carey Co. Ehret Keasbey &t Mattison Ruberoid / Product Name Superex Hi-Temp #19 Enduro Hy-Temp Block High Temp. I. Base Material Diatomacecus Earth Diatomaceous Ear:." Diatomacecus Earth Diatomaceous Earth Diatomaceous Earth MEDIUM TEMPERATURE BLOCK - Temperature Use Limit - i200*r Manufacturer Owens Illinois Johns Manville Ruberoid Phillip Carey Co. Eagle Picher Co. M. H. Detrick Co. Baldwin Hill Refractories & Insulation Product Name Kaylo Thermobestos Calsilite Alltemp Super temp MW Block Monablock #18 Insulating Block Base Material Lime Silica Lime Silica Lime Silica Lime Silica Mineral Wool Mineral Wool Mineral Wool Mineral Wool Johns Manville Phillip Carey Co. 1500* Superex Tempchek Med. Diatomaceous Earth Med. Diatomaceous Earth 85% MAGNESIA BLOCK - Temperature Use Limit - 550*F Manufacturer Johns Manville Phillip Carey Co. Ehret Keasbey it Mattison Product Name 85% Magnesia 85% Magnesia 85% Magnesia 85% Magnesia Base Material Magnesia Carbonate Magnesia Carbonate Magnesia Carbonate Magnesia Carbonate HIGH TEMPERATURE PLASTIC CEMENTS - Temperature Use Limit - 1500F Manufacturer Johns Manville Phillip Carey Co. Eagle Picher Co. Ehret Baldwin Hill Refractories St Insulation Product Name J-M 450 MW50 Eagle 66 Ehret #18 BH #1 Stic-Tite Base Material Mineral Wool Mineral Wool Mineral Wool Mineral Wool Mineral Wool Mineral Wool 72 - ASBESTOS CEMENTS - Temoerature Use Limit - 1'000'F Manufacturer Johns Manville Phillip Carey Co. Ehret Keasbey & Mattison Ruberoid Eagle Picher Product Name #302 #707 #200 #152 #115 #20 or #99 Base Material Asbestos Fibres Asbestos Fibres Asbestos Fibres Asbestos Fibres Asbestos Fibres Asbestos Fibres INSULATING BLANKETS - Temperature Use Limit - 1000'F Manufacturer Baldwin Hill Phillip Carey Co. Johns Manville Webbers Eagle Picher Co. Product Name Rockwool Industrial Banroc "48" Copr-Fibre ;-;Base Material Rockwool Mineral Fibre Mineral Wool Mineral Fibre Mineral W'coi SEALING COATS - INSULATION MASTICS Manufacturer Synco Corp. Johns Manville Johns Manville Eagle Picher Co. Eagle Picher Co. Baldwin Hill Insulmastic Corp. Benjamin Foster C.o. Jr Product Name Powerseal Insulkote Aertite Insulseal Stalastic Weatherseal Insulmastic 90-7 H.I.Mastic T.ree Cutback Emulsion Cutback Emulsion Cutback Emulsion Cutback Emulsion Application Outdoor, Indoor Indoor Outdoor, Indoor Indoor Outdoor, Indoor Indoor Outdoor, Indoor Indoor ss*-. I - 73 I / -h I r V- t IMS 1X s u ION M A N U A L Part 11 Materials Introduction Wall Constructions ................................................................................................... a. Tube and Brick Walls................................................................... b. Tangent Tube Wails ....................................................................... c. F at Stud Tube Walls.................................................................... d. P rtial or Full Stud Tube Walls ......................................... Inside Casii \ ................................. Prevention < f Leakage .......................................................................................... Insulation fo Boilers ............................................................................................ Insulating M terials ............................................................................................... 1. Di. tomaceous Earth Base Block......................................... 2. Mi .eral Wool........................................................................................ 3. SSfo Magnesia Block ..................................................................... 4. Asbestos Fibres ............................................................................... 5. Lime Silica Block............................................................................. 6. Kaolin Wool........................................................................................... 7. High Temperature Plastic........................................................ 8. Asbestos Cement............................................................................... 9. Sealing Coat Mastics..................................................................... Insulating Material Specifications .............................................................. 2 Z 2 2 3 $ 9 10 11 . i1 11 11 11 12 12 12 12 12 13 x INTRODUCTION Heat insulation may be defined as those materials or combin ation of materials, with air or evacuated spaces, which will retard the transfer of heat with reasonable effectiveness under ordinary conditions. Heat may be transferred by conduction, convection, or radiation, or any combination of these three methods. In the days when all boilers had solid brick settings without furnace water cooling, the outside temperature of the furnace walls was often as high as 350F. On most of these boilers, if insulation nab been placed outside the walls to improve working conditions and to reduce heat loss, the temperature of the brick would have gone up enough to adversely affect its performance and life. Therefore, the only practical way of approaching comfortable conditions was by good boiler room ventilation, and in some instances, by the use of air cooled furnace walls. Water-cooled wails permit covering with any desired thickness of insulation without materially changing the inside temperature. It is now- general practice to make the insulation thick enough to assure comiortable working conditions and, at the same time, to maintain a reasonable balance between the cost of the fuel saved by insulating the boiler and the cost of the insulation. The heat economy and comfort requirements, of course, can be satisfied with practically any arrange ment and type of insulation if it is the correct thickness and the material will stand the temperature to which it is exposed. However, insulation can also be used as an effective seal against air infiltration into the boiler. Therefore, the possibility of using the insulation in this man ner must also be considered in the economics of the design of suction furnace units. WALL CONSTRUCTIONS The most corr.mor.iy used arrangement o: water-cooled setur.;.' tor 'Suction" furnaces over which insulation is used are: (a) Tube and Brick Walls. The arrangement of a tube and br:c^. wall is shown in detail in Fig. 15. The tubes are spaced a: intervals ar.d are usually backed with 2-1/2" refractory tile. The brtck-acru is sufficiently cooled by the water circulating in the tubes to permit the use of this type of wall as a part of the setting envelope ever. ir. high duty furnaces .fired by gas, stoker, pulverized coal or oil. Its location is limited to the cooler convection zones of the boiler adjacent to boiler tube banks, convection superheater banks, and economizers. This tvpe of wall may also be used in the main furnace of most gas and oil fired boilers, but its use with stokers and particularly pulverized coal =hr..lr. be limited to units where the coals are of a relatively high ash fusion temperature, and to dry ash or hopper bottom furnaces only when pul verized coal is fired. This wall should not be used in the main furnace of slag tap boiler units. In zones of high draft, where additional sealing against air infil tration is required, the refractory brick in back of the tubes is backed by castable refractory reinforced by metal lath. For this purpose, 3&W K-20, a refractory concrete, is widely used with good results. (b) Tangent Tube Walls. The closely spaced tube or tangent tube wall, illustrated in Fig. 16, where the tubes touch one another, may be used for any type of firing. This construction forms a continu ous steel envelope which encloses the furnace of a steam generating unit. When its area is properly proportioned, an enclosure of this type will eliminate trouble from excessive accumulation of slag. It is usually sealed against air leakage with reinforced refractory concrete, backed with block and plastic insulation. The castable refractory backing, as shown in Fig. 16. is rein forced with expanded metal lath, close to its outer surface, which makes the castable act as a reinforced concrete mat outside the tubes. The metal lath is installed on the wall first and the castable applied through it so that the lath acts as a reinforcement. Insulating block and a plastic finish or outer casing are installed outside the brick or castable refractory. In some cases, the space between the tube surfaces to the outside tangent point is filled with refractory concrete. This space i^ filled flush with the concrete. Pressure casing or insulation is fitted directly against the tubes. (c) Flat Stud Tube Walls. The flat stud tube wall, illustrated in Fig-. 17, is intended for use under conditions similar to those that apply to the use of the closely spaced tube wall. It is somewhat more economical in the use of steel as it is made of tubes spaced at intervals. -2- Each tube has a series of flat rectangular steel plates welded along its entire length on both sides. The plates or studs on two adjacent tubes close the space between them and present a practically continuous metal surface to the furnace. This type of wall is backed by a comparable arrangement of castable refractory, insulation, and casing or plastic insulation finish described for the closely spaced tube wall. (d) Partial or Full Stud Tube Walls. Where a higher furnace temperature is desired than it is possible to maintain with the closely spaced tube or flat stud tube wall because of their high absorption of furnace heat, the partial or full stud tube wall, illustrated in Fig. 18, is used. This type of wall is made of water wall tubes spaced at inter vals. The space between tubes is (a) partially closed with two rows of round studs welded to each side of each tube, and (b) for the full stud wall the furnace side of each tube as well is covered with studs. Some times, close-spaced tubes are also full studded on the furnace side. The studs are packed with a chrome base plastic pounded in place or a chrome base castable gunnited or trowelled in place to form a con tinuous wall. When plastic chrome ore refractory is used, it is put on in the closest possible contact with the tubes and studs and is itself thoroughly bonded as it is applied lump by lump. In service, the chrome refractory is, in effect, water-cooled because of the extended surface heat transfer effect of the studs. The stud tube wall is sealed against air leakage and insulated in a manner similar to that used for closely spaced and flat stud walls. One particular application of the full stud tube wall is in the lower portion of a slag tap furnace where it is necessary to keep the coal ash above its fluid temperature in order to remove it as a liquid. This con struction is very resistant to the fluid slag found in this type of furnace. In the upper part of the furnace, a partial stud, flat stud of close-spaced tube wall construction may be used. -3 - Fig. 15 his figure will be furnished at a later date. Fig. 16 This figure will be furnished at a later date. -5- Fig. 17 This figure will be furnished at a later date. 6 Fig. 18 This figure will be furnished at a later date. -7- INSIDE CASING This type of casing as differentiated from the outside casings is a pressure tight casing de veloped for pressure firing. It is also used on some suction fired units when a pressure tight casing is desired. Block insulation is secured to this casing and covered over with a plastic finish insulation or an outside casing. PREVENTION OF LEAKAGE In designing a waterwall, the refractory lining of tile or fire brick is made as air-tight as possible. Without any supplementary seal, where the draft within the setting is fairly low, this makes a com mercially tight wall. However, in high draft zones, the brickwork is not sufficiently air-tight. Therefore, the entire wall may be covered with an outer casing which is sealed against air leakage by using welded casing. With a casing of this type, some slip seals may be required to take care of relative expansion caused by a temperature differential of about 400F between wall tubes and casing. The refractory serves to limit the amount of leakage which occurs through the slip seals and often at casing terminals. Insulating block can be used to supplement the leakage resistance of the refractory by being tightly laid up. The performance of many units indicates that an air-tight casing is not required if, by careful ar rangement and installation, the insulation construction is made to act as an air seal by using multi-layer con struction with the block laid up with staggered joints and having a layer of plastic cement. -9- INSULATION FOR BOILERS Materials used in the insulation of waterwalls must have the following characteristics: 1. Reasonably low conductivity which will not increase appreciably in service. 2. Sufficient mechanical strength to withstand shipping, application and handling. 3. Resistance to moisture. 4. Low shrinkage when heated. 5. Good resistance to disintegration or settling by vibration even after prolonged service at operating temperature. 6. The ability to retain structural strength at operating temperature. For some special applications, such as on boiler settings under pressure instead of suction, where the casing is over the insulation, the insu lating material should be capable of retaining its strength and thermal properties after repeated ex posure to dilute solutions of sulfuric or sulfurous acid. 10 - INSULATING MATERIALS The basic materials most frequently used in heat insulation and some of the commercial forms of insulation made of these materials and their use, are listed below: (1) Diatomaceous Earth Base Blocks: At present this is the most widely used high temperature insulator. It is a silica composed of the skeletons of simple organisms, uncalcined or calcined, with as bestos fibre and clay molded under heat and pressure. This type of block is relatively expensive and is therefore confined to the tempera ture range of from IZ00F to 2000F. It comes in rigid blocks 1" to 4" thick, or molded pipe covering from 1" to 3" thick for pipes up to 30" in diameter. A medium temperature Diatomaceous Earth Block is also available. This block differs from the high temperature block in density and its preparation at a lower fifing temperature limits its usage to 1200*F to maximum. It is used principally for boiler walls, flues, ducts, fans and steam lines. (2) Mineral Wool: This is made from molten slag, glass or rock blown into fibres by steam or air jet. (a) Mineral Wool Base Block: This block is made of mineral wool fibres and clay molded under heat and pressure. Temperature limit (controversial) up to 1800*F is claimed by some manufacturers. Usual size, form and principal uses are the same as for (1). (b) Mineral Wool Blanket: This is made of mineral wool fibres compressed into blanket form held in shape by retaining between chicken wire or expanded metal lath. Temperature limit is 1000*F maximum. Comes in 24" by 48" or 96" flexible blanket up to 6" thick. Used principally on cased boiler walls and tanks. It could be used on flues, ducts and uncased boiler walls, but it is difficult to cover with a good finish coat. (3) 85% Magnesia Block: Magnesium carbonate (MgC03), asbestos fibres and clay molded under heat pressure. Temperature limit is 550*F maximum. Usual size, form and principal uses are similar to (1). (4) Asbestos Fibres: Produced from the raw mineral asbestos by successive crushings. This material contains numerous small air spaces and is therefore a good insulator. For use as a high tempera ture insulator, the fibre is fitted and pressed into sheets or block to give it a high mechanical strength. The pressing necessary to give the high mechanical strength required for handling reduces the effec tiveness of the air spaces, and consequently, the thermal conductivity of this product is not as low as that of other insulators in which many air cells are retained. 11 (5) Lime Silica Block: This is a lime silica based block made of reacted hydrous caiciurrTsilicate with sufficient mineral fibre in cluded to give good handle ability. Temperature limit of 1200*F maxi mum warrants use of this block for medium temperature applications. (6) Kaolin Wool: A pure white wool blown from melted Kaolin ch /. Because of the high (3200F) melting point of the clay, the final pr^ duct retains its resiliency up to 2100F. It can be used commer cially in blanket or block form as described for mineral wool. (7) High Temperature Plastic: Insulating cement made of min eral wool fibres processed into nodules and then dry mixed with clay. To apply, this shall be mixed with enough water to give good trowelling consistency. In final dried condition, it is a tough fibrous monolithic insulation. Drying shrinkage may be considerable, and therefore scor ing of the surface is necessary to prevent random cracking upon driving. Temperature limit (controversial up to 1800^ maximum) is claimed by some manufacturers. This is used principally on boiler walls, ir regular shaped valves and fittings and heated tanks. Thickness of ap plied layers should be limited to from l/2" to 2", with suitable rein forcement. (8) Asbestos Cement: Asbestos fibres dry mixed with clay. To apply, this shall be mixed with enough water to give good trowelling consistency. In its final dried condition, it is fairly hard but not as tough as the mineral wool base cement described in item (6) and is easi y damaged. The drying shrinkage is comparable to that of high tern erature plastic. Temperature limit is 1000F maximum. It is usee principally on indoor installation as a finish coat for insulation on {'. ;es and ducts and also sometimes on uncased boiler walls. (9) Sealing Coat Mastics: (1) Cutback Type: Asphalt with an asbestos filler blended with castor oil that may have naptha as a filler. Highly inflammable when applied, but tends to remain more flexible over a long period of time. Sprays fairly smooth but is difficult to trowel. POWERSEAL is a brand of approved cutback type sealing mastic. (2) Emulsion Type: Asphalt with an asbestos filler and emulsified with water. Fireproof when wet, but tends to become stiff and hard over a long period of time. Sprays rough but is easy to trowel. INSULKOTE is a brand of approved emul sion type sealing mastic. - 12 ADDENDUM SPECIFICATIONS FOR INSULATION MATERIAL ALL INSULATING BLOCKS SHALL MEET THE FOLLOWING REQUIREMENTS (a) The linear shrinkage shall not exceed 2% after a 24-hour soaking heat test at the following temperatures: TYPE OF BLOCK SOAKING TEMP.(F) 85% Magnesia Block ( To Specification Listed Here In) Medium Temp. Block ( " " M n ") High Temp. Block ( " " " " ") 600 1200 1800 (b) The compressive strength after a 24-hour soaking heat test at the temperature listed above shall not be less than three-quarters of the strength of unheated samples. (c) The flexural or breaking strength (measured by ASTM Designation C-203) after a 24-hour soaking heat test at the temperature listed above shall not be less than one-half of the strengths of unheated samples. (d) Unrestrained warpage of a 6" by 18" sample after 96 hours on a hot plate at the temperatures listed above shall not exceed 3/8 inches. The specimen shall have not more than one deep crack (extending 3/4 through it). Insulation thickness for the hot plate test shall be as follows: Hot Face Temp. Sample Thick ness Total Insulation Thickness Over Hot Plate (add insula tion as necessary to sample) 600 85% Mag. Block 1200 Med. Temp. Block 1800 High Temp. Block 3" 4" 4" 3" 6n 8" HIGH TEMPERATURE INSULATING BLOCK This block shall be moulded type composed predominantly of calcined diatomaceous earth uniformly mixed with suitable proportions of mineral reinforcing fibre and of heat-resistant inorganic binder. The physical properties shall be as follows: Density Compressive Strength (at 10% deformation) 22 to 27 Ib/cu.ft. 50 psi minimum Flexural Strength (lb/sq.in.) 2.5 x density minimum Thermal Conductivity - maximum BTU/(hr.) (sq.ft.) (F/in.): - 13 - Mean Temp. 400 800 1200 Conductivity 0.70 0.80 0.90 MEDRJM TEMPERATURE INSULATION BLOCK Medium temperature insulating block may be any of the types listed below unless there is a customer objection to a particular one. If one or more of these materials is excluded by the customer's specifications the fact should be noted on the Contract Information Sheets. (1) Lime-Silica Base Block - This block shall be reacted, hydrous calcium silicate with sufficient mineral fibre included to give good handle ability. The physical properties shall be as follows: Density (lb/cu.ft.) 11 to 16 Compressive Strength (at 10% reduction in thickness) 50 psi minimum Flexural Strength (per ASTM C-203) 40 psi minimum The thermal conductivity (expressed as BTU/sq.ft./hr./(F*/in.) shall not exceed the following: Mean Temp.(F) 200 400 800 Maximum Conductivity 0.44 0.52 0.70 (2) Medium Temperature Diatomaceous Earth Base Block - This block shall be moulded type composed predominantly ~6f either calcined or uncalcined diatomaceous earth uniformly mixed with suitable proportions of mineral reinforcing fibre and of heatresistant inorganic binder. The physical properties shall be as follows: Density (lb/cu.ft.) 16 to 24 Compressive Strength (at 10% reduction in thickness) 50 psi minimum Flexural Strength (per ASTM C-203) 40 psi minimum - 14 - a' The thermal conductivity (expressed as BTU/sq.ft./hr./F*/in.) shall not exceed the following: Mean Temp. 200 400 800 Maximum Conductivity 0.54 0.60 0.72 (3) Mineral Wool Block - This block shall be a moulded type composed of the best grade~of mineral wool fibres with suitable heat resistant inorganic binding material. The physical properties shall be as follows: Density (Ib/cu.ft.) 16 to 24 Compressive Strength (at 10% deformation) .12 Ib/sq.in. minimum Flexural Strength (per ASTM C-203) 30 psi minimum The thermal conductivity (expressed as BTU/sq.ft./hr./F*/in.) shall not exceed the following: Mean Temp. 200 400 800 Maximum Conductivity 0.48 0.58 0.80 85% MAGNESIA INSULATING BLOCK This block shall be made of 85% of pure carbonate of magnesia (4MgCOj, Mg02H2" 5H20) and between 10 and 15% of asbestos fibre. The carbonate of magnesia, and asbestos shall be thoroughly mixed and uniformly distributed throughout the block. Carbonate and sulphate of lime shall not exceed l-l/2% of the total compound. The thermal conductivity (expressed as BTU/sq.ft./hr./F /***) shall not exceed the following: Mean Temp. (F) 200 300 400 Conductivity 0.47 0.50 0.53 The physical properties shall be as follows: Density (Ib/cu.ft.) 11 to 14 Compressive Strength (at 10% reduction in thickness) 50 psi minimum Flexural Strength (per ASTM C-203) 40 psi minimum - 15 - material contract MINERAL WOOL BLANKET INSULATION Shall be composed of the best grade of mineral wool fibres compressed between metal fabrics to a density of not less than 10 lbs. per cu. ft. Tie wires between the metal fabric on each side, shall be spaced on a maximum of 12 inches. Thermal conductivity shall not exceed 0.70 BTU/sq.ft./hr./in./F* at 200T (mean) n m t 0.80 ,f M H " 11 M " 400*" H FIBRE GLASS BLANKET INSULATION Shall be composed of the best grade of glass wool fibres compressed between metal fabrics to density of not less than 10 lbs. per cu. ft. Tie wires between the metal fabric on each side shall be spaced on a maximum of 12 inches. Thermal conductivity shall not exceed 0.70 BTU/sq.ft./hr./in./F* at 200*F (mean) ff * tt 0.80 " ' HM M M M M 400*" 11 HIGH TEMPERATURE PLASTIC INSULATION High temperature plastic insulation shall be the best grade of mineral wool insula ting cement, make predominantly of mineral wool fibres, dry mixed uniformly with other ingredients. Thermal conductivity shall not exceed 0.70 BTU/sq.ft./hr./in./F* at 200TF (mean) 11 m ii ii ii 0.80 * " " " " M 400*" M ,f * tt n n 0.93 M " n 11 M n 800*" M To insure a homogeneous structure in applied high temperature plastic, it is definitely required that factory premixed ingredients bd supplied. SEALING COMPOUND (EMULSION TYPE) Insulkote or equivalent fibrated asphalt emulsion (long fibre asbestos with suitable binder and filler): This compound shall have S5% maximum shrinkage, with a minimum covering capacity, when dry of 42 sq.ft. l/8" thick per 100 lb. It shall be capable of withstanding without blistering, cracking, melting, running, or con tinuing to support combustion after flame has been removed, when a dried test piece is placed vertically 2 in. from the end of a blowtorch with a 4 in. long blue flame, and exposed to flame 30 seconds. SEALING COMPOUND (CUTBACK TYPE) Shall be Powerseal or equivalent fibrated asphaltic type cutback. It shall be capable of good adhesion to steel having a temperature of 200*F to 250*F or to Plastic in sulation. ASBESTOS CEMENT All asbestos cement shall be high quality long fibre. It shall not contain Portland cement and none shall be added. SUBSTITUTIONS No substitutions for material specified shall be made without approval of B&W Co.