Document OE9EzrbeopYwwvROQOEy1GkMX

TEXACO INC. PUGET SOUND PLANT TRAINING.DETAILS PAGE NO. 1 DEPARTMENTS INSULATION CLASSIFICATION: INSULATOR (TRAINEE) DATE: JUNE 18, 1973 A. BASIC TRAINING INDEX SUBJECT 1. 2. 3* 4. 5. 6. 7, 8. 9. 10. XX 6 12 13* 14. Departmental Organization Relationship of Department to Refinery Operations Departmental Standards and Working Rules Departmental Safety Practices a. Location'of Equipment b. Use of Equipment Departmental and Plant Fire Protection a. Fire Prevention Practices b. Location of Fire Equipment c. Use of Fire Equipment Departmental and Plant Housekeeping Care and Purpose of Shop Equipment Types and Purpose of Insulating Materials Procedure for Obtaining Tools* Materials and Equipment Types of Weathereoating Departmental Standards of Craftsmanship Location and Use of Utilities Procedures for Obtaining and ./sing Permits Read, Interpret, and Work from Blueprints, Sketches and Bills of Material PAGE NO '5 6 7-8 9-11 12-14 15-16 17 18-20 21 22 23 24 2,5-26 27-29 WA-TEX 001527  VfOi SUBJECT 15. 17. A BASIC TRAINING Measuring and Layout Methods First Aid Training Job Instructor Training PAGE NO. 2 PAGE NO. 30 WA-TEX 001528 SUBJECT 1. 2. 3. 4. 5- 6. 7. 8. 9. 10. 11. 12. 13. B. ON THE JOB TRAINING PAGE NO. 3 Procedures for Obtaining and Transporting Tools and Equipment Procedures for Hoisting Tools and Equipment Protection of Materials and Equipment Clean-up of Shop and Work Area Procedures for Erecting Scaffolds and Ladders Procedures for Removing Old Insulation Salvage of Insulation Materials Procedures for Mixing Insulation Cement a. Hand Mix b. Machine Mix Procedures for Cutting Materials Procedures for Operating the Tar Pot Cleaning and Preparing Surfaces for' Insulation Procedures for Operating Space Heater Procedures for Preparing Insulation for Application a. Calcium Silicate b. Cork c. Plastic d. Block e,, Monolithic f. Fiberglass g. Acid Proof Cement h. Mineral Wool i. Hair Belt PAGE NO. 32 33 3^ 35 36 37 38 39 40 4l 42 43 44 WA-TEX 001529 SUBJECT 14. 15. 16. 17. 18. 19. .20 21. B* ON THE JOB TRAINING PAGE NO* 4 PAGE NO* Procedures for Operating Saws 45-56 a. Band b. Bricksaw Procedures for Cutting, Preparing and Applying Materials 57-58 a * Roofing Paper b. Muslin and Canvas c. Wire Mesh d. ' Metal Lath e* Aluminum Jacketing Layout Work 59^-60 Procedures for Applying Insulation 61-78 a Lines b. Pumps Co Valves and Fittings d. Vessels (Outside) e* Vessels (Inside) f. Heaters and Exchangers Procedures for Painting InsulatingCovering 79 Procedures for Applying Erosion and Corrosion 80 Protection to Insulation a. Acid Proof Cements b. Refractory Cements c* Weatherproofing .. Procedures for Concrete Finishing 81 Procedures for Repairing Furnaces 82-96 WA-TEX 001530  TEXACO INC, HTGET SOUND PLANT TRAINING DETAILS PAGE NO. 5 ATE;APRIL 3,1973 DEPARTMENT; INSULATION ' CLASSIFICATION; ISOLATOR (TRAINEE) ITEM NO. A-l S'GKi'EOTs DEPARTMENTAL ORGANIZATION The Insulation Department Is one of several departments of Puget Sound Plant which comes under the jurisdiction of the Assistant Plant Manager (Maintenance). The Supervisor - Maintenance is in charge of the^ planning, scheduling and execution of work involving all the maintenance departments in the plant Including the Insulation Department. The foreman of the insulating department is in direct supervision of the personnel of the department and is respond Bible for the selection and assignment of craftsman and trainees in accordance with, the requirements of the dally work schedules. He is also responsible for the follow up of work performance to assure proper application of craft skills and quality workman ship . . The Insulation Foreman directly supervises the work of insulators, assigned to respective units, coordinates the work and cooperates with the various operating departments in accomplishing scheduled work. INSOLATION DEPT. [ASST PLANT MANAGER (MINT)1 {off P3L0T ENG^r| 1 SUPERVISOR M &.c| {FOREMAN INSULATION PEEtI 1 ASSISTANT FOREMAN 1 j insulation"department1 fc)N PLOT ENG R WA-TEX 001531 TEXACO INC, PUGET 'SOUND PLANT TRAINING DETAILS PAGE NO, 6 DEPARTMENT ; CLASSIFICATION; ITEM NO. ; A-2 INSULATION INSULATOR (TRAINEE) SUBJECT; DATE; JUNE 18, 1973 RELATIONSHIP OF DEPART MENT TO REFINERY OPER- TIONS ' ` " The purpose of a refinery is to process crude.oil and convert it into highly refined and saleable petroleum products, as economically and safely as possible, while maintaining high standards of quality which assure continued confidence of the buying public. Each operating unit and department is designed, con structed and operated with the objective of providing a continu ing supply of quality-controlled petroleum products for a highly competitive market. Maintaining each unit in a safe, operable condition requires the knowledge and skills of many people and crafts. New techniques, materials, tools and methods are constantly being developed which require increasing knowledge, skill and training in order to take advantage of these develop ments and remain competitive.' Since the Insulator's work may Involve other crafts, or affect several operating departments. It Is essential that he closely coordinate his work and cooperate with others in order to do a safe, workmanlike job. It can thus be seen that the Insulation Department plays an important part In relation to both the maintenance and operation of refinery equipment. As equipment or procedures are changed the Insulator may find It necessary to adapt himself to the use of new methods, new tools and undergo re-training. However, the Insulation Department still bears a continuing responsibility and rexationship to operations of the refinery which contribute substantially to the maintenanceof the safety, economy and continuity of the refinery productive capacity. | WA-TEX 001532 TEXACO INC. PUGET SOUND PLANT TRAINING DETAILS PACE NO, 7 DATES APRIL 3,1973 DEPARTMENTS INSULATION CLASSIFICATION; INSULATOR (TRAINEE) ITEM NO. A-3 S'lB^ECT; DEPARTMENT STANDARDS AND WORKING .- RULES 1. When you cannot report for work as scheduled, and on time, give your Craft- Supervisor or the Night Foreman on duty as much advance notice as possible. If you are unable to call, have someone call for you. 2. Request for time off should be handled with your Craft Supervisor as far in advance as possible. 3. When you have been absent for any reason such as sickness, accident, vacation, etc., call your Craft Supervisor as far in advance as possible before returning to work so he can arrange schedules and advise you when to report for duty. A. In case of change of address, notify your Craft Supervisor of new address and telephone number. 5. ' When you have finished a job, go at once to your next assignment. If kncwnj otherwise, contact your supervisor. Do not loiter or loaf between jobs,. 6. It is an Insulator's responsibility to see that his job progresses in a safe working manner, keep his helpers lined up and working, and to know where his helpers are at all times. 7. It is an Insulator!s duty to make sure all necessary ma terials, equipment and tools are transported to his assigned job. ' 8. Instruct his helpers of proper tool handling and work procedures on the job. 9. Request work permits when required to do a job, such as entering and burning lights in vessels or towers, etc, (Read permits and follow special instruction written on permit.) 10. In an oil refinery, we must eliminate all possible causes of fire. Smoking is permitted, therefore, only in certain clearly marked areas and at specified times. People who cannot observe this very important safety rule just donft belong In an oil refinery. For the safety of everyone, this rule is rigidly enforced. ! WA-TEX 001533 ITEM A-3 TRAINING DETAILS PAGE NO. 8 11. Insulators will be furnished the tools necessary to per form their specific duties. It Is thp responsibility of each Insulator to make sure that the tools he uses, or returns for the use of others, are in safe working con dition, Replacement of broken or damaged tools will be handled by the Main Tool Room, 12. The plant telephone system is primarily for the transaction of Company business. Personal calls ordinarily should not be made during working hours. You are expected to use good Judgment in this respect. Please use the phones for personal business only when absolutely necessary. 13. It is an Insulate, r's responsibility to train and .instruct. a Craft Helper or Trainee in the methods and procedures of his trade whenever so assigned by his supervisor. WA-TEX 001534 TEXACO INCV~ PUGET SOUND PLANT TRAINING DETAILS PAGE NO. 9 DATE;APRIL 3,1973 DEPARTMENT; INSULATION . CLASSIFXCATIONi INSULATOR (TRAINEE) -f * ITEM NO, A-4 SUBJECT; DEPARTMENTAL SAFETY PRACTICES a. Location of Equipment b. Use of Equipment The purpose of this section Is to assemble In one place the more Important and pertinent safety Information applicable to the work of the Insulators. In general, all of the Regu lations, Procedures and Practices and information contained herein should be studied carefully by every craftsman and trainee and.practiced constantly. b, REGULATIONS The following regulations MUST be observed? (1) No tank, vessel, tower, drum or other enclosed space is to be entered until a SAFETY WORK PERMIT has been issued authorizing entry. ` (2) No electric hand power tools, such as Skillsaw, or elect ric drill can be used which could be a source of ignition for any flammable materials, unless and until a HOT WORK PERMIT, Form R-241, (pink form) has been issued in proper form by the operating department involved and properly countersigned by an authorized operating supervisor. (3) Standing instructions for issuing both Hot Work and Safety Work Permits must be reviewed by each Insulator and trainee. - (4) CAUTION - Always read the PERMIT - be sure you understand . the precautions which must be observed - note the time period it covers - be sure it describes or identifies the line, vessel or equipment to be worked on - note the re quirements for use of personal protective equipment - be sure the condition of the line, vessel or surrounding area is specified - and obey all the precautions written on the permit. WHEN IN DOUBT, CONSULT YOUR FOREMAN. (5) Do not open or close valves on lines, vessels and operating . equipment (except valves at utility stations - air, steam and water)v Only Operators on the particular unit or area are permitted to operate valves. (6) Hard hats must be worn on the job. Goggles must be.used whenever a hazard to the eyes may be encountered. For example Chipping, breaking concrete, working where dust and rust is blowing around, grinding, etc. Protective clothing (impervious suits) and other protective equipment must be worn when specified on HOT or SAFETY WORK HERMITS, when Instructed to do so by the Foremah In charge of the work. WA-TEX 001535 I ITEM A-4 TRAIIIHG DERAILS FADE 130. 10 (7) When work is performed on pipe lines connected to equip ment or lines in service and there is any danger of oil or other products scaping from an open end* or open-end valvefl the valve flange or open end of the line should he (blinded) off or plugged. (8) When using buckets to raise or lower tools* equipment and material to top of towers or vessels,* remove hail and replace with a heavy gauge wire or small cable. (9) If working in a trench with straight up and down walls over 4 ft. deep* shoring should he installed to prevent caveins of dirt. (10) Before operating on air tugger* cable and spool should be inspected for tangles in cable on spool and broken strands in cable. Cautions When pulling scaffold from towers with tugger* tugger operator on ground and Insulator working inside of tower will be equipped with a two-way telephone system. (11) Hearing protection.must be worn in zoned off areas indicating that hearing protection is required. c. PROCEDURES The procedures outlined herein should be followed whenever performing the work described. (1) When working near pumps Or vessels handling TEL (Tetraethyl Lead) the current rules and regulations of the supplier (Dupont) shall be followed* therefore* consult your foreman and secure properly prepared SAFETY WORK PERMIT. (2) Working on Scaffolds; After building a scaffold* Insulator should check the'following to assure safety? (a) Supports should be solidly set on level surface or properly blocked. (b) Cross braces should be firmly attached. (c) Guard rails should be provided. (d) Decking boards should be free of splits and checks (boards should be at least 2s' x 10" lumber at least as good as select structural) (e) Decking boards should extend one foot beyond working ledger. (f) Decking boards should overhang the bearing ledger at each end at least 12". Where overhang exceeds 12"* Tubelox bars are to be clamped to posts on top of scaffold planks at each end to prevent tilting. WA-TEX 001536 ITEM A-4 TRAINIM DETAILS PAGE NO. 11 (g) Decking boards must be free of oil and grease and ' kept free at all times. (h) Ladders should be installed in best position for climbing and exit. (i) While building scaffold, check all exits possible, in case a quick descent has to be made. d. PRACTICES The following practices are considered as precautionary in nature and it 1-2 recommended they be observed. (1) Avoid walking on pipe lines whenever possible. Major -Jobs of work should not be done while .standing on lines or fittings. (2) Avoid walking on asbestos or transit roofs, on defective roofs, and on insulated lines. (3) Keep clear of suspended loads wherever and whenever hoisting is being done. (4). When lifting make full use of the leg muscles, keep the back as nearly upright as possible and avoid, twisting while lifting. Set help with heavy loads. (5) When working with or around welding operations secure and use safety glasses (goggles) with dark lenses. These may be obtained from the Tool Room. Sfever look directly at electric or acetylene welding rays. Reflection of electric or off light colored (aluminum) surfaces can cause flash burns. * (6) All excavations of any kind in any area where employes are likely to walk must be either refilled, covered, fenced or roped off, and warning flashers used at night.. (7) Leather- gloves should be worn at all times when "building s'caffold. WA-TEX 001537 TEXACO INC. PUG^T SOUND PLANT TRAINING DETAILS PAGE NO. 12 DATEsAPRIL 3,1973 DEPARTMENTS INSULATION , CLASSIFICATION* INSULA#* (TRAINEE) ITEM NO. A-5 SUBJECTS DEPARTMENT AND PLANT FIRE PROTECTION a.Eire ^ b. Location of Fire Equipment o. Use of Fire Equipment Fire protection and fire fighting are the concern of each and every Individual at Puget Sound Plant, All employes, exclusive of women, are subject to fire fighting duty as re quired, whether or not direetly attached to the Fire and Emer gency Organization, Accordingly, supervisors assigned a copy of this manual are responsible for keeping all personnel under their supervision Informed in regard to their Individual roles, I. HOW TO REPORT A FIRE OR EMERGENCY ' To report a fire or other emergency there are simple rules which should be followed? 1. REMAIN CALM - DO NOT PANIC , You have certain vital functions to perform ~ functions which must be carried out promptly and effectively functions which call for clear thinking and sound judgment, 2'. SIZE UP THE SITUATION QUICKLY .................... 1 l ,, V`'' *--1 Is the fire small enough to handle alone - or will - help be needed? Spot the nearest fire extinguishing equipment - weigh the possibilities of personal injury 3. TAKE ACTION (a) Extinguish Eire If you can handle it alosse - SAFELY' or (b) Give Alarm if the fire Is too large to handle without help - even If necessary to leave location to do so. TAKE NO CHANCES OF LETTING FIRE GAIN SERIOUS HEADWAY BEFORE GIVING ALARM. 4. GIVING THE ALARM 4 0&11 the Boiler House immediately by telephone (242) giving* 1. Your name 2. Location of fire and department: Have this informa tion repeated back. 3. Nature of fire - seriousness. WA-TEX 001338 Iffl A-5 TRAINING DETAILS PAGE MO, 13 Mobile radio equipment may be used if telephone is not convenient and would cause delay in sounding alarm. In this case* call thV^ate 'br the'oarage who In turn will relay the call to the Boiler House. However* it la preferable to call the Boiler House direct. REMAIN CALM - HAVE PERSON RECEIVING CALL REPEAT INFORMATION BACK ~ BE STffiE BE CLEARLY KNOWS LOCATION " II. EIRE AND EMERGENCY SIGNALS REGULAR FIRE ALARM? One wildcat cycle followed by number of short blasts to indicate zone- number, Repeat wildcat cycle and zone signal one time* as follows? ZONE NO. Wildcat e (pause 10 sec.) 1 short blast ; (pause 10 sec.) Repeat wildcat and zone Wildcat oft (pause 10 sec.) 2 short blasts g (pause 10 sec.) Repeat wildcat and zone Wildcat .0 (pause 10 sec.) 3 short blasts (pause 10 sec.) Repeat wildcat and zone Wildcat A (pause 10 sec.) 4 short blasts (pause 10 sec.) Repeat wildcat and zone Wildcat O (pause 10 see.) 5 short blasts (pause 10 sec.) Repeat wildcat and zone Responsibility? When Regular Fire Alarm Sounds* all personnel assigned" to" the Fire- and Emergency Organization who are on duty are required to report to their respective assign ments. The only exceptions would be In the case of scheduled fire drills when Individual members may be excused by authority of the Fire Chief (Assistant Plant Manager) only. Persons temporarily on "limited duty" due to physleaTnohdition will be considered as temporarily relieved from fire fighting duties. Off duty employes are not required to report unless called out* except that Supervisors on Cs.ll Out Lists should not necessarily wait to be called. The term "wildcat" or "wildcat cycle" refers to the variable pitch feature of the wildcat fire whistle* sounding the whistle through Its range from high pitch down to low pitch and back to high pitch again. ^ The high pitch is used for zone signals. repeat. Fire Drill? Same as Regular .uding Recall? One long blast of the high pitch. "Recall" to be sounded-only when authorized by person acting as Fire ' Chief* Assistant Fire Chief* Fire'Marshal or Acting Fire Marshal. Person calling the "recall" to the Boiler House should Identify this authority. ; WA-TEX 001539 ITEM A-5 TM1HXM DETAILS PAGE HO, 1ft OEHERAL ALAfils 10 continuous wildcat cycles {approximately two rnlHS^esT} "General Alarm" to be sounded only when authorised by person acting as Fir Ghlef* Assistant Fire Chief, Fire B&rshal* or Acting Fire BSarshal, Person calling a.General Alarm" to the Boiler House should Identify this authority. Responsibility* When General Alarm is sounded* all available employes11'except worsen are required to report as outlined In SECTION 307X1 - General Alarm - of the Plant Fire Manual. Off duty employes should report on hearing the alarm or on being called, _ ffHIT EMERGEHCT ALARM; Series of short blasts (approximately 10)* of* air whistle'"on"unit concerned. Fire whistle will be tested each Friday noon imme diately following the regular plant noon whistle. Test will consist of sounding one wildcat cycle. If wildcat fire whistle is Inoperative* the plant shift whistle will be used. Signals will be the same as above* substituting one long blast for each wildcat cycle, Hourly employes reporting In response to General Alarm or Gall Out Should punch In as usual at the Main Gate. WA-TEX 001540 TEXACO'INC . FffGET SOUND PLANT TRAINING DETAILS PAGE MO. 15 DATEsAPRIL 3,1973 ISOLATION ; XOTLATOR (TRAINEE) .SUITE 3T 8 DEPARTMENT AND PLANT HOUSEKEEPING A. DEFINITION The term "housekeeping" Is generally used throughout the petroleu& industry and refers to the contlnuo-i i maintenance of clean. neat; and orderly condition within a refinery. Lack of good housekeeping practices contributes to safety, fire and health hazards detrimental to all employes. B. responsibility It is the responsibility of each supervisor and employe in the Insulation Department to maintain the department and assigned Work areas in conformance with the ''Refinery Housekeeping Practices". . C,, INSULATION DEPARTMENT PRACTICES In addition to the general practices applicable to every employs in the refinery there are a number of ^'Housekeeping Practices" which are emphasized here and wrlch must be ob served by everyone in the Insulation Department,, 1. All roadways, passageways, aisles, stairways, platforms,, etc.;, shall be kept free of unnecessary t-.ols, materials and debris. Clean up after every job.. 2. Oil or chemically damaged scaffold decking boards should be. promptly removed from service .and tagged for destruction in order to prevent re-use. 3. Any oil or chemical spilled bn stairways., platforms, scaffold decking, walkways and similar areas where persons must work or walk should be cleaned up Immediately and Super-Dri or sand applied 'to prevent slips and falls ,, 4. Waste material should not be allowed to accumulate but should be cleaned up and arrangements made to keep it hauled away. Salvageable materials should be neatly piled until they can be hauled to the plant salvage area., 5* Never 'block access to fire fighting equipment with equipment or materials. 6. If It is necessary to leave job before clean up can be completed, advise the Insulate? foreman so arrangements can be made to reschedule clean up. WA-TEX 001541 ITEM A "6 TRAINING DETAILS PAGE NO, 16 It: is the responsibility of every Insulator,, after a 3oo to leave the work site in a clean* orderly and safe condition unless specifically directed otherwise, ?. All tools and equipment should be cleaned and returned to their proper storage area. Broken tools should be tagged and .sent to main tool room for repair* 8. Area around power saws and all machinery is to be kept free of pieces of lumber* sawdust and bent nails to prevent tripping or stumbling. After cutting lumber* Insulators' are to pick up any scrap pieces and place them on scrap pile. * j WA-TEX 001542 TEXACO INC, PUGET SOUND PLANT TRAINING DETAILS PAGE NO. 17 DATE:APRIL 3,1973 DEPARTMENT: INSULATION GLASSIFICATION: INSULATOR (TRAINEE) ( ITEM NO. A SUBJECT: CARE AND PURPOSE OF SHOP EQUIPMENT A. PURPOSE 1. Band Saw - is used for various angle cuts for in sulation ells, 2. Pexto Shears - used for cutting aluminum Jacketing. 3. Rollers - used for rolling Jacketing for various size lines. B. CARE 1. Band Saw - the blades should be kept sharp* motor oiled* bearing greased and table should be kept clean, 2. Shears - bearings greased, monthly. 3. Roller - bearings greased, monthly. ( WA-TEX 001543 TEXACO INC PUGET SOUND PLANT TRAINING DETAIL'S PAGE NO. 18 DATE: APRIL 3*1973 DEPARTMENT: INSULATION GLASSIFICATION: INSULATOR (TRAINEE) ITEM NO. A-8 -- TYPES SUBJECT: TYPES AND PURPOSE OF INSULATING mmj-MS. 1. Calcium Sillicate 2. 85# Magnesia 3. Foam Glass 4. Foam Plastic 5. Fiberglas 6. Mineral Wool 7. Kaowool 8. Finish Cements 9. Metal Lath 10. Wire mesh 11. Aluminum Jacketing 12. Wire 13. Metal Screen 14. Weatherproof Coating 15. Insulation Sealer 16. Heat Transfer Cement B. DESCRIPTION AND PURPOSE . 1. Calcium Sillicate Insulation is a light weight, molded material, manufactured by reviting a blend of special in organic ingredients, reinforced with selected long fibers under suitable condition of heat and water, then is chemically converted into a strong hard material. The low thermal conductivity of this product makes it ideal high temperature insulation for piping, ducts and equipment recommended for temperature from 600F to 1350F. 2. 85$ Magnesia is composed of hydrated basic carbonate of magnesia bonded with asbestos fiber and molded, into both pipe and'block form for a high insulating valve. Recommended for temperature up to 600 F. 3, Foam Glass insulation is a rigid; light weight material containing millions of individual hermetically sealed cells. Because of its inorganic nature it will not deteriorate. It also is resistant to acids; Recommended for temperatures up to 300F. 4, Foam Plastic Is a flexible foam plastic material in pipe covering form, used on cooling and heating lines. This insulation is used to prevent heat gain, condensation and frost formation on cold temperature lines. It also pre vents heat loss for liquid heating and dual temperature piping. The flexibility of this .insulation makes it very good for copper lines that are curved. Recommended for temperatures from 40F to 220F. j WA-TEX 001544 ITEM A-8 TRAINING DETAILS PAGE NO. 19 g. Fiberglas Is a low-density resilient, blanket-type thermal and acoustical Insulation made of long, extremely fine, flame. blown..glass... libers,. .bonded with thermosetting phenolic resin. Piberglas Is used for piping and duct insulation for temperature up to 300F. 6. Mineral Wool is composed of high temperature spun mineral fibers and an Inorganic binder. Recommended for temperatures up to 2000P. 7. Kaowool - This material is an alumina silica ceramic that can be Used for temperatures up to 3200F. It comes in rolls 24" X 24' long and from 1/2" to 2!' thick. It can be removed and used again. Due to Its high melting point and high cost, Kaowool is used only In heaters and for annealing welds. 8. Finish Cement - OC 30 - This cement is made of the same material as calcium silicate. It Is a one coat application that will not shrink or crack. Recommended for temperatures up to 1350F. 9. Metal lath is expanded metal sheeting. It is used to support and reinforce insulating cements and refractories. It is used primarily for boxing in instruments and refractories inside heaters. 10. Wire mesh, or "chicken wire", used in insulation Is woven galvanized wire In one inch mesh, generally 19 or 20 gauge, on large equipment such as vessels, tank breechings, stacks, on large diameter piping where block, segmental on blanket type insulation has been applied, a layer of wire mesh netting is usually applied, to provide a firm light weight reinforcement that will follow and support Insulation on a contoured or flat surface, and also used for binding weather proofing to the vessel. 11. Aluminum Jacketing Is used for covering insulated lines and vessles, for weather protection. It comes in rolls of various sizes and thicknesses, corrugated;, with or without a polycraft vapor barrier. 12. Wire - The purpose of wire is to permanently attach Insulating materials in various forms, to piping and equipment. The gauge, or thickness, of wire used depends on the size of material or load which the wire or group of wires will be required to support. For most Insulation materials #16 gauge galvanized wire is satisfactory. : WA-TEX 001545. ITEM A-8 TRAINING DETAILS PAGE NO. 20 13. Metal Screws - Metal screws are used for fastening aluminum Jacketing to lines and vessels. The type used at PSP are 1/2" x #12 .cadmium plated, pan head, self tapping metal screws. . . 14. Weatherproof Coating - Foster H.I, Mastic #90~07 is used to weatherproof ells and various shaped Insulation Jobs. H.I. Mastic is an asphalt emulsion weathereoat and water vapor "breather" for thermal Insulation In hot service. 15. Insulation Sealer - Insulation sealer is designed for dual teraperautre service with foamglas, styrofoam and other rigid foam insulation. Effective as a vapor barrier in Joints and between courses of vapor barrier Insulations, also used as a bedding compound between metal and Insulation, performing as a cushion and providing additional adhesive strength to the Insulation and corrosion protection to the metal. The type used at PSP Is Poster 30-46 insulation sealer, suitable for temp - 50 to 200P and can be applied at temperature as low as 15F. 16. Heat Transfer Cement - Thermon is a non-metalllc plastic compound with highly efficient heat transfer properties. It Is supplied In a'ready to use paste form for application over either conventional steam traced or electrical ' resistance systems. When cured to a cement like hardness, thermon bonds itself to the coils and the equipment, forming an unbroken thermal oonvertion. Utilizing the entire surface of tracer tubing or eleotrie heating cable, thermon conducts the heat to the surface to be heated or away from the surface to be cooled, Thermon can be installed by either hand trowel or by air operated equipment. j WA-TEX 001546 I TEXACO INC PACE 330., 21 PUGET SOUND PLANT _ ','T-vRsA--I-N--I-N---G------D--E--T--A--I-L--S- ' DATE s APRIL 3,1973 DEPARTMENT: INSULATION GLASSIFICATION: .INSULATOR (TRAINEE) ITEM NO. A-9 SUBJECT: PROCEDURE FOR. OBTAININO_.T_QP_LS. MM1BIALS.JND-EQSIPME1T A. TOOLS 1. Each Insulator is issued the basic tools needed to perform his duties, 2. Tools needed but not issued, can be obtained from the tool room (located in machine shop or from the insulation foreman.) ^Footnote B. Equipment' Equipment needed for the Job, can be obtained from the warehouse or recovery yard. 0. Material 1. Each Insulator Is authorized to order material from the Storehouse. Before.calling for material, compile a list giving the name size and weight, type of material ' and a charge * to which the material is to be credited, ^Charge - Estimate number, bill of material number casualty claim number, or unit where used. 2. Insulation-can be obtained from the insulation ware house located upstairs in #1 Warehouse. * Basic Tools Issued: 1. Pruning Saw 2. End nippers 3. 4" Screw driver 4. Awl 5. 12* tape rule 6. 6" fish knife 7. 2-6" pointing trowel 8. Small tin snips 9, Rubber palm . ` I WA-TEX 001547 TEXACO INO. PUGET SOUND PLANT TRAINING DETAILS PAGE HO. 22 DATE:APRIL 3,1973 DEPARTMENT: INSULATION CLASSIFICATION: INSULATOR fTRAINEE) * ITEM NO. A~10 SUBJECTt TYPE OF WEATHERCOATING 1. Asphalt Emulsion - See Oh-The-Job Training Item B-19. 2. Aluminum Jacketing - See On-The-Job Training Item B-19. : WA-TEX 001548. TEXACO me. PUGET SPUED PLANT ' TRAINING DETAILS PAGE HO, 23 ' DATEsAPRIL 3*1973 DEPARTMENTS INSULATION CLASSIFICATIONs INSULATOR (TRAINEE) item no, a-ii subjects mmmimmAjLwmEm.m-mAm_3~ mmaz , An insulator as directed, performs on his own respon sibility all types of insulation work necessary to install, repair, and maintain equipment in the Shop or in the field. May direct the work of others assigned to the Job. Cooperates with others In the performance of duties assigned. Performs customary rigging incidental to the work of his department. Observe safety instructions applicable to to work performed, and adherence' to general safety instructions appli cable to all plant employes4 Also, while actively directing others, is responsible for their adherence to such safety in structions , May be required to instruct or train employes or others in the work of his craft. Should have the ability to understand, verbal and ' written orders and issue instructions accurately and clearly for their proper execution. Requires a general knowledge of company standards, ' requirements, specifications, and common practices for insulator work in order to perform duties and Jobs in a standard manner. This would include the proper use of Safeway scaffold, insulating^ brick laying, cementing, applying refractory and a multitude of oommon practices that are standard to- Texaco and Puget Sound Plant. This refers to knowledge gained only through experience and might enable an insulator to perform a Job without benefit of prints. Requires a general knowledge of condition under which equipment operates and plant location of such equipment. WA-TEX 001549 tekaco ate. PUGET SOUND FLAX? mmmriminm PAGE NO. 2D date?april 3,1973 DEPARTMENT? INSULATION CLASSXFICATION? INSULATOR (TRAINEE) ITEM NO, A-X2 SUBJECT? LOCATION AND USE OF UTILITIES (1) A utility is a form of energy used to get work done. At Puget Sound Plant, utilities Include steam, electric power, service water and compressed air. These utilities amount to approximately 40# of the total cost to operate the plant, (2) Pa Insulator uses these utilities almost every working day. Compressed air Is used for pneumatic tools, sandblasting and guniting equipment. An Insulator uses electric power for light to work inside towers, vessels and for operating some types of portable power equipment. CAUTIONS ALWAYS USE A 32 VOLT LIGHT WITH VAPOR PROOF COVER "" ` WHEN WORKING IN TOWERS OR VESSELS,, (3) It is each Insulator's duty to see that utilities are . not wasted. LOCATION? (l) In every operating unit and designated spots throughout the refinery, utility stations are mounted on stanchions. In most cases, service water, air and steam are mounted together. Steam lines are'insulated to prevent per sonnel from burning their hands. Water lines are usually 1-1/2" pipe and are marked with a sign "Service Water Do Not Drink". Air and water lines will have a Chicago fitting attached. Electricity is mounted separately, . 440 volt tie-ins,are also provided for electric welding machines. Utilities are also mounted in all of the working shops. WA-TEX 001550 TEXACO INC, PUGET SCOOT PLANT mir-DlTO DEPARTMENTS INSULATION ' CLASSIFICATIONS INSULATOR (TRAINEE) PAGE NO, 25 LATEsAPRIL 3,1973 * ITEM NO. A~13 " SUBJECT? ..EB-O.gEDIIRES...Fm.DBTAMXM.Am USIM..J^BEIT.a A. PERMITS Before any eleotrlo hand power tool can be used on a field job or before entering a heater, tower or vessel to 'bu^ld scaffold ing', a Safety or Hot Wopk Permit (which ever the job requires) must be obtained. B. SCHEDULED DOWN PERIODS 1. A permit list is turned in to operations each afternoon by a down period supervisor for the work permits required the next day. ' (Notes This does not preclude the crafts man calling to his supervisor's attention that a permit may be required on a specific job.) 4 2. If a work assignment arises duping the shift that requires . a permit, and the permit has not been issued, the Insulator should contact the Supervisor In charge and advise him accordingly. 3. A permit board is usually set up during the unit down period and Operators will post the permits on this board. All 'requirements noted on the permits should be carefully followed. , C. OPERATING UNITS The Stillman should be contacted for permits to work on units in operation. Explain the work to be performed and the equip ment that is to be worked on. Conditions on permits must be followed, D. TANK FARMS ' The Operating Supervisor in charge should be contacted and advised of work to be- performed. If equipment or material Is required, a Hot Work Permit should be re quested for Transportation to enter firewalls around . tank in order to make material delivery. ` NOTE; All permits should be posted In open sight for inspection. I WA-TEX 001551 ITEM A-13 TRAINING DETAILS PAGE NO. % SAFETY WORK PERMIT ro"H R M!'A (This DOES NOT Permit Burning, Welding or Other Hot Work) ,H BKa' This Will Permit To: Unhead Enter (Crafty Department or Fcnsoo) Disconnect Work On Remove or Replace Type of Equipment .,... (Veanel, tank, line, pnrnn, compressor, manifold, etc,) Location:_____________ ___ A.M. - (Unit, Aren, Building, eta.) A.M. FromP.M,19_ To.______________ ___P.M.,, o (Specify Other Work) 19. Condition: QEmpty Blinded Off Steamed p Line Disconnected Drains Open p_ (Specify Other) Safety Precautions-....-____ ________________________________________________ _ a (Specify; Man on guard, Wet down shell or roof, spark-proof tools, vapor-proof lights, protective clothing A equipment. Gas Free Gas Test Taken... Taken Tty SinmfiH * enniater mask airline hoee mask and blower* and other similar precautions). (Ye* or No) (rime) (person Making Test) AM. .. P.M. Poison Gns Gas Test Taken. Taken Rv . ` (Yes or No) (Time) (Person Making Teat) (Foreman or Operator) Countersigned; (Authorised Personnel) v AM. P.M. HOT WORK PERMIT FORM R*24| (T.8SJ1 1500 BKS. This Will Permit . (Croft or Dept.) Tn ' ' -. (Burn*--Weldr-Ltehfc,jTOrcfi'--Sandblast--Break Concrete--Grind--Chip---Operate Internal Combustion Engine, Etc.) Af _ '* *. . '. - ` V *' -'y; ` i,oconiUnlk~VeoseI--Building--Tank--Area--Eta.) A.M. . P.M. 1ft To P.M '1 . (Time) . (Date) (Time) _ (Date) 19 ' '(Specify all 'special requirement* such ass Hrcsunrd--Fire Equipment--Wei down area, etA--Coirer sewer, Ditch or Data. . ' , , Personal Protective Equipment--Other special precautions,) 1 *-* ' ' ......... . Gas Test Taken-- (Time) (yes or no) Taken Rv (Tenon Making Teat) (Foreman or Operator) ........ . A.M. P.M. Poison Gas_________ i (res or no) Gna Test Taken (Time) | Taken Rv .................. (Person Making Test) Countersign erf................ (Authorized Personnel) . AM. P.M. I WA-TEX 001552 t TEXACO INC, PUGET SPUED PLANT TRAINING DETAILS PAGE NO* 67 , DATE?APRIL 4, 1973 DEELRTMENTs INSULATION CLASSIFICATIONS' ' INSULATOR (TRAINEE) ITEM NO, A-14 SUBJECTS READ, INTERPRET.. AND WORK FROM BLUEPRINTS,, SKETCHES AND BILLS OF MATERIAL Refer to Job Training Manual on Blueprint Reading for Craftsmen located in the foreman's office and to the following copy of a Bill of Materialo j WA-TEX 001553 BILL OF MATERIAL REFINING DEPARTMENT T. TITLE GENERAL - REPLACE PLANT ENTRANCE SIGHS Form R-415-E B. M. No. 1737 2-8. EST, NO. LOCATION ?CPSP ITEM NO. ' QUAN. AND UNIT MADE BY HOP CHECKED BY, DESCRIPTION DATE 8-13"71 SHEET NO. 1/2 - DWQ.NO. MARK FURNISHED BY t SCOPES 2 PLANT FORCES REPLACE EXIST PLANT ENTRANCE 3 SIGNS @ INTERSECTIONS OF W. MARCHES POINT RD/ 4 S,, TEXACO ROAD & "C" ST/S. TEXACO ROAD PER 5 DWG 50-76^"Y, EXCEPT5 6 1* SIGNS WILL BE FURNISHED AND INSTALLED BY 7 OTHERS ON POSTS INSTALLED BY TEXACO. POSTS 8 TO BE READY FOR USE BY 8-27-71 9 2 PLANTINGS TO BE FURNISHED & PLANTED BY LAWN MAINT CONTRACTOR W/CHARGES TO PSP tr MW-352. 12 ALL OTHER WORK BY PLANT FORCES TO BE COM- 13 PLETED AS MANPOWER & MATLS PERMIT. 14 R L KIRKPATRICK A J ^ ................ .. 15 P 16 .MATERIALS8 -;(ALL by 8-27-71) 17 2 18 2 DIRECTIONAL SIGNS - PER DWG 50-758-Y POLES - 12tt MIN DIA X 20' LONG - WESTERN RED -*L-123973 19 CEDAR, PEELED & CLEAN, UNTREATED (AVAILABLE 20 FROM MAC GILLIS & GIBBS CONWAY, WASH) . 21 b "DITTO" X Ilf* LONG 22 6 "DITTO" X 5* LONG 23^ 2 GAL. - rYERITHANE"9 CLEAR, GLOSSY f 24 25(D3 M DRW WWC JWA KWE RLK) AOS(S) AHB(2) GDJ CEL(3) DFS( 2) ENG ;s) 26 WA-TEX 00155 > f ESt. TITEE BILL OF MATERIAL REPINING DEPARTMENT Form R-415-E a. M. no. 1737 29 LOCATION MADE BY CHECKED BY ITEM NO. ' QUAN. AND UNIT DESCRIPTION t 12 DRIFT PINS - 3Am 0 X 2* LONG A-3& 22 PIPES - hn SCH 4o'a53 X 7*-8 DATE SHEET NO. 2/2 DWG. NO. MARK FURNISHED BY ` ---- AJU 32 42 DITTO X 9*"*8m , PLATE - i X M5 0 A36 5 4 GOER FIBERGLASS - k QZ X 26'" X 10* GREEN 6 4 DITTO X 12* 74 SONOTBBE FORM - 1268 0 X 6" 8 9 Mlk 1(L 20 * 3A 2 YD WIRE MESH - 2 X 2 X 12 GA STL X 2`-688 YD - 3000 PSI CONCRETE SHALE ~ PIT RUN . ` 5 YD PLANTING SOIL 12 2 2D BEAUTY BARK <>*> kS --DPS - --AiH --J 13 30 JUNIPER TAMS - FURNISHED BY MR,, R HALLENBEGK * / '14 . 15 - i. -* 16 , I 17 18 19 20 21 22 liSl 24 25 - - .26 -. . -- . j Wil-TEX C101555 TEXACO INC. PUGET SOUND PLANT TRAINW " DETAIL PAGE NO. 30 DATE s APRIL 4,1973 DEPARTMENT*. INSULATION CLASSIFICATION INSULATOR (TRAINEE) ITEM NO. A-15 SUBJECT! MEASURING AND LAYOUT.METHODS A. MEASURING 1. Principle of Insulation measurement -will be for pipe insulation. 2. The greater majority of Insulation- job in a refinery . will normally be replacing Insolation on existing lines. B. LAYOUT METHODS 1. Determine the size of pipe or vessel to be covered by using a square and level. . The inside angle of the. square is placed against the pipe and the top leg leveled. One point on the center Is located under the scale at a distance from the in side angle of the square* equal to 1/2 the outside diameter (0D) of the pipe. This will give the size of insulation required. WA-TEX 001556 TEXACO INC. PUGET SOUND PLANT TRAINING DETAILS PAGE NO, 32 DATE s APRIL 4,1973 DEPARTMENT! INSULATION CLASSIFICATION! INSULATOR (TRAINEE) ITEM NO. B-l ----- SUBJECT! PROCEDURES FOR OBTAINING AND mAlSp_QBT.3^,,TDOM..A]@-EmTMI.T 1. Tools will be In the Insulator Shop tool room or upstairs in the shop. If additional tools are needed you can get them from main tool room in the Machine Shop. You must sign a charge out sllpj) do the Job and return the tool to the tool room. 2. Equipment may be located in the following areas. Warehouses 1, 3 . or 4 and north of 6th Street between "B" and "C" St. in stor age area. 3. Storehouses Each Insulator is authorised to order and receive material from the storehouse. 4. Methods of Transporting 8 Call trucking department giving . type of raa^^riaTi^equipmerit to be hauled where equip ment or material is located, and where It Is to be hauled. Also state type of trucking equipment that is needed. WA-TEX 001557 TEXACO INC PUGET SOUND PLANT TRAINING DETAIL)? PAGE.NO. 33 DATE % APRIL 4,1973 DEPARTMENT! INSULATION CLASSIFICATION? INSULATOR (TRAINEE) ITEM NO. B"2 ------ ' SUBJECTS PROCEDURES FOR HOISTING TOOLS AND EQUIPMENT A. AIR DRIVEN HOIST The insulators use air tuggers to hoist tools and materials needed for covering of lines and vessels upon towers* vessels,- structures, etc. Before operating, the tugger should be inspected? (1) Check cable for frayed places, kinks or loops. Be sure cable is not overlapping itself on the drum. If strands are broken, cable should be replaced. DO Not Take .a Chance With a Frayed Gable as it could cause a serious accident. If cable Is"t'angleeTbr looped on the spool, run cable out and respool it keeping tension on the cable so it will be spooled evenly. Always keep cable neatly wound on the spool. (2) Check oil in the gear box. (3) Check spool drum brake. The tugger must be firmly anchored to a dead man or some other solid support where operator can see all of the lift. NOTE? Never anchor tugger or snatch blocks to operating lines. Always place the tugger so the cable will unwind from the top of the drum. If pull is from the bottom of the drum, a heavy pull on the cable will have a tendency to.lift the tugger and control, could be lost causing an afeeident. After tugger is secured, pull the cable to the top of the tower with a rope and install the cable in a snatch block hung on the overhead trolley. As an extra safety precaution, the snatch block should be wired closed so it cannot be pulled from trolley, A snatch block is also installed on the cable at the bottom of the bower directly in front of the tugger no higher than the top. of the tugger spool. NOTE; It may be necessary to use more than one snatch block at the bottom to clear obstructions. First block must be installed as directed above. A rope or tail-llne must be tied to the cable end. It is used to pull the loadless cable to the ground and to' keep loads from hitting anything bn the way up or down. WA-TEX 001558 TEXACO 1IC0 PUGET SOUND PLANT TRAINING DETAILS PAGE NO. 3*1 DATE?APRIL 4,1973 DEPARTMENTS INSULATION CLASSIFICATIONS INSULATOR (TRAINEE) '* ITEM NO. B-3 SUBJECT? PROTECTION OF MATERIALS AND EQUIPMENT When material and equipment is left out in the weather, protect them by covering with a tarp or vis queen. WA-TEX 001559 TEXACO INC PACE NO, 35 . PUGET SOUND PLANT TRAINING DETAILS DATE?APRIL 4,1973 DEPARTMENT: INSULATION '- CLASSIFICATION: INSULATOR (TRAINEE) ITEM NO. lS4 SUBJECT: CLEAN UP OP SHOP AND WORK AREAS 1. The shop should he kept clean at all times. 2. The.^ob site should be kept clean and cleaned up at the end of each day. > 3. In addition all housekeeping practices should be followed,, according to the General Housekeeping practices 1st in Basic Training in this manual. WA-TEX 001560 TEXACO INC PUGET SOUND PLANT MMTim PACE NO, 36 DATES APRIL 4,1973 DEPARTMENTS INSULATION CLASSIFICATIONS INSULATOR (TRAINEE) ITEM NO, B-5 ------ SUBJECTS PRO,GEPUBES FOR ERECTING SCAFFOLDS 'AND-LADnERS, The insulat r at PSP are required to build scaffolds up to 2 sections high. 1. First obtain the scaffolding needed for the ^ob. a. One section, consists of'the followings 2 - end frames - 64" high and 3' high section 2 - cross braces 5 - scaffold planks 4 - hand rail post 4 - side hand rails 2 - end hand rails If more than one section is required, it will require 4 connecting pins per section 2 to assemble. Connect the braces to the end frame, by sliding the end of the brace, over the pins' on the frame, lay the planks on top of frames. Pat the hand rail post on top of frames and connect the hand rails to the past with a wing nut. If more than one section Is needed connect the two frames together with the pins Inserted in the top hole of lower frames to the bottom leg of the next frame If half sections are required, the braces will have to be shorter* half section braces are generally colored orange, EXHIBIT - See Department Foreman ' Ladders .' When erecting a ladder, the bottom of the ladder, should be 1 foot from .the place for every 4' in height! Securely tie off ladder at the top. WA-TEX 001561 TEXACO INC PUGET SOUND PLANT ' PAGE NO. 37 DA*PEs APRIL 4*1973 DEPARTMENTS INSULATION CLASSIFICATION* INSULATOR (TRAINEE) ITEM NO. B-6 ------ SUBJECT* PROCEDURES FOR REMOVING OLD IH- gH&TOBSL ' A. PIPE INSULATION When removing pipe insulation* first remove the jacketing by removing the screws. Cut the wires with end nippers - while holding the insulation from falling. When finished* move insulation to storage* and clean up area. B, ALL OTHER TYPES OF INSULATION When removing insulation from pumps* meters, orifice flanger* etc. Use hatchet to knock off the-old insulation* being careful not to mar the piece of equipment that the insulation is being removed from. Clean up area when finished. ! WA-TEX 001562 TEXACO IMG, PUGET SOTO PLANT PAGE N0o 38 DATE? APRIL 4,1973 DEPARTMENT! INSULATION CLASSIFICATION; INSULATOR (TRAINEE) ITEM NO. B~7 SUBJECT! SALVAGE OF INSULATION MATERIAL When removing Insulation from lines and vessels^ try to salvage as much Insulation as possible and move to storage. | WA-TEX 001563 TEXACO INC. PUGET SOUND PLANT TRAINING DETAILS PAGE NO. 39 DATES APRIL 4*1973 DEPARTMENT: INSULATION CLASSIFICATION: INSULATOR (TRAINEE) . . ITEM NO. B^S SUBJECTS .PROCEDURES FOR MIXING INSULATION _b-._JMach.lne.Mix A. HAND MIX Hand mix is used, when only a small amount of cement- Is re quired. Mix the cement by pouring the amount required in a bucket and adding enough water to make a firm enough consis tency that will hold its shape and will not slump. B. MACHINE MIX Machine mix is used .when a large amount of cement is required to do the job. Pour the contents of a sack Into the mixer and add enough water to make a firm enough consistency that will hold its shape and will not slump. ' ! WA"TEX 001564 i' TEXACO INC. mm SOOT? PLAIT PAGE NO. 40 DATES APRIL 4,1973 DEPARTMENTS INSULATION CLASSIFICATIONS INSULATOR (TRAINEE) . ITEM NO. B^9 SUBJECTS. PROCEDURES FOR QCTOIO MATERIALS Refer to Iteaj B~17* this Manual. WA-TEX 001565 TEXACO INC PUGET SOUND PLANT TRAlMO fe'AgiS PACE NO. 41 DATE*APRIL 4,1973 DEPARTMENT* INSULATION CLASSIFICATION* INSULATOR (TRAINEE) ITEM NO. B-IO SUBJECT* PROCEDURES FOR OPERATING THE TAR POT Refer to operating Instruction Manual in the Yard Foreman's office. WA-TEX 001566 TEXACO INC - ' PUGET SOUND PLANT . garnrum PAGE NO. H2 date*april 4,1973 DEPARTMENT 1 INSULATION CLASSIFICATION: INSULATOR (TRAINEE) ITEM NO. Bll SUBJECTS CLEANING AND PREPARING SURFACES FOR .... Refer to Item B-17 of this Manual, WA-TEX 001567 TEXACO INC- PAGE NO. 43 PUGET SOUND PLANT TRAINING 1E!M DATES APRIL 4,1973 DEPARTMENT: INSULATION GLASSIFICATIONS INSULATOR (TRAINEE) ITEM NO. B-12 SUBJECT: PROCEDURES FOR OPERATION,SPACE mgiBs, Refer to operating Instruction Manual located In Yard Foreman's Office. I WA-TEX 001568 TEXACO INC PUGET SOUND PLANT TrAINMT""BEgmg` PAGE NO. 4It DATE? APRIL 4*1973 DEPARTMENT: INSULATION - CLASSIFICATION: INSULATOR (TRAINEE) ITEM NO. B-13 . -------- SUBJECTS PROOEDMESJOR. PREPARING. INSULATION EflumMa a. Calcium Silicate b, Cork 0. Plastic d. Block e. Monolithic f. Fiberglass g. Acid Proof Cement h. Mineral Wool 1. Hair Felt Refer to Section B-16 On-The-Job Training | WA-TEX 001569 TEXACO INC. PUGET SOUND PLANT TRAINING DETAILS ' PAGE NO. 45 DATE?APRIL 4,1973 DEPARTMENT? INSULATION CLASSIFICATION: INSULATOR (TRAINEE) ITEM NO* B-14 SUBJECTS PROi^!DURES_FOR..J)RERATim..SAWa a.,_,Barri ' Band Saw . (a) Use - Puget Soui*d Plant? s 20" band saw Is fully enclosed in a welded steel cabinet and is equipped with miter gage and rip fence complete, with guide rails for accurate work. Use of correct blades makes it an efficient unit for ripping, re-sawing and for cutting wood, insulation, plastics, aluminum, manganese and other non-ferrous metals. . (b) Description - Standard blade length of this band saw is l4l inohes. Maximum blade width is 1 inch. All adjustments necessary for proper centering,.guiding and tensioning of blades are provided. Blades of various widths from 3/16 to 1 inch wide are available. The table tilts 45 degrees to the right and 12 degre'es to the left. Maximum height of cut is 13. 1/4 inches with clearance of 5 Inches between the blade and upper frame. The full throat width, however, is 19 3/4 inches for cuts up to a height capacity of 12 1/8 inches. These clearance, location of mounting holes and other dimensions are shown in Fig. 2. On this machine the slot for removing the blade Is at the side of the table. This patented feature permits the use of widely spaced trunnions for greater rigidity of the tilting table, and avoids interference with the front rip fence bar, screw feed or other attachment which may be used. The blade guides are fully and independently adjustable for ' blade width and thickness to permit the exact settings required for accurate work and long blade life. The lower guides are within 1 inch of the table surface. Thus the blade is supported close to the work, reducing blade breakage. Convenient adjusting screws permit each setting to be made separately. The front blade guard rides with the upper guides, protecting the Operator in all cutting positions. Other features presented in this band saw are the convenient blade tracking adjustment, bla.de tension control with indicator, aluminum wheels with tensioned removable rubber tires which have been ground to uniform thickness, the foot brake and dust spout. Sealed ball bearings are used for both wheel shafts and for supporting the blade, thus reducing lubrication requirements to a minimum. f WA-TEX 001570 l ITEM B~l4 TRAINING DETAILS PAGE NO. 47 The correct motor speed with 60-cyele or DC power Is 1725 rpra, which will run the blade at 4500 feet per minute. (o) Lubrication - The upper and lower wheel shafts are supported in sealed ball bearings. The same type of bearing is used back of the band saw blade to take the thrust developed when cutting. These bearings need no lubrication throughout their life. Oil the sliding ways of the upper wheel bracket, the trunnions, the adjusting screws and other movable parts occasionally to keep them in free operating condition. Do not lubricate the saw blade. Keep the blade contact surfaces of the guide blocks and the support bearings clean and free from oil. (d) Adjustments *- The controls and adjustments described below are ImpoFEant for accuracy and convenience in various operations. Follow these directions for best results? (i) Blade Tension - For accurate work and maximum blade life it is important that the blade be centered on the wheels. When the adjustment has been pro . perly made, the blade will "track"j that is, it will run steadily in the same line. If the blade weaves across the crown of the wheels, cutting will not be uniform and blade breakage will be Increased. Both the upper and lower blade guides and the support bearings must be moved back to clear the blade entirely while the tracking adjustment is being made. Alignment of the blade on the wheels is accomplished by tilting the upper wheel slightly with respect to the lower. The upper wheel shaft housing is pivoted. Its direction Is controlled by the hand knob 0 which ' is the upper knob in Fig. 3. Having brought the blade to correct tension, turn the upper wheel clockwise by hand. If the blade creeps forward, tighten the knob slightly to tilt the wheel toward the rear, thus centering the blade. Loosen the knob If the blade creeps toward the rear. Spin the wheel and check again. When it is certain that the blade will not run off the wheels, start the motor and make any final minor adjustment which may be- necessary at operating speed. Never begin the tracking adjustment while the machine is running) at high speed' the blade may run off almost instantly, injuring the blade or operator. Adjust the hand knob-only a small fraction of a turn at a time, as very little tilt of the upper wheel is re quired to draw the blade across the rim of the wheel. WA-TEX 001571 48 Ffg. 5 ' Auto-Set Miter Goge. .... .... Fig. 4 / RJp F<mee Mounted on Table. ' WA-TEX 001572 ITEM B-14 -TRAINING DETAILS PAGE NO. 49 Each blade has Its own tendencies, especially after welding or brazing. The blade centering adjustment must therefore be repeated whenever a new or repaired blade is installed, regardless of previous adjustments. (il)'. Table - The table will tilt up to an angle 45 to the right and 12 to the left. Table tilt loclcing lever and table angle indicator are .'located under front of table. Ciii) guides - , Upper guide steadies the saw, It should be set just above stock being worked. Upper guide locking lever is located behind upper wheel case, ' . Lower guide is below table. tv) Rip fence - Knob A locks fence in place. Knob B drives gears to move fence right or left. To`make;accurate cuts use tape to measure between fence and blade 1 ' (v).! Meter gauge - See figure 5. Knob A locks fence in place. Indicator B shows angle of fence. (e) Operation - Before starting.the machine, see that all ad- justraents have been properly, made. Turn the. wheels by hand as a final check. Close the cabinet doors before starting the motor. . ' Keep the upper blade guides and guard down as close to the work as possible, for maximum protection to the Operator as well as best support for the blade. Move the stock steadily against the blade and no faster than required for easy cutting. Do not force the work) light contact will permit closely following the cutting line and prevents excessive friction, heating and case-hardening of the blade at its back'edge. A sharp blade of the correct typecfor the work will cut,, easily without much pressure. Use the foot brake to stop the wheels after shutting off the power. This is a safety precaution which will prevent injury to the Operator and others who might not notice the blade running idle after work has-been completed. It is also useful if the work becomes jammed and when a blade breaks. (i) Straight cuts - Use- the widest blade available for straight cuts, in order to have the greatest possible support for the teeth which do the work. Keep the blades which have closer tooth spacing for fine work, always using the coarse blades for resawing and other rough cuts. i WA-TEX 001573 ITEM B-14 TRAINING DETAILS PAGE NO. 50 (ii) When cutting curves, turn the stock oarefully so that blade may follow the line without being twisted. Clearance for the blade in the Baw kerf is provided by the set of the teeth. Wider tooth set and less blade width permits the cutting of sharper curves. The narrow blades should therefore be reserved for curve cutting. Remember wider blades are used for straight cuts and narrower blades are used for cutting curves. If the curve is so abrupt that it is neoessary to back up and out a pew kerf,.a narrower blade or one with wider tooth set should.be use. However, the cut is usually rougher when the teeth are set wider. When backing out of the work in order to change the cut, or for any other reason, be careful to avoid pulling the blade off of the wheels. It is generally easier and safer to turn the stock and saw out through the waste material, rather than try to withdraw the stock from the blade. (f) Blades - Band saw blades are subjected to heavy strains when cutting. Long service can be' obtained only by selecting the correct blade for the work, and by carefully adjusting and operating the machine. Blades should be of the correct thickness and temper for use on 20-inch wheels. A sharp blade will cut effectively under moderate pressure and uniform feed. When excessive pressure is required, the blade should be sharpened, as continued use is harmful to the blade in addition to taking extra time. Sharpening and setting a saw blade requires skill; those who lack equipment and experi ence should send the blades to a competent sawyer for sharpening. Broken blades may be welded or brazed. Care should he taken to preserve tooth spacing, to keep the blade straight, and to remove welding flash at the joint. It is not economical 'tp weld a blade which has become case-hardened, as it will soon break elsewhere. Standard blades furnished for this machine are l4l inches long. The adjustment, of the upper wheel bracket will accomodate blades up to a maximum length of 142 1/2 inches and to a minimum length of 139 inches. Thus standard blades may be shortened 2 Inches by successive repair. Excessive blade breakage may be due to a number of causes. In some cases it is unavoidable because of stresses which come upon the blade in the work. More generally, it Is due to lack of care or judgment on th&'part of the Operator in making the adjustments. Common causes of blade breakage ares WA-TEX 001574 ITEM B-14 - TRAINING DETAILS PAGE NO. 51 (i) Faulty alignment or adjustment of guides. ,(11) Force or twisting the blade around a curve or very short radius. (ill) Feeding too fast. (lv) Insufficient tooth set or dull teeth. W Excessive biade tension. (vi) Upper guide set too high above the work. (vii) Itaproperly finished or lumpy braze or weld. (viii) Wrong blade for the work being done. (g) Safety Precautions (i) Adjust guide to suit work to be done. (li) (iii) Keep hands away from saw blade while It Is in motion Prevent overcrowding of the saw by feeding stock to fast. (3,v) When operating saw and a nicking sound develops at each revolution of the blade, "STOP IT", and ex amine the blade carefully as it will have either a bent tooth or is cracking. . (v) Keep all guards in plaee. WA-TEX 001575 ITEM B-14 ' TRAITOR DETAILS PAGE NO. 52 Before cutting be sure you have the proper specification Eveready blade., whether it be Diamond, Tuffie Break-Resistant or Xtra-Cut Abrasive, If in doubt, consult the blade re commendation chart on the inside of the rear cover or see your Eveready distributor. How to Mount Blade . Be sure blade shaft collars are free of grit or dirt before mounting blade on arbor shaft. Tightening blade against an uneven surface can cause fracture of an Abrasive blade, or cause blade to run out of alignment causing excessive blade wear. When tightening nut against outside blade shaft collar be sure to tighten enough to hold the blade firmly without slipping, but do not overtighten - excessive tightening can cause fracture of Abrasive blades. NOTE: Blade shaft nut has left hand .threads. TURN COUNTER CLOCKWISE TO TIGHTEN. Tap nut lightly with hammer or equivalent. How to Adjust The Height Of the Cutting Head The Eveready crank raises or lowers the cutting head to any desired position. No secondary adjustment is necessary. When the foot pedal is depressed, the patented blade pressure equalizer spring automatically takes over. (See section on"Step" cutting with Abrasive blades). To lock out blade pressure equalizer spring when "Step" cutting with Diamond blades, tighten wing nut on top of spring until the spring is compressed solid. When the foot pedal is not depressed the blade pressure equalizer spring is locked out automatically. Use this position for "Jam" cutting with diamond blades (See Page following) How To Use "Step" Cutting With Abrasive Blades Use "Step" cutting without exception when cutting Wet or Dry with Abrasive blades. ("Jam" cutting which is discussed and illustrated in the section below, is to be used only with some Diamond blades for Wet Cutting). Hold material firmly against Backstop on Conveyor Cart. Be certain material does not slip or rock during cutting operation as this Will bind blade causing excessive wear and fracture. Move Conveyor Cart forward near the blade, and 'press down on the Foot-Pedal until blade is .lowered to a point where it will lightly contact top of the material. Then start "Step" cutting - which means passing the material beneath the blade with RAPID, (50 to 60 strokes per minute) full length strokes, taking a shallow cut WA-TEX 001576 !^`4^-;<appr&ximateJx';i/8w 4ep) -on .the 1 forward^ And AL0O`oi>;tli backward. stroke. Complete each RAPID stroke backward and forward fry. passing th< .-.&? ^X;a%aterial beyond-the center, of''the blade 'before starting the reverse:- fts#'fy movement '' of the cart.--.The harder the material, the'more-rapid the . < forward and-backward strokes.-.' - ' ', ' .j^step^^'Cuttingl..as.'can be seen`in Sketchy lessens the area of the i/J-'-v-'1 '-.'/^"blade'-circumference'.in contact wL th the material, keeping the blade 'fyijvty-' cool, running free* and cutting, at peak efficiency*. Don't get . the. ^impression "Step" Catting means slow-cutting- actually ,-lt is. 6;`: times, faster than trying to; ''force" the cut fry strong - arming the tfrroufif* the. blade*. ..Forcing the-blade, through with a deep.; tf'%'f^'sV/-,'^owt';causes a-.longer-..area-of the blade circumference to be in contact. , 4\.with; ^the material,, causing excessive friction heat to be generated causing blade to "smear" or "load" with fused material particles . and lose:.its sharp cutting surface. (NOTE: If improper operation ;'^'Due;io^ tjhe ^automatic pressure'-control provided "by; the. Blade. . , f `^Pressure Equalizer Spring/ Operator will find the blade "Rollling" ; .y ;as it passes, through the material on both forward and backward ;?r..'Strokes-'^ making' the -"cut slightly lower.-at! each end, and slightly.' ' Vhigher, in .the center as .shown in .Sketch. B. With .the. cuts slightly f'-; ; ;lower at-each end/masonry: particles are freely and cleanly ejected. (``.$$^7 *>m -the ''cut,- and there is free access of air or water into cut'.tp .Jtoeep; blade :cool ' and -at peak`efficiency,;- y\-. ; ;* ' ' '- " y/ ' .................. v.` . * -. ; t v ' r i' 'i * r;.' v '* ;./v : v\;;: >-rK^:;v'. J ' . *'W- i ,, i i.- * ; V : vf>rlt * .-'/S''Dow To:use:"Jam" Cutting or (Fixed'Cutting) and* "Step"1 Gutting V'i , ., . ... Fixed Cutting adjust cutting-head to proper -..'^'.heifeh^yead-`do not step oh foo/ pedal. Push the material through .ITEM B-lfo ' ' TRAINING DETAILS PAGE NO. 55 In cutting, hold the material firmly with both hands against the Conveyor Cart backstop. If the material is allowed to slip, resulting seizure of the blade may bend the Diamond blade center or .cause a rim section to be twisted off. Do hot force the material or bump into the blade. When nearing completion of the cut retard and slightly hold back the conveyor cart. If this is not done the material may be pulled Into the blade so fast that excessive pressure on the rim may cause warping or twisting of the rim section. When a new Diamond blade is broken in make the first few cuts slowly until the blade cuts free and easily. When the blade is cutting freely and' easily USE IT I As long as it continues to cut satisfactory do not dress the diamond blade or remove It from the blade shaft. After continuous cutting of extremely hard and dense materials, the blade may slow down and it may be necessary to "dress" the cutting edge. To do this; 1. Use a rapid "Step" Cutting method for a few cuts - push material back and forth under the blade while it is cutting down. Or - if this,is not sufficient; 2, Make one or two cuts in a soft brick or light weight block. However, "dressing" should be done as seldom as possible - too much "dressing" reduces blade life. ,, NEVER USE DIAMOND BLADES DRY. How to Use your BrikSawMatic Masonry Saw for Dry Cutting 1. Use proper blade for dry cutting. 2. Remove water curtain. ' 3. Disconnect electric water pump. 4. Use "Step" cutting.-- .. How to Use your BrikSawMatic Masonry Saw for Wet Cutting 1. Fill pan with water to within 1/2" of top. 2. Install water curtain. 3* Be sure that water pump is plugged to connection to Masonry . saw motor, (it will start when the main .switch is turned on). This applies only to single phase models. In case of three phase motors provide a separate supply of 115 volts single phase for the pump. WA-TEX 001578 ITEM B-14 TRAINING DETAILS PAGE NO. 56 It is pot necessary to prime pump. Be surp that water covers bottom flange of pump at all times. Do not let sludge and dirt get deep enough In the pan to block the pump inlet. Use "Step" Cutting with Abrasive blades as described on Page proceeding. Use "Jam" Cutting with Diamond blades as described on page proceeding. > WA-TEX 001579 TEXACO INC, PUGET SOUND PLANT TRAINING'...BEm PAGE NO. 57 DATE 8 APRIL 4,1973 DEPARTMENT8 INSULATION CLASSIFICATION: INSULATOR (TRAINEE) ITEM NO. B-15 SUBJECT: PROCEDURES FOR CUTTING. PREPARING. a_._ E_oof_lng_mper. o. Wire_mesh CUT..PREPARE.. AND..APPLY, cL. Metal lath s'.iAIumlmim Ta oketinfo A. ROOFING PAPER When using roofing paper for* weatherproofing cover, the Joints should be overlapped at 2" minimum. The overlap on horizontal lines should be towards the underneath side of the line fastened by galvanized wire approximately 2" from each end and one In the center, B. MUSLIN AND CANITAS . ' Muslin and canvas covering are used Inside building. They' are applied by using a wheat paste to fasten them to insulation. The paste..is also" used for sizing. C. WIRE MESH ' Wire mesh both secures the insulation under it and forms a good bond for master applied over it. The mesh should be applied around the vessel, and the Joint and.end should be wired together with. 18 gauge galvanized wire. The mesh silbuld fit firmly to the insulation.IfIfhObvesselvdoes not have tie wires. To hold the mesh firmly, use staples to hold the mesh down, by ' driving staples Into the Insulation. D. METAL LATH Metal lath is expanded metal sheeting. It is used to support and reinforce insulating cements and refractories. Metal lath is used by the insulators .to"'fabricate irregular size boxes for orifice meters and leads, and various other types of equipment that require uneven shapes. The lath is fastened securely to the piece of equipment by wire and pins with all loose ends fastened securely by wire. E. ALUMINUM JACKETING Aluminum Jacketing comes in 100' rolled 36" wide. It ranges from .006 inches to ,040 inches ip thickness. It Is obtainable in either smooth or corrugated form and with or without a vapor barrier. The advantage of using aluminum Jacketing, other than another type of covering is its easy application and little maintenance necessary. - 1 WA-TEX 001580 ITEM B-15 TRAINING DETAILS PAGE NO. 58 We use two different gauges here at PSP. ,010 gauge is used for covering small line and .016 gauge is used for covering larger line and some vessels. On all horizontal lines the lap should be towards the underneath side of the line to pr.otect it from wind and rain. The lap should be about 2" on ends and on the overlap and fastened by 1/2 x 12 cadmium sheet metal screen every 6 inches or less. I WA-TEX 001581 TEXACO INC. PUGET SOUND PLANT MM8' "gm DEPARTMENT; INSULATION CLASSIFICATION: INSULATOR (TRAINEE) ITEM NO. B-l6 SUBJECT; LAYOUT WORK PAGE NO. 59 DATES APRIL 4,1973 ' The layout of the Job, depends on 2 factors; the amount of material needed and type of material required. 1. The amount of material needed. This is figured in square feet on flat or curved surfaces. In measuring pipe, only the' length has to be measured. , (a) Piping - figure the length of pipe estimate the amount of valves and fittings to be covered. (b) Measuring areas - An insulator must be sure to figure the areas of all surfaces on pieces of equipment that' are to be insulated. (1) To find the area of a square or retangular surface, use the formula; length times width = . area (square, feet). (2) To find the surface area of cylindrical equipment like large pipe, exchangers, or even tanks, figure th.e area of the sides, and the area of the ends on top. To find the area of the sides of cylinder shapes use the formula: ' Circumference x length = (square feet). To find the circumference, either measure it or figure it from the diameter UBlng the factor 3.14, which applies to any calculation in volving circles. . Diameter times 3.14 = circumference. To find the area of a circle, like an exchanger head or tank roof, use the 3.14 factor the radius (radius is. 1/2 .the diameter) times radius times 3.14 a area. 2. The coverage and type of material required; (a) For example, 100 pounds of high temperature insulating cement will cover 5D square feet, one inch thick. (b) 85$ magnesia cement: 50 pounds covers approximately 29 square feet, 1" thick. . i WA-TEX 001582 < i' .1 / ' ITEM B-16 TRAINING DETAILS PAGE NOo 60 (c) All-Purpose Cement: 100 poundB covers 20 square feet 1" thick. (d) Weatherproof Cement: Poster HI Mastic 15 gallons will cover 100 square f&et 1/4" thick. (e) Wire: 10 pounds of 16 gauge wire will be enough to secure a layer of one-inch thick pipe Covering as follows: 240' of 2" Pipe 180' of 4". Pipe 140 of 6" Pipe 120' of 8" Pipe . | WA-TEX 001583 TEXACO INC. PUGET SOUND PI^ANT TR^SMr WM ' PAGE NO. 6l DATE; APRIL 4,1973 DEPARTMENT; INSOLATION CLASSIFICATION; INSULATOR (TRAINEE) . . ` ITEM NO. M? SUBJECT: PRQCEDURES^FOR.. APPLYINfL-INSULATXQN k,--Emm 4^.^^a5QlP.,.CQVLi?.9.1dg4 ft,--XmaslnJUmMsl a. PIPS STRAIGHT RUNS v Pipe straight runs can be insulated using either sectional or segmental Insulation. (1) Sectional - Pipe insulation, molded of 85# magnesia, cs'j calcium silicate, or high temperature insulation, is m&GCin two halves (sectional), and is performed to fit piping of many sizes. Sectional pipe insulations are molded in 3 foot lengths In the following thicknesses; 1" ("Standard thick"), l-l", 2" ("Double standard thick"), 2-f, and also in double layers (1" or l-" layers), to fit standard pipe sizes. The terms "Standard thick1' and "Double standard thick" apply to 85$ magnesia pipe insulation. Pipe insulation Is furnished in sectional form with muslin Jackets glued on. . (2) Segmental - Segmental covering is also performed for spe cificlarger^lzes of pipe. Instead of being made In halves, it is made in narrower pieces, so that.3 or more pieces are needed to surround the pipe. Large size pipe covering, is made this way for economical packing, and for ease of handling during instal lation. Segmental insulation does not come with a muslin cover ing. Equal segments are supplied about 5" wide along the inner arc. Odd width segments# where necessary, are furnished In the proper width to complete the circumference of the particular 'pipe size. Smaller pipe sizes are furnished sectional. Larger pipe sizes are fabricated from segments. (3) Single Layer - Single layer covering, or the first layer, is fastened to the piping with wire loops. Each section or **'- segment should be butted tight against the next section to avoid heat loss through the cracks or seam. Any voids or racks that are caused by breakage or rough handling, along with joints and seams, should be filled with a mud or cement made of - the same material as the covering. On flanged piping, the covering should stop far enough short of the flange that the flange bolts may be removed without damaging the insulation. The insulation should be cut to a 45 bevel at these points to facilitate opening the flanges and still getting the insulation close to the flange. ! WA-TEX 001584 ITEM B-17 TRAINING DETAILS PAGE NO. 62 (4) Double or Multiple Layer - Multiple layers are applied when extra thiokness is needed to prevent heat loss. Each layer is secured with wire loops before the next layer is applied. Joints or seams are Btaggered between layers* so that there will be no heat loss through cracks that extend straight from the surface of the pipe to the outside of the insulation. To stagger the Joints* apply the first layer of covering with the 36" lengths of covering. Then cut a 36" section in two and start the second layer with1 dn 18" length. This will put the first Joint of the second layer over the solid part of the first layer. Continuing the second layer with full 36" pieces will . then automatically stagger all the Joints, (5) Different Materials for Different Layers - Under high temperature Insulation* two layers may be made up of different insulating materials; In high temperature work* the first layer of pipe covering may be an expensive material of good re sistance to heat* but not very high Insulating value. If such a first layer will bring the temperature at the outside surface of the insulation down to 600 or less* then subsequent layers should be of a material like 85$ magnesia which has better insulating value and is safe to use on temperatures below 60.06. (6) Wiring - Soft wire loops are fastened around sectional or performed pipe insulation to hold the insulation in place. 18 gauge wire may be used for pipes up to li- inches in diameter with Insulation not over 1 inch thick. 16 gauge wire is used to hold coverings on pipes that are as large as 12 Inches in diameter, 14 gauge wire should be used on larger pipes* and for securing segmental and block insulation to valves* vessels* and other large equipment. At least 3 loops are applied on each 36 inch long section* on 12 Inch centers. For short sections* loops are placed 2 or 3 inches from each end* with additional loops on 12 inch centers If the sections are over a foot and a half long. For long runs of pipe covering, it is efficient to cut enough wire loops in advance to secure a large part of the covering. These wires should be cut 5 or 6 Inches longer than the circum ference of the insulation. They may be hung from the Insulator's belt* or draped over the line that is being insulated. An alternate method is to use wire from small coils located along the Job in positions where they will not snag while being un coiled. In this method the end of the wire Is brought around ' the insulation before the wire is cut. While the loop is being applied* the covering must be held firmly in place. With large diameter sections It may be necessary to have a helper hold the sections in place* or to use spring tension bands which are readily attached and are removed after the loops are secured. To apply wire loops, place the wire around the two halves of Insulation and hold the ends either in both hands or with one hand and the pliers. Twist one or two turns* making the twist snug against the covering. Do final tightening with the pliers* ! WA-TEX 001585 ITEM B-I7 TRAINING DETAILS PAGE NO. SB r making sure that both strands of the wire wind around each other to form n corkscrew spiral. (If only one strand makes a spiral and"the other stays straight, the loop will be weakened artd will' probably break.) When all the slock is twisted out, clip the wire ends off to about 3/^ inch. Bend the twist down to lie alongside the wire loop. Hammer the twist into the insulation with the pliers so that no part protrudes f.rom the covering. b. PIPE ELLS ' . 1. (1) Sectional or ..Segmental - Sectional or segmental insulation . isJappTfed~To yireils and bends by cutting mitres from pieces of the straight pipe covering. Mitres are wedge-shaped- short pieces as shown in Pig. l. Mitred pieces should start at the beginning of the curve on bent piping, at the flange on a flanged ell, or Just covering the weld on a weld ell. The pieces are butted tightly against each other until the whole bend is^' insulated, - ! To cut mitres, hold the section of covering level, with the seams at the sides. This position of the section and the seams will' ' make cutting easiest and most accurate. . .' . m-TEX 001586 -r ITEM B-I7 TRAINING DETAILS PAGE NO. 64 Keep the cut pairs, or halves, together to assure good fit. To keep them together, as .well as to aid in cutting,- leave the muslin on, or hold the section firmly closed with a couple of wire loops. ' ' i ** Use a sharp saw. Keeping saws sharp makes insulating work easier, cleaner, and quicker. Cut straight down through the section, so that the small edge of the mitre is at the near or far side of the section, not at the top or bottom of it. Cutting at about a 30 angle with the section gives the approximate taper needed. . Each mitre should be installed as it Is cut. As each Alt red pair Is applied to the pipe, the insulator should observe whether a slightly larger or smaller angle should be used for the next mitre, he cuts. 4- . NOTE: -Tf'a-mrtre-has-treen-'cut i -and doe not-fit very well-, it should be saved. It might fit elsewhere as the Job progresses. A rule of thumb in mitre cutting may be used In work on pipe up to 10 inches in diameter with covering up to 2 inches thick: Cut mitres about 3 Inches wide on the outside and 1-1/4H wide at the Inside. Five mitres are usually enough for a 90 ell. To cut more and thinner mitres might give closer fit, but is usually not worth the time expended. To cut more accurate mitres, consult Table A for long radius ells, and Table B for short radius ells. Cracks or openings up to an inch wide between mitres should not be removed by re-cutting mitres, since the whole Job will be covered with cement. Experience will reduce the number of poor fitting mitres. Apply mitres to an ell at the lowest point first. If the ell is not horizontal. Butt the first mitre tight against the end of the straight section (unless the ell Is flanged), with the narrow part of the mitre in the inside or throat of the bend. Fasten the mitre snugly with a wire loop. If the mitres are large, they should each have 2 wire loops, one loop an inch from each edge of the mitre. Large diameter mitres can be held in place with temporary tension springs until the wire loops are secure. (2) Small Piping - On ells or bends for small piping (3 inches or less in diameter), Insulation cement Is usually applied Instead of mitred sections. In such cases, the cement used must have the same insulating value as the.insulation used on the rest of the piping. The cement should be applied to the same thickness as the adjacent Insulation. | WA-TEX 001587 tI MITERED.SEGMENT DIMENSIONS ' ITEM B-17 training details >. r~ page no. 6-5 | -NOMINAL. THICKNESS OF INSULATION PIPE SIZE :p&i ; *4* u> *o l*s 00 o o V. u cs 2 in h 2! <N C(XM TCOM 24 ; I I > I St at at at fit g* &<* 2? z1 X <*l *o <0 CO ,C9 CO CO CO CO CO co CO co* CO CO s0S0 f at atot f at IA aIAt to IA a0t TO * aTOs m. J<W2 >* Z X a? at at st S{? IS sS at if Zf stRo 2? 2? C| r o CO CO CO CO co CO to 0 to CO co 0 TO CO ao-t aU?) aWtl imS amt Smt at a*sr aIAt aIA: SUilt O *0 s TO aTOt aTOs EH y Nz sS a: at :S In |M n* 0 <o s? a: 05 to rf; a o CO at CO CO g: CO *C0 <0 2? 0 2? StRo Kv?* CD tO TO NCO X o TO pm* StoR Smit strSy pw^ Sroit <? as*t 5? SinP *0 a0t gO 1TO? PTOro > z N at it , SR <: 5fS & ss St pit N 0 *o 0 to co CO CO *0 CO CO at o oa CO CO Pro co N CO aICSOt X surt sSo <ms aMt sNit Smt amt M SS sS aptt a*s . as*t U> atot aUtl. u> aot a0t 0 TO y 3$ rfc at at - z * TO M* * -* X cs smit to amt aNt *4lB4B| JO/,L.^t}S U| paanppjnueUl *c U K3U^3lH*HI ^ uLJ___ ___ ___1 1 --L_1,..L_. " 1 1 1 JfiUI * g |gA 523: 2 wg w '` *. ' Mil'll' ' "wTT !i ji li *u >%z g <t Pft P) * *0 sit at 4> s> CO CO a CO a: CO as 00 ;CNSO S<CoSP CCsO4S aICSOt m09 tcno ' TCOO T0O aTTOOt TO STOOt X > &ft z X ai p to t* Pnit iMS a: -o <m: at pms * at *6 amt a*t g <o Pmit a<*t tCmO #CO Prtit at at-s CO a'sr IA CO <A if CO aUtl aAt at A o S aICSO: atCsO? aos .at aA*t CO ars fs mCO ar-t co aotoot ah*t P0? aTCOO: p*0ft aTOs . a0*t a0s* CO STTOOR aTCOOt *<0r STOOR aCOt ao*t a0s* >* p 1* z M* 0 0 at *o NO at a? * CO to CO if <o sCO aIcSos sCeSit SM00it mco rco tCoO aTaO>t PCTODit 'CTO at TO aTOOs X r an: ?CSit IS amt Pmit a*t amt * * aIAt aIAt sS soS is as attos aCOt'* 5CDft o*.- bOR. aTOs > z Pit 't* at *0 *o sR *o at <A as *0 $ CO a? CO ?5 CO C(OM aICSO: aICSOs artost mco am<ot iaTCOOs aTCOOt TCaOOs *CO TO sTOOa I EH X y . p Pmit . * aCM: p "PMMit sm5t at at at art; amt aot- . at aIAt aIAt aot aot is aCOt aCOs iTSO STOt PTOit - z <* '* >6 o * X tMSt* aNt aCMs n aTOt *436js 10,, 91i*u! pajripe nue 41 40u It;>u*>] 1M 41 <n m N- <! io <o p. CO o* O " cs in o t". ctoow O* N0 8 CfrMt sCM* PIPE | NOMINAL THICKNESS OF INSULATION 'SIZE {. DIMENSIONS TO NEAREST J /B * FOR FIELD USE ONLY. WA-TEX 001588 I ^ . & XTm B-lt < INSULATING CEMENTS '' i TRAINING DETAILS ' " PAGE NO* 67 (l) General - Insulating cements are used for filling and smootH5jSg~BTock or p&?formed`insulation,' and for insulating odd shapes. f The pointing trowel is used most often with Insulating cements, hut for large area jobs either the bullnose or broad trowel may be used. ' '' , The cement that is to be applied should be mixed with water to a firm enough consistency .that it will hold its shape and not slump. Insulating-tmeftts shrink as much as 20$ when they dry. This tends to cause cracking. Also, when the cement dries from the outsidet in, there is a tendency for it to crack and curl away from the ' equipment. These difficulties are reduced when' cements are applied to bare flttipgs and equipment that are hot o`r warm at the time the cement is applied'.. Heat in the equipment causes the adhesive tbinders In tn@ cement to adhere more firmly to It. The hot surface also causes the cement to dry from the inside out, eliminating the likelihood of "curling". . When insulating cements are used to fill cracks anti voids in solid insulation, the cement should be applied and smoothed out quickly. This is necessary because the.moisture in the cement is absorbed by the solid insulation, making the cement" unworkable in a short time. - ? '|| For large areas, like vessels, drams, towers, and ducts, that are . covered with block or segmental insulation, wire mesh should be ^ applied to serve as an anchor for the cement. 19 or 20 gauge. '& galvanized 1 inch mesh wire should be fastened securely over the I whole insulated surface before the cement is applied* Because cements tend to. shrink and crack. It is better to apply two , 3/4 inch layers than one ljr inch"layer. After one thin.Jayer: ' -.^has. bean applied and allowed to dry thoroughly, surface;%racks ` sth'ould be filled and the surface scored with the edge of. the : trowel to promote adhesion of the next lawyer ,, If the cement is to be more than l- inches thick,' a layer 'of wire mesh pr expanded metal lath should be applied over every 1- inches of , cement. ~ The irregular shape of such equipment as pumps,' turbinesp`:and ,. valves makes it necessary to use cements for the entire thickness ' `of the insulation. Small scraps of solid insulation may be ' embedded in the cement to add bulk and to hasten drying. This method was discussed in Item B-ib (2) (See figure 2). Figure 3 shows the same technique where sectional Insulation is stopped at a pipe hanger. i WA-TEX 001589 ITEM NO. B-17 ' TRAINING DETAILS PAGE NO. ^8 ' ' &U02^,,..3. Each layer of cement should be dry before the next layer is applied. If the second layer is applied too soon, the whole mass may soften and fall off. When the job must be completed before the first layer has dried fully, a few wraps of asbestos or jute twine may be used to hold the'flrBt layer together. The final coat of cement should be troweled smooth. The smooth surface is especially important when it is the foundation for such finish coatings as paint, weatherproofing |cement or aluminum jacketing. ` (2) Applying Acid Proof Insulating Cement - When applying acid proof cement, first clean the hexsteel or- floor-steel lining. Chip off slag or excess weld metal. .Clean off oil, grease, and dirt with steam or hot water. Let dry thoroughly. Do not prepare more cement than can be applied in 20 or 30 minutes, as it sets up guickly, place the sodium silicate solution in the mixing container. Gradually add the dry cement and stir thoroughly. Stir until the mixture is free from any dry or unmixed cement. Continue adding powder to form a thick, heavy mortar. If the mortar will very slowly slide off the face of a trowel that is turned on its side, the mortar is thick enough. The mix should be about one 50 pound bag of cement to one 2 1/2 gallon can of sodium silicate. Never add any water to this mix. . O | WA-TEX 001590 , - ***-- ITEM B-fo.7 TRAINING DETAILS PAGE NO. 69 NOTE: .' When a large amount of cement la to be mixed* It 1b ` helpful to use a 5.x 5 inch blade steel mixing paddle mounted in a low speed drill. This will, make mixing easy In a bucket of 14 quart capacity.' ' Apply the cement with a 6 inch-pointing trowel. Start at the center of each area and work toward the edges. This helps to eliminate air pockets or voids under the cement. Apply the full thickness of cement in one coat. Never try to apply a seoond layer. Firmly press the mix into each opening of the hexsteel or grating. Be sure each openipg is completely filled, flush with the surface of the gra'ting. Do not apply any cement above the surface of the grating. The grating and the cement should be smooth and flush. NOTE: If;.any excess of cement is allowed to overlay the steel, it will eventually flake off In .hard chips.. NOTE: Once the mortar is.^applied, do not, go over it. The mortar sets quickly, and trying to rework it will cause it to stick to the trowel and be dragged out of shape. After the mortar has become stiff, but not completely hard, brush the surface lightly with sodium silicate solution. Nse- a trowel to smooth the surface to a glazed finish, and to push back sags in the grating. d. POMPS AND FLANGED VALVES (!) Pumps - Pump bodies are usually Insulated with cements rather than block or pEOformed Insulation. This is because of the Irregular shape of the equipment, and because pump castings usually have no seeureraent anchors for the wires needed to hold block Insulation in place. H&ve some heat in the pump, if possible. Cements applied to. warm or hot equipment stick better and crack and curl leas than on cold metal. The heat also reduces the drying time between application. Make the cement a little thicker or dryer than cement that is applied over solid insulation, as metal doeB not absorb moisture from the wet cement. The less water in the cement, the quicker it dries and the less it .shrinks. Apply cement to pump body by hand, applying Ip In the form of small balls to cover the surface. Do not let the balls exceed 3/4 inch thickness after they are pressed into position. Small pieces of scrap Insulation may be embedded in this layer. Cover entire pump this way, but do not cover flanges, the area next to flanges, areas near studs that' may need to be removed, drain plugs, or manufacturer's tags with important Information. Where there are flanges, measure the length of the bolts and stop the WA-TEX 001591 ITEM B-17 TRAINING DETAILS PAGE NO. 70 Insulation that distance from the flange. After the rough spotting of insulation is done, let the cement dry before applying more layers. Trowel on the next layer of cement. Do not let the total thickness of cement on the pump exceed ! Inches In this step. If the pump requires more than 1|- inches of insulation, fit and embed wire mesh into the surface of .this troweled coat, and let the cement dry thoroughly. Build up required thickness in 3/4 inch layers, letting each one dry* before applying the next. Apply wire mesh on every if inch thickness. .' Use Portland cement in the final layer of cement. NOTE? If pump Is outdoors, apply a f Inch layer weatherproofing cement Instead of the Portland cement mixture. Insulate flanges after all layers have been applied to the pump body. By Insulating the pump completely, before the flanges, the flange Insulation overlaps the pump covering and can later be torn off as necessary without damaging the unit of insulation on the pump body. Cover the flange with small lumps of cement, and finish the same as the body of the pump. If possible to use block or segmental Insulation on flanges, fit and apply block on the outside circumference of the flange 1/2 inch less in thickness than the covering on the pump body. Have the flange covering extend at least 2 Inches over the ad jacent covering of the pump casting or piping. After block Is wired in place, trowel on the required cement layers to smooth finish. Apply aluminum jacket, if. required, (2) Flanged Valves (a) Insulating End Flanges and Body - Use sectional or segmental insulation the size of tfie""flanges. If available, or use block insulation. Cut the sections, segments, or blocks to a length that will extend over-both end flanges, plus a dis tance to overlap the adjacent pipe insulation. Make the length of the overlap equal to the thickness of the insulation, but never less than 2 inches. When using sectionalInsulation, have the 2 seams parallel to the valve stem. That way an equal amount will have to be cut away from each half for fitting around the bonnet, and a better fit will be made. If overlap lies against pipe WA-TEX 001592 ITEM B-17 1`h-A.nmio i.'KTAj ij PAGE NO 71 oovorinr;, rft>iJ,v wire .loops an incti from the end of the? vnl'.e covoidn*". if chore is a space between the pipe eo'.epln.o md the overlap,, place tempurar%y loops around the r.!,-,Ju;e area. .1n'.i j in the space pc*tween the pipe cove pin.' nut flit);. e cove id mi with lnuuL'itln^ cement and J.Ot dry. Tighten and secure the insulation v;ith loops an .inch from the end of the overlap, dee figure t.|, NOTE: I).' Mock insulation is used, score it to make it conform an closely as possible to the fannies end valve bou.v. (b) 1Jii:,;uia :.i .i ; BpMi.ol. U :l.`oi'iiiCij j n: j I. i-.-j. s*': anry* mm punnet - Kit with pre. 'ii* ebe r.'i :',c of (.ho I'J at, or use scored l.ic.c- iuoii !'i .m. iiotini.t !.' i ij;*.-.`i arc: uhij.- j. iv the some r,lot; i.l.-u end i` > ijm':-. . lino tenc.iu.j .'.priiv, . 1and 'ltti.ir:. u.> incti pi ..us jii pjace dui'in , cut tin;*; Cut: lnau.i..-Ll-.,i to i'll, t.i(>,nt:o/ur the cuj'vo of the insula tion on the I'Laiiiio bo<v- Let insulotion extend above ficrine studs a distance equal to the tl'i.it:Ktit;;::i uf che insulation, but do not let it extend above pacu.'uj ^.land. WA-TEX 001593 ITEM B-I7 ' ^ TRAINING DETAILS PAGE NO. 72 Hold insulation In place temporarily with a hand-tight wire loop around the bonnet flange, and another loose loop near the top and bottom. Pill the space between the insulation and the bonnet with small pieces of scrap insulation and cement; Let dry. Tighten and secure wire loops. Pill voids and cracks with insulating cement. Apply a rough coat of insulating cement on entire valve covering, not over 1/4 inch thick. Let dry and follow with specified finish coat. e. EXCHANGERS AND VESSELS (l) Block Insulation - Block insulation is used mostly on large vessels/ drunis/ ducts, and on piping that is over 12-inches In diameter. Block Insulation is made with straight flat surfaces and it comes in several dimensions. In refinery work, the most common size is 36 inches long, 6 inches wide, and 1, 1-|, 2, or 2% inches thick, Blocks for curved surfaces should be cut, mitred, or-scored and bent, to fit snugly. Tension springs or heavy rubber strips around'the vessel or pipe are used to hold blocks In place until the whole surface is covered, The last block inserted should fit very loosely, so that when the wire loop Is tightened it will be able to pull all the blocks snug up against the vessel. When all the blocks are In position, they are secured by wire ban1 ds or loops on 9 or 12 inch centers, as specified. When multiple layers are required, the joints of successive ` layers are.staggered. To do this the first round of block alternates between full length and half length blocks. The first layer is then continued with all 36 Inch high lengths. The second layer is started the same way, with alternate full and half lengths, but the blocks are centered over the seams In the first layer. (a) Insulating Drum and Vessel Heads - The ends of an exchanger,.vessel, or drum are insulated the same as the sides of the equipment. The main problem with ex changer heads, etc,. Is securement of the Insulation. Supports for securement wires are installed in the form of small lugs, clips or wire rings. These are welded to the vessel, and wires are attached to them to hold the blocks in .position against the surface. The wires are criss-crossed ' ' or laced over the blocks to hold them in place. ] WA-TEX 001594 ITEM B-17 TRAINING DETAILS PAGE NO, 73 (i) Drum Heads - For boiler drum heads* securement lugs are welded on 12 Inch centers over the entire head. A ring of 9 gauge wire Is tack welded around the manway. It should be tacked about 3 Inches out from the outside diameter of the manway. Securement wires are attached to the lugs and to the ring. Since drum heads are slightly convex* the best fitting of blocks is accomplished by scoring the blocks crosswise so they will bend easily. Applying fibrous insulation adhesive to the blocks will give temporary securement and make fitting easier. After all block is secured with the wires that run from the lugs and wire ring* hairpin wires are applied ' if mesh Is going to be put on the insulation. Voids are filled with scrap and cement. The-entire surface is cement coated and wire mesh Is applied. Where mesh is cut away for the manway* the edges of the mesh* are secured with 'tie-wires from the wire 'ring. Sharp edges of mesh are hammered down with staples. Mesh at the edge of the drum head is cut to conform to the circumference, of the drum* and Is laced or wired to the mesh bn the side of the drutei. V (ii) Exchanger Heads - Flat exchanger heads have a row of bolts around the edge. The area of the bolts is usually not insulated, ' NOTEs Convex heads are Insulated with cements* covered with wire mesh* and secured by a wire loop around the base of the installation. ' When a flat exchanger head Is to be insulated* a wire loop or ring is tack welded around the head* 1 Inches in side the studs. The loop is tacked down about every 5 Inches. Tie wires are attached to the loop on about 6 inch centers. Enough tie wire should be attached to secure the required number of layers of blocks. (2) Roll Insulation - Exchangers and vessels can sometimes be insulated with roll (blanket) Insulations Regular fiber glass in sulation for'equipment up to 250F.* and fiber glass. T.W.F. thermal wool for equipment up to 1000F, These products come In rolls 4 feet wide and up to 520 inches long. | WA-TEX 001595 ITEM B-17 TRAINING- DETAILS PAGE NO. 74 To insulate an exchanger with fiber glassy wrap the Insulation around the exchanger with the ends at the top., over lapping 3 inches. Making sure the insulation is pulled snug against the metals tie on with jute twine; tie twine 2 inches In from edges, and then about every 9 Inches along the entire length of the exchanger. NOTE? The twine must not be tight enough to make deep grooves or creases in the insulation as that compresses it and reduces its Insulating value. After exchanger is completed covered with the fiber glass, wire mesh is applied. Cut the wire mesh 3 laches shorter than the circumference of the exchanger, tfel.ng 48 gauge galvanized wire, saw ends together pulling the wire mesh tight. Apply the next section of wire mesh leaving 3 inches between the edges of the sections. Sew the. edges together using 48 gauge galvanized wire. After all wire mesh has been put on, apply one coat of the specified insulating cement. After the cement.is dry, apply a coat of weatherproofing mastic. f. BREECHINGS For the outside of breechings, have studs, clips, or 9 gauge annealed impaling wires welded on staggered centers as follows* Vertical sides Top Bottom 18 inch centers 24 inch centers 12 Inch centers For the inside of breechings Vertical sides Top Floor 18 Inch centers 12.Inch centers 24 Inch centers If impaling wires are not used, attach the needed number of lacing wires to the clips. - Apply block or blanket Insulation to side, top, and bottom. Hold block in place temporarily with fibrous adhesives. If lacing wireB are used, secure each layer of block or blanket as it is applied, , -- ^ If impaling wires are used, let them protrude through all layers of insulation. Press the insulation firmly down around the Impaling wires, and with pliers bend the wires at the surface of Insulation. Bend wires to a right angle so they lie flat against the Insulation, Bend two out of every three wires, leaving the remaining wires to secure the wire raeBh and insulation at the ' same time. NOTE* An alternate method is to bend all Impaling wires against, the Insulation. Mesh is then secured with short lengths of lacing wire that are passed under the bent Impaling wires before cements are anolied. , wa-teX 0015D6 l ITEM B-17i TRAINING DETAILS PAGE NO. 75 Pill voids and apply a rough coat of insulating cement. Let dry. Apply and secure wire mesh* lacing all adjoining seams together. NOTES On the Inside of breechings* floor and overhead mesh is installed separately from wall mesh. The mesh Is then laced together On the outside of breechings* apply a inch wet coat of water proofing cement over the mesh. On the inside of breechings* apply a inch layer of serairefractory Insulating cement. This will protect the blocks from abrasion due to erosive particles passing through the breeching. Follow manufacturer's instructions for mixing semi-refractory cements. Be sure to trowel the surface smooth. g. COLD INSULATION Gold lines that are likely to sweat should be out of service while being insulated* if possible. This is to keep the line from being cold enough to attract moisture which might then be trapped inside the insulation and damage it. Whether a cold line is in use or not* it should be wiped dry before the Foamglas (or Styrofoam) is applied. The cold system should not be put into operation until the whole insulating Job is completed* including its vapor barrier and outside coverings. (1) Applying Foamglas - Foamglas can be used on equipment getting as" cold"as -4$*0F. Apply the Foamglas to the clean surface of the pipe. Butter the joints with a permanent mastic type sealer (Foster Foam Seal). Making sure the joints are tightly butted* secure the insulation with metal bands on 9 inch centers. In multi-layer applications where temperature of piping is below the recommended range of the sealer* seal only the outer layer. (2) Applying the Vapor Barrier - Since it. is essential to keep moisture "out of -the Foamglas insulation* and since cold lines attract moisture* It is necessary to apply a vapor barrier over the insulation. In the refinery* we'use a fiber impregnated asphalt cutback called Pittcote 300c as a vapor barrier. Insulation shall first be tack coated with Pittcote using about 2 gallons per 100 sq. ft. Into this* a layer of asphalt impregnated glass cloth shall be embedded over-lapping all ends. Then another coating of about 4 gallons per 100 square feet of Pittcote is applied. Aluminum jacketing is then applied over the insula tion (See item B-lh(2)). (3) Fitting Insulation - Fitting insulation shall be applied in the same manner as adjacent pipe insulation with sufficient bands to hold it In place. Where it is Impractical to finish fittings the same as adjoining pipe insulation* fittings may be finished with glass fabric and Pittcote and then painted to match the jacket covering. WA-TEX 001597 It pfe,:.. Pipa.-; .^. -v rts `rSi'5^*' V;J|3^;.r i * * .1 . "Mu '` X;(v34y,, V"v '' j'i-Y %SVs&izer- $?: ffi .s !*-* ** /''* ft? M*`" >; el Jpr\ 1 * >** 1 *i * : D .. .. T ><, .* .-Of- T^r rf^rrT **.'. ,J*I " ,!* * .t-v CO'1-] ;4 D; ykji niff 1... { v ;* 1*1 ff; . .V'Jv'-;*:, HtMk M }?& fm 'Ln.\ :'8'' 73%'` 13%. ,{# ..^1' ' ' 'bh.88 ;;!j75- ;Ke<r f\6&- 'Y-MAt?/ //?< 1^5 r; &- V f^pfv fm>- ifjjC*. V&'A'- " j'i*K1'J W \ty. .'V*" ;:-;75- :- .66' , '.66 ;-/ i; -vITT *>. .',8\ i-rr'-i V3f$ '4- v,* i Vtt' V' '1%:' V1 ^ 4661' & Mv'i., t ^ && 'iv1 is Jj.iT `.7 (- ` - }0'<:. Vo.*. * ^J'v**' ` 'hV*,> ^ -Me i-h' .V--.V'. 1.66 ff ivT' )rt]i .&< .f4j:,;. 1',. \ T!' ' '*1 iS'V ;;. wr. 14' ! % .>58 ..8' '4 fr&.v ': ;.58 ' S;8r. -wi >^8-. m %%- ;v%r .58 %: ;% .".60 W ;4w4. .50 S5Q, '-8.7 ;.sk* ;:^d; '..*-i: v i-y.b'<''>; K'l&iX &! ip-;? 4*" ;441' y-'r..'.. *V. 1. ;;t4:,v '1"T" * K *. -Y-l-:. 5 *. a-/`4* v..**t HfiaW M' AT :'> V-'-^V `i, t ;'r<` :: ::>` 9-`- ~%t\i kES-&iw^ysi* ^:20^, ,'6% m-. Cl. g&t& a: 22^; V;8S: #?' 'life- -;29' Y-l '1%'. 1,20 VY'- 'jv ':;0 ,!fii ` y> :m * 1'.'rt l-y. .KsU., .xf ^11' YY * tt./f* v^ i;' \ \\ v/^v*; li }t ; 'l!' 1 *' y^v "*< i\ 1 .j-^rr .Sv^* *V, -V' ijfi i; j ..f'ftj :.' `ff^eV, -* *. a` \$0> wy'v'i-yyC. v .1 - -- TEXACO INC, PUGET SOUND PLANT ' TRAINING DETAILS DEPARTMENTS INSULATION CLASSIFICATIONS INSULATOR fTRAINEE) ITEM NO. B-18 -- SUBJECTS PROCmm^m am. Refer to' Item B-19 Paragraph * 0 *. PAGE NO. 79 DATEsAPRIL 5,1973 I WA-TEX 001599 TEXACO INC PUGET SOUND PLANT TRAINING" DETAILS' PAGE NO. 80 .DATE? APRIL 5,1973 DEPARTMENTS INSULATION CLASSIFICATIONS INSULATOR (TRAINEE) ' ITEM NO. B-lp SUBJECTS mO^DURESJE_Q?L^PPLYING,, BRQSIOKLAND QORRQSXQNJO.TEIH1XON_TO INSULATION a*__ b.--Refmebors: cements g-..~ A, Acid Proof Cement - refer to Item 19 Acid Proof Cement B, Refactory Cements - refer to Carpenter Manual Item 26. C, Weatherproofing Since insulating cements soften when wet. It is necessary to protect Insulation against moisture when It is outdoors or subject to getting wet. Normal exposure to the weather is controlled by weatherproofing cements and aluminum Jacketing. H.I. Mastic - the only type of weatherproofing cement used in ` the plant is an asphalt emulsion called H.I. Mastic #90-07. The mastic is applied to ells and fittings where it is impractical to apply aluminum Jacketing. The mastic is applied to the cement surface and then wrapped with a fiberglass bandage, another layer of mastic is applied about 1/4" thick and then smoothed down with a wet paint brush. Before applying the mastic be sure that the Insulation cement Is dry. ' WA-TEX 001600 TEXACO INC, ~ PUGET SOUND PLANT TRAINING DETAILS PAGE HO. 81 DATES APRIL 5,1973 DEPARTMENTS INSULATION ' CLASSIFICATION? INSULATOR (TRAINEE) ' ITEM NO, B-aO SUBJECTS PROCEDURES FOR CONCRETE FINISHING Refer to Carpenter's Manual Item B-8. WA-TEX 001601 V TEXACO INC. PUGET SOUND PLANT TRAILING DERAILS PAGE NO. 82 DATE{APRIL 5,1973 DEPARTMENT: INSULATION CLASSIFICATION: INSULATOR (TRAINEE) ITEM NO. B-21 SUBJECT: PROCEDURES FOR REPAIRING FURNACES a. GLOSSARY OF TERMS COMMONLY USED, IN THE REFRACTORIES INDUSTRY (1) Abrasion - The wearing away of a material at its surface through!.the1 2c3u4tt5in6g* 8a9ction of solids. Refractories are often subjected to the abrasive action of moving charges (such as lumps of lime in a vertical lime kiln), dust laden gases, or tools used for charging or cleaning. (2) Batter - A slope of the face of a wall, usually causing a diminution of thickness as the wall ascendsj the angle at which a face of a wall slopes from the vertical. (3) British Thermal Unit - The amount of heat required to raise the temperature ofone pound of water one degree fahrenheit. (4) Calcination - An industrial heat treatment to which many rocks of mineral substances are subjected, mainly for the purpose of effecting dissociation, and driving off some .constitu ent in the form of a gas. A familiar example is the calcination of limestone which in ttye process, loses weight and is converted into lime, through loss of carbon dioxide. Clays are calcined not only for the purpose of driving off combined water, but also to effect shrinkage, (5) Cold Set - The hardening or ''setting" of a mortar material which takeB place merely upon drying. Bonding mortars containing agents which give them greater strength after drying than is obtainable with a clay or other refractory base alone are said to be cold setting, . (6) Corbel - An arrangement of brick in a wall in which each course of brick projects beyond the course immediately below it. (?) Corrosion - Gradual wearing away of a solid body through chemical action, as the rusting of iron. Corrosion of furnace linings through chemical attack by gases, slags, coal ash, or other fluxes, occurs in many types of furnaee practice. (8) Course - A layer'or row of brick as built into a furnace structure. * (9) Density - The mass ofa unit volume of a substance. usually expressed either in grams per cubic centimeter, or in pounds per cubic foot. It is ! WA.-TEX 001602 ITEM B-21 TRAINING DETAILS PAGE NO. 83 (10) Devitrification - The change In a solid body from a glassy State to a crystalline condition. (11) Erosion - Wearing away of a solid through abrasion or cor- .. rdsion, or through removal of loosened particles by the-action of a moving gas, liquid or solid. In furnace practice, the blowing away by the furnace gases, or washing away by a slag or molten bath, of loosened particles of refractory material from the lining, is called erosion. The sand blast action of dust-laden gases moving at high velocity is an example of erosion caused by abrasion. The washing away of grog particles from a brick- by a molten slag, after the bond of the brick has been weakened by chemical attack, illustrates erbsloh resulting from corrosion. (12) Fusion - A state of fluidity or flowing, in consequence of heatj the softening of a solid body,' either through heat alone or through heat and the action of a flux, to such a degree that it will no longer support Its own weight, but Will slump or flow. A1S0 the union or blending of materials, such as metals, upon melting, with the, formation of alloys. ' (13) Fusion Point - The temperature at which fusion takes place. Most refractory materials have no definite fusion point, as they soften gradually over a relatively wide range- of temperatures. (14) LE2L ** Non-plastic material, frequently preealeined, added to a brick or mortar batch to reduce shrinkage In drying and firing. (15) Header and Header Course - A header is a brick laid with its length perpendicular to the face of a wall, A header course is a course of brick laid in this manner. (16) Jamb - An upright structural member forming the side of an opening in a furnace wall. '' (17) Lintel - A orte-piece horizontal structural member spanning an opening In a furnace wall and usually supporting a super- structure. ' (18) Mortar (Refractory) - A finely ground refractory 'material which becomes plastic when mixed with water, and is suitable for use in laying refractory brick. (19) Nine-Inch Equivalent - A brick volume equal to that of a standard 9"' x 4 ^"x ^l" 'straight bricks the unit of measure ment of brick quantities in the refractories industry. (20) Spalling - The loss of fragments (spalls) from the face of a refractory structure, through cracking and rupture, with exposure of inner portions of the original refractory mass. .(21) Stretcher - A brick laid on flat with its length parallel to the face of the wall. ' WA-TBX 001603 ITEM.B-S1 TRAINING DETAILS PAGE NO. 84 ' CONSTRUCTION BRICK MORTAR........................: ...................................... . ---- I Iiiniini-- m ._ The amounts of the Ingredients used In brlok mortar can he ... varied depending on the job being performed, 'For brickwork in non-bearing walls with, average loads and exposure,' use 1 volume of Portland cement1 1 volume of hydrated lime* and 5 volumes of loose mortar sand. . . . .. . For bearing walls or walls requiring extra strength', use 1 ' volume of Portland cement, volume of line, and 3 volumes of sank.. . '' ' " ' . .Place the sand in the mortar box. Spread the cement and lime , evenly, over the sand. Turn the material over with.a square shovel until the mix . has an even uniform color. Add-a little Water, and hoe the mixture.. Add just enough water to mix the mortar into a workable plastic mass. Mix the mortar thoroughly to make a smooth mortar. Extra stirring will improve the consistency of the .mortar without the addition of water. NOTE! Do not mix more mortar at one time than can be used before It stiffens. If stiffening'mortar can not be restored to . workable consistency without adding water. It .must be discarded. CONSTRUCTION BRICKWORK REPAIR When making brickwork repairs, the area to be repaired must be cleared of old mortar. Scratoh out any loose mortar from the joints. Wet the area with a wet stiff brush, at the same time brushing out any powdered mortar. Mix mortar of 1 part cement, 1 part lime, and 6 parts sand, with just enough water to make the mixture workable, Slice off a small amount of mortar with a pointing trowel. First into the vertical joints and then into the horizontal joints, strike or press the mortar into place with the edge of the trowel, pressing with a downward and then outward motion. When the mortar has become firm, strike the joints again to compress the mortar, using the same patterns first the vertical joints, then the horizontal joints. At the same time, press the trowel into the surface of the joint to make It slightly concave.. THERMAL MORTARS .. (l)-^ Fire Clay. - Fire clay can sometimes be used when the temperatures involved are not too great, and when resistance to abrasion is not an Important consideration. ' Put some water Into a mixing through or pan. Pour in dry clay at the edge of the pan or the end of the through, stirring it Into the water. Add clay, and stir out any lumps, until a heavy troweling texture is obtained. WA-TEX 001604 \ ITEM B-21 TRAINING DETAILS PAGE NO. 85 If leftover clay mixture Is to "be used in the next few days, pour a thin layer of water over the top of the mixture. When ready to use it, pour off the water and rertlx. If the mixture is too thin, add more dry play and stir. If the need for clay : is known a day in advance, mix an extra firm batch of the mortar cover with water, and let stand overnight. This practice mattes the mortar Smoother and more adhesive. (2) Ganlater - Ganister is a mortar made by mixing ground fire brick with' fire clay in order to give the clay more body. It -iSvUs'ed;fpr;:)?atch-,.work-:In`furhaoeS'.' ............................... Httx'.:Vith-'^t'er -to a heavy putty-llke. consistency . Use just enough water to permit the mix to be troweled or rammed into the voids. " V. ', . NOTE? Excessive water will result in excessive shrinkage of the mortar as it dries. (3 ) Fire Brick; and^Insulating Fire Brick Mortar In the re finery, two kinds 'of fIfe'Wfc^mbrta^^r^commohly used. These are Babcock and Wilcox Mulset, .and H.W. Harwaco Bond. These mortars are essentially the same material as the brick, but finely ground. They are mixed With water until a troweling consistency is obtained, ' ' NOTE?. Portland cement, lime, and other additives should not be used in thermal mortars as they reduce the mortar's resistance to abrasion, heat, slag, and corrosion. e. REFRACTORY CASTABLES (1) General - There are many kinds of refractory castables used in the refinery depending on the particular job to be done (See Item A-lOd (5)). These castables come In dry form and are mixed with water to the proper consistency. They can be applie' d_ by either ' gunning or tr, ow_ eling, '. The material should be thoroughly dry mixed before adding water to ensure a uniform distribution of the ingredients. After the proper amount, of water has been added, thorough mixing should again be carried out because the initial dry strength of the refractory depends on the action of water with the, hydraulic binder. Over-mixing should be avoided as it affects the strength and characteristics of the castable. . >, 'ft . The mortar box or concrete mixer should be carefully cleaned of old concrete and any foreign material. It should be wetted down to prevent lps,g of moisture from the mix. Do not prepare too large of a batch at one time. Generally, the maximum amount . should b.e one that can be applied within 1/2 hour after mixing. W&-TEX 001605 ITEM B~gl. , TRAINING DETAILS . PAGE NO. 86: In certain lines, boilers, furnaces, vessels And any place when ; > : there is a need for high Insulating value alon^ with rehlStatioe ! r , ' to abrasion, a dense castable Is' sometimes' applied' over' a layer : '-1 of insulating castable o The insulating material IsappXledapprox- imately If inches thick, before hex metal or expanded metal,/lath: : is welded to studs which have been attached to the, metal surface. . Then the dense castable is troweled or gunned into the hex . , .\ ; metal of other`reinforcement material that is .us'e'd^v-: $he -dins'! ; ..castable is- applied flush with the top of the hexVmethlir ;Any ^/ . -material that Is above the hex metal will flake off during:- the ;,. : : , y operation of the equipment. ' y-:0;..-.' ''s// f. PLASTIC REFRACTORIES . ; :y . .. Plastic Refractories are .refractory materials prepared in a . ,-o stiff/plastic condition of the proper consistency for use with- , out further preparation. Various grades are supplied commercial ly, corresponding in coraposlton to high-duty and. superduty, ` fireclay brick, high-alumina brick, and chrome brick. Most., grades of plastic refractories are supplied in both heat-setting and aif-setting forms. They are applied to form monolithic or joint-free furnace linings in new construction, or. to repair existing refractory masonry. .; . Plastic refractories are generally rammed on with the use of a pneumatic hammer, although in certain applications they are pounded into position using a mallet. In some applications, such as arches, rigid forms must be used to achieve the deisred con tour. In patch work, the surface should be cleaned thoroughly be fore, the plastic .refractory is applied. Because of the many types of plastic refractories available, manufacturer's specifications should be referred to for application details. ' STANDARD REFRACTORY BRICK SHAPES The following brick shapes have been generally adopted by fire-brick-, manufacturers as standard shapes for brick which are molded to size and cannot be machined easily. They are used either alone or in combination as shown in the tables. However, since Insulating fire brick are readily machined to exact dimensions, it is common practice to furnish them Haller- made" to fit any specified arch or curved wall and also eliminates the necessity for handling a number of different shapes. In the event that standard shapes are desired, the following tables give sizes and combinations of standard shapes to turn circles of various diameters. WA-TEX 001606 \ ITEM B-21 ' TRAINING DETAINS . ! /' PAGE N0,g7' '.""ittVoj* *J' I)1' t.r.M 1 i'llt. r,,s'`ic r'!*. ft. FI.. Thlr.lftp.'-.j o[' I'.'tl ! l.'/i J nchticj ... 4`i " ` <) -- II..wi r i'r;<'l' . i* r.. ; ;i(5. ui* '.i" i'LruJ/'lit Fi'lcl* j. rou. :'t IV. 07 '-'H.- \i}h t Ft* I'M--- nY*. T.*>r * - . 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V tl.< in. 0 3 :t ft. ti i. t> it. in. 3 I r.in. :i ft 'i iii. ifc.n in. .. * I It. .`till. 1 ft. ti ill. t tl.-'l iii. I I ,t * .. * 1'! i.t II / a i. .t. ; .. ! 1 1. * '* .... r, ii i-i t'o 11 1 h It i I'l J .l.l (' !; n !, i; i: u\ i*> M *i ittfi 1*1, - s r ti It. fn. i', ft, t. mi. tilt `*1.,. V Ii "hi. t it. a V li. 1, in. r fi. '* ill. Kit Hill. 1! It..' ii.. K It, li ill. Kli.'li.i. H It. H ill Yi- <!..! II / . .. ,r <l..Ie II It, 21 .i! :>-i a a I i Hi-i.lit) f. * r*I*t .t.u-u; n ?i m .>/ * . ; , 13 in ?.! 10 3D n WA-TEX 00X608 1 t.l 1 'i it ITEM 33-21 TRAINING DETAILS PAGE NO. g g >s \ v * X. ; n ' ' I \ , )> n N":`. hT: Y . 9^"' ' L 9" IH-y r.vlelc (T:\l>1 n tWn !t unod fitr 11}!," nri'l X" !.*rio;i:)! ! t- M m. iUrf ) ft. .'', in. : *t.t) in. n.ti in. :< ii.d hi. '3 ft. hill. 4 It.U in. 4 ft. (> in. A ft.(tin. flit 3 i.i. !. It.n i;i. (ill It in. fi |i fi i.i it. 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Tib. 2 l.rr -- ri. i , `r 11.1 113. iif-i. Ii TiitsT i; 2i IV1 lit ........ .... ... 113 m. 11.1 11.1 in :>, ;*> .I .t 1! in in in in n.t 1'. !1 !i '. * :i m . it in ii in * m 11 ji.i si 1 'I Ii: 11/ 1 .t I l'.'i 1l 1* l..' In l.'.i ) J 1 ): i i,' .... .... m ni m n:t ] 1.5 11.7 in in -- Cl *:i .i 'll* : iu l"l 2't 11.1 :.i i j-i ff m t U7 '21) __-- - -- WA-TEX 001609 v. ITEM B-21 TRAINING DETAILS OUwt 1-1 ,-ip j " ;'< ^ PAGE NO , 90 Unit Slni- 'A Ibil" . ' . Siilr Sirin <>"x(4W' . iV")xW'i' AV>*i> .SVrn/i ( I yx")x2W" St'uip ' D".t-2'A".f2ya" : SillIIIl 9" 2" Hrirk 0"xlV,"V,r V. item R-21 . training DETAILS . PAGE NO,. 91 h. REFRACTORY BRICK STRAIGHT WALL CONSTRUCTION / (1) Courses - There are -several, types of courses, or continuous level ranges, that can be used In straight wall construction. Among these are: , (a) Stretcher Courses - Long dimension of, brick is parallel , to face of wall. This construction is desirable; in . - that fewer joints are exposed .> ..... - , .--W- :-a-- :. (b) Header Courses - Long dimension of brick is perpendic- , ular to face of wail bo that less ar<ea of; each brick is exposed with the result .that.the brick are less subject . to spalling and falling out in service. - , (c) Other Types of Courses - As it is, desirable to confine the loading on, the largest face .of. a brick, other 1 ' types of courses are seldom used in straight refractory walls ' ,. . - . (2) Types of Construction - Courses can be arranged to form many different types of wall constructions. ' Among the' more common are the following: . _ (a) All Stretchers (See Pig. l)- Not very rigid and is not recommenc except for walls under 3 feet J height, or walla having other means of support such as suspended walls or veneer courses between a heavier wall and exterior casing. V"-thick wall, all stretchers Even for walls under 3 feet high other types of construc- Figure No. 1 tion are preferable. ' . (b) All Headers (See Pig. 2) - Many 9"-thick insulating fire brick walls are built of all-header courses. This is especially true of bell-type annealing furnaces. Advan tages are a reasonably stable wall with the back side of all brick under comparatively low temperatures. Hence, a preferred construction for walls operating near their temperature limit . 'i'r-thick wnll,all headers Figure No. 2 WA-TEX 001611 v .? b-21 TRAINING DETAILS . f>AGE NO. 3 2 (c) Alternate Headers and Stretchers (See Fig. 3, a & b) - > ' 1 Wall? of both 9 and 13-i/?" thicknesses constructed of alternate headers and stretchers make .a very stable wall and ; is considered -gpod practice.'' Walls,pf, this ,,type, are most'. '! - eo^hnNiH-'-Mi^rfurhace-' conotruetion, especially where dense r Figure Ho. 3 (d) .Walls Mainly of Stretcher Coursea (See Fig. 4, a & b) This type of wall is extensively used where the brick are subjected to slagging or other erosive action. The*advantage of tills type is that the exterior face can be repaired by applying a 4"l/2,l-3kih wall tied into the remaining brick work. (e) Walls Mainly of Header Courses (See Fig. 5* a & b) This' type of wall possesses many of the advantages of one constructed entirely of headers, but sacrifices the advantages of the all-header wall on a minimum number of courses in order to. obtain greater rigidity. Thi3 wall is usually laid with thi'ee to four header courses to each stretcher course. WA-TEX 0016X2 , ITEM. B-21 TRAINING DETAILS PAGS NO 91 . Figure No* J5 . . NOTE; The most common construction where insulating fire brick is used are those consisting of all headers or of alter nate header and stretcher courses. These constructions are recommended unless other factors Influence the type of wall used. (3) Permissible Unsupported Height - Unsupported wall 4-1/2" thick, should be no higher than 3 feet. Unsupported wall 9" thick, tied in by combinations of header and stretcher courses, can be used up to 8 feet heights; 13-1/2" walls under same conditions are suitable up to 12 feet-heights. (4) Veneer Courses of Insulating Brick - A large proportion . of modern furnace walls are constructed of exposed linings of fire brick or insulating fire brick with "back ups" of lower- temperature, insulating brick or block. Typical examples of such construction are: . Exposed Back Up 9" Insulating Fire Brick or Fire Brick -with 4 i/2 Insulating 'Brick or Block* 131/2"Insulating Fire Brick or Fire Brick with 3" Insulating Brick or Block*i. i. GUTTING BRICK \ (l) ^ General r It, Is usually impossible or at least Impractical ` to predetermine all of the brick sizes required for a piece of equipment.' Consequently, it is normally necessary to cut some brick to size in the field. Some places where cutting is necessary are for the last course in an arch or wall, at the end , of an arch or wall and around openings such as burners.. WA-TEX 0016X3 A ITEM B-gl TRAINING- DETAILS . PAGE NO. 94 , The amount of cutting is normally not great, particularly : where the,furnace has been laid out completely and materials;; ordered accurately. However, occasionally it may he- necessary* to do a great amount of cutting in the field. An example would be where it is desired to cut arch or wedge brick from straight brick carried in stock. . ................ Insulating fire brick can easily be cut without special tools. This is in contrast to dense fire brick which must be chipped to size or out with abrasive wheels. The cut edges of insulating fire brick are even and the- size is accurate. When fire brick ; are chipped to size the edges are rough and the size is inaccurate to a degree,'dependshtupbn the operator's "skill. ...... ! (2) Tools for Cutting Brick ~ Several, different tools can be , used for cutting brick. The more common are as follows? (a) Pruning Saws - For the average job where a small amount of cutting is involved.* a pruning1 saw is: the best tool to cut insulating fire brick. Ordinary fearpenters? or key hole saws can be used if a pruning saw is not available. The pruning saw has an advantage over the other hand saws in that, the arrangement of the teeth will eliminate any tendency for the saw to clog. These, saws .will cut' through the brick very easily. (b) Hand Saws - Hand saws will be most satisfactory for the majority of the jobs. For accurate cuts, be sure the saw is sharpened properly. {c) Masonry Saw - For cutting brick in quantity lofs, it is usually easiest to use the masonry saw. This saw , is especially designed for cutting masonry products. The cutting is done by a rotating abrasive disc. The bricks to be cut are' placed on a movable table and pushed against the disc. (d) Circular Saws - An ordinary circular saw can be * converted to cut insulating fire brick by substituting a steelcentered abrasive blade for the steel blade. . This type of blade should not, however, be used on extra high speed equipment or mounted on an unstable mandrel. Such use, where the blade would be subject to excessive vibration, might result in explosion of the blade and injury to the workman. (e) Other ~ When it is desired to reduce the dimension of an insulating fire brick qnly slightly, or smooth up a rough saw cut, the brick may be rubbed to accurate dimensions against coarse abrasive paper or cloth, a rough file or a rough fire brick. LAYING "REFRACTORY BRICK ..... .." "" ' "" '' '' .... (l) General - The joints .between insulating brick or insulating fire brick should be just as thin as possible. The ideal ' WA-TEX 001614 ITEM B-21 TRAINING DETAILS PAGE NO. 95 .......... is to have the brick in physical contact at the high points With only the.Irregularities filled with cement. The; most . common practice is to lay these types of brick with so called ; dipped Joints, in laying brick in this manner, the cement ov mortar is thinned to a creamy consistency and the brick dipped into this slurr^<before being placed in the wall, It Is very difficult to apply cement placed in the .wall* It Is very difficult to apply cement to insulating brlok sufficiently thin with a : troWel, The practice Is discouraged* as It requires a degree . of skill that is mastered by only a very few. \ fg) Insulating Fire Brick - Insulating fire brick . , to: lay because they ten&"~rapldly to absorb che water out of ,. cements and mortars. The brick should, therefore, be placed into position as rapidly as possible after dipping. With the mortar box near'the work, this can and should be almost a continuous . motion. ' To slow up the rate of absorption by insulating fire bricky, they are sometimes dipped In a very thin cement solution .or water , . (the former preferred) Just before dipping them Into the layering mixture. The disadvantage of this is that it greatly increases the time for drying out the finished furnace, (3) Laying the Brick ~ While the brick can be laid by several different methods,'"the most common practice (after dipping in cement or mortar) Is to place them in the wall one to three Inches from their final location, then rapidly slide them into place. After this, it Is best to tap the brick lightly with a mallet or hammer op the top end or side to firmly bed it In place. With insulating brick and insulating fire brick it is Imperative that this whole operation be done rapidly before the brick absorbs the water out of the cement. A good share of the insulating firs brick and insulating brick used today are laid dry. For certain conditions, this is the preferred manner of laying these brick and can be considered good practice. Laying brick dry offers an advantage In that it permits expansion to be taken up at the individual brick Joints, whereas when mortar or cement Is used all expansion must be taken up at expansion Joints. , . k. EXPANSION JOINTS ' (l) General - In the construction of any equipment it is necessary to consider expansion of the refractories. In most straight walls the refractory can expand freely vertically but horizontal expansion must be provided for. This expansion may be taken care of by expansion JcintB or by laying the brick loose or dry. Hie most common practice, however, is to use expansion Joints. It is preferable to use a larger number of small expansion Joints rather than a few large Joints. For example. It is better to use three wide Joints than one 3/^" Joint although common practice varies between these two extremes. The smaller Joints result In, less loss due to radiation than a smaller WA-TEX 001615 v ITEM B~21 TRAINING DETAILS PAGE NO. gg ; number ' of large joints and;greatly rehbrict the totaldistance that; it ;ia .:neqestary,; of the wall, to move during .;., ex^nsioh; .orh bOhtfaOtioh.. ; bbpeoihlly ' impoftantin walls Witha: large rmmber of openings, - ' ' NOTE? In all cases where expansion is;provided for with - ;defihiter'%pfi(iife'i'c?n' should be taken to see that a noint la located qlose to and Oh, each side of all corners*. 2); i:1 odftstfUbtIhi^E&Pandidfryydinti^ . it is difficuitto lay up ; a briok: wall leaving'open spaces 5for;:'.expanaibti joints ,. : There fore> it/is!::custpmary:ito^Insert';#'roaterial;intheexpansion . "'hpace '`which';;'daft:,'.-fee.^reraOte^^ftef-^the; wa.ll:- Is built Wr, which win burn out after the furnace is fired* Materials commonly used ' are ihsUiatlhg'v; hd.ard;;dr:-'c:dfrctgated.>paper * Wood is commonly used should5 notV be usbd `:;WIth^ihsulatihgl;^^efbridJ^unlesS',rsoyd manually;-as,;the',, s ; i^ateepltempefatnfe'iigradiehtithrdugh^these,.brick^may^reBult -in;'.. .' j the wood In the fear portlon of the wall not burning out completely, ' ' " ' ' (3) Vertical Expansioh: ofj stacks, and Furnaces ~ As most boiler and furnace; stacks dperate.af compaFatltely low temperatures and have relatively little expansion^ it is customary to depend oh the cushioning together of the brick;and expansion of the shell to take, care of the expansion. The vertical expansion merely results in the wall moving in that direction. On stacks operating at high temperature, pit furnaces, blast furnace stoves, etc., the brick are either lald=up loose to . - pro^dd: for-eispansibn or Superex or some other cushioning materials Is:'nispes'Bary Bince the cushioning materials will; compfdss sufficiently to take up the cireum- ferential expansion7 Again, vertical expansion results in the wall moving vertically. : ` WA-TEX 001616 v