Document RBbp4EDaeBovb0erM5wZEKvn

THE BABCOCK & WILCOX COMPANY BOILEJI DIVISION REFRACTORY 3Y 4Y IP 2/3-31-70 OASH --R--E-V--I-S--IO--N--S------------IPIC"K'CRO. , bkcxiptioh [ ori. MEManE FURNACE FJ)0R WALES DO NOT S C A ll-- USE DIMENSIONS O N l >N: REOUEST. THE EQUIPMENT SHOWN HEREON IS PROTECTED IV PATENTS OWNED t BT. OR USED FOR BURNISHING INPORMATION TO OTHERS. OR fO R AN Y OTHER PURPO* TO PROSECUTION. "|)A* lN (0 UPON CONDITION THAT IT IS NOT TO IE REPRODUCED OR CONED. IN W HOIE OR TO THE INTERESTS O f THE SAICOCK A W IIC O X COMPANY, AND IS TO BE RETURN!.' .ED SV THE IA IC O C X 1 W IIC O X COMPANY AND ANY INPRINOER OP SUCH PATENTS IS : THE BABCOCK # ~'*lCOX CO. THIS DRAWING IS THE PROPERTY O f NOTES 1. SUPERVISION OF GUN PLACEMENT OF M&GMEEflE REFRACTORY BY REFEACTOPY MANUFACTURER RECOMMENDED Z REFRACTORY TO MAKE INTIMATE CONTACT UJ1TH Pll|AETP\L SURFACES. PETSOUND MATES\RL SVlALL MOT BE ENTRAPPED DWH. RrgBF [ cxrs. 0^,7-1 -GO! 1WB. INSULATION DETAILS RCALR ihchks -- i rooT _ A- A 0. CC, THE BABCOCK t WILCOX COMPANY ^ BOIIE* DIVISION IP KCFgftCTORV______________________ 3/3-31-70 MEMBRANE FURNACE FtDCRS ^ WALLS OAH | i 1 1 1 REVISION* eiUXIPTlON 1 o*i. ( r~ "j-- i 1 A P P R O *. NOTES- l. SUPERVISION OP GUN PLACEMENT OF MAGNESITE REFRACTOR BY REFRACTORY MniUUFFiCTUP.tR RECOMP1EKJDED 2 REFRACTORY PLACEMENT TO BE SUCH THAT NO YO'DS OCCUR FIND REBOUND MFTTERiAL. \S NOT EN'TR/APPEDREFRACTORY TO MARE CONTACT WITH ALL METAC SURFACES. own. it ^3 3F j -------- -I . C / A ! INSULATION DETAILS menu -- t foot A- THE BABCQC* 4 wiuwva BOILER DIVISION INSULATION REFRACTORIES DESIGN 2A 9/8-4-72 CONFIDENTIAL FACTORS AFFECTING THE USE OF CASTABLE REFRACTORIES 14. KEATING <Cont*d) The heating rates as given are not intended to apply to refinery vessels, which are subjeot to special conditions. 15. KROMIGHT-GUN This material is, strictly speaking, not a castable but is normally applied by means of a gun or by slap troweling in a manner similar to a castable. When gunning this material, it should be placed with as much water as the material will absorb without slumping. Also, for a slap troweling mixture, it is desirable to have it on the vet side rather than the dry side. A furnace lined with Kromight-Gun must be protected before firing as follows: BAW Kromight-Gun will air-set and the top surface will dry in a-coopara- - tively short time after installation but the portion beneath the surface will remain plastiq for quite some time. Walking or resting tools, ladders, etc,, on the dried surface while in this condition will produce cracks and depressions in the upper surface which will permit slag penetration, shorten the life of . the installation, and close off the vent holes causing the surface to peel upon heating, Even placing boards on the floor will not protect, it if traffic over the floor is permitted before it has deeply air-set. Firing a furnace with Kromight-Gun lining should be as follows: Provided that the refractory has been thoroughly vented, the best in stallation will result if heat is applied immediately upon completion. Since on most jobs this is impossible and the refractory is allowed to stand for a considerable length of time, shrinkage cracks will develop. If these cracks are large (over 1/8"), it is necessary to fill them before applying heat with a chrome bonding mortar having good air-setting qualities. Smaller cracks (under 1/8") may be neglected since they will close up when heat is applied. The furnace temperature should not be increased too rapidly. If the moisture in the refractory changes into steam too rapidly, it will not be able to escape through the vent holes quickly enough, resulting in a blistered or bloated surface. For the average furnace, the refractory should be thoroughly dried out if the temperature is brought up to about 5QQF and held for 6 to 8 hours and then raised to about 1200F and held for 3 to 4 hours. After drying out by the above procedure the refractory must be "bumed-in" at the final operating temperature of the furnace. The period of the 'iburning-in" process should be a minimum of 5 hours. The Kromight-Gun cannot be overfired by in creasing the burning-in temperature. Actually the structure of the refractory is improved if burned-in at temperatures somewhat above the maximum operating temperature of the furnace provided other components and materials in the boiler will permit this overfiring. 16. STORAGE When our refractory castables are stored under dry, well ventilated conditions, the loss of strength over a period of a year is very low, on the order of only lOfc. If, however, the material is stored where the sacks can become vet or exposed to dampness for extended periods, a certain amount of moisture may get to the material and cause a partial setting up with loss of strength. If necessary to store it outside, the castable should be placed on a ventilated platform off the ground. It should be protected by some type of covering, such as a tarpaulin so arranged that no water can come in contact with any of the sacks. The covering should stop a short distance from the ground and effective ventilation must be provided. This is important to avoid the possibility of ground moisture building up a high humidity. MAT1L- -h B&W Easic Gun Mix ? POWER GENERATION DIVISION INSULATION REFRACTORIES ORDERING REQUIRED QUANTITY 152 #/cu. ft. 4A2 9/4-16-70 SKIPPING UNITS 100# Bags Quantity shown doss not include extra material to cover rebound losses. Limited storage life is four (4) months. Applied with dry type nozzle mix gun. Compressed air required-------------------300 CFM @ 100 PSI confidential BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION 4Y(IPGD) 1/12-12-83 SCOPE AND PURPOSE BRICKWORK & REFRACTORIES .Q This section contains information on brickwork and refractories which are commonly used on industrial boilers. Jobs having special conditions re quiring constructions outside the scope of this section should be referred to Design Engineering. On contracts where the material and labor or material only for brickwork are in the B&W contract, all brickwork and refractories (with the excep tion of special shaped tile which shall be specified and furnished by Engineering) shall be supplied and applied by Erection or their subcon tractor. See 3Y-1A and 3Y-1A5-VI. On all contracts, the drawings should show B&W products where applicable. Where B&W products are not applicable, the drawings are to refer to the required material by ASTM specification and pyrometric cone equivalent rather than trade name. For example A. P. Green first quality firebrick should be referred to merely as high duty firebrick, PCE 31-32. BABCOCK & WILCOX INSULATION, REFRACTORY, LAGGING REFRACTORY MATERIALS 4Y 2A1 1/6-29-89 Approved Manufsecuring Materials To insure that proper materials are used that will result in the most satisfactory jobs, it has been necessary to develop a list of approved manufacturing materials. Due to the large quantity of B&W standards and contract drawings showing the Thermal Ceramics products, no changes will be made to the drawings presently on record or on future drawing releases. B&W will continue to show only Thermal Ceramics products where applicable and the following comparative listing will be used to determine equivalent substitutes. If any manufacturer's product, which is'not listed, is desired on a contract, the manufacturer's name and material name should be referred to Design Engineering for written approval, and for addition to these comparison listings, if warranted. In specific cases where a single or limited number of products are acceptable for a given application, the brand name or names should be shown on the BRIL drawing with no substitution indicated. Over the past several years, the following companies have under gone name changes as indicated herein. Present Name Previous Name Thermal Ceramics Premier Refractories National B&W Refractories Division C-E Refractories Kaiser Refractories COTtftf)ENT1AL CONFIDENTIAL 8A8CCCX i WILCOX IXSUmTICN-a?CTCRIE3-Ui6SINQ LISKTW6ISHT CASTA8LS CCRWMUVS LISTING CONFIDENTIAL *Y 251 3/6-29 Thersal > Ciraiics ! Xaoliti j 1600 1 Xaoliti i 2000 HS 1 1 Xaoliti j 2200 ! Xaoliti 1 2200 HS ! Xaoliti | 2300 LI ! Xaoliti ] 2500 U : xaoliti : 2500 > Xaoliti ; 2800 ! Xaoliti l 2000 C 1 Xaoliti | 3000 1 Kaoliti I 2300 Presier ifractoriis .National -- Vh Slock 33 Six ISC 20 liti Watt 58 IRC 23 Liti Watt 70 IRC 22/ SI-208 Plibrico Nortn Pfteriean efraetcriis A.P. Gretn Harbison Halkir "JiiMir** * Viriliti 1 Airliti PI least UI 20 Liticnti HS 2053 Cast Iftsul 120 'TT ghtwight Cast atIt 29 PI icast . LUX 22 Liticnti 2350 --pa Cast chtwight Insul 122 Castabli 22 "PImn Suotr Suniti -- 1 11i ___ ightwignt Castabli 22 Sisco LHV 124 RS-3 SS-7 i1 I tl j 1 11 1 ! 11 1 1ai1 i 1111 LIHS 50 ISC 2H.I Purelite -- -- ISC 2S-LI PI i east Tuff-lit* Liti Hati 80 ISC Pligun iyi 2S Cirlita 75 -- ISC 2S-U HoTssr*" Subtil Alusina nernr* Bubbla flluiina Pliaun W1 28 -- BubbW Aluaint -- Bubbli Cast -- Liticnti HS 2580 --------------- 1 VSL-50 ! ii -- RS-3A !il1 lilt 11 1 11 : :i --pa ! Xastolia Lightwight i 25 Castabli S i 1 a ' 1 a 1 -- py t ightwighi 1 1 Castable 1 SS-36 |l i i 1 1 1 t1 > t 1 1 l l 1 \ i 1 1 Lightnigftt Castabli 30 i 4 a j t Bubblt ! Cast t 1 pa-- UbbtttigM Castabli 33 I i i t i 1111 1111 till !! ! 1 ll l 5 i !1! .. CCNFIKKTIA. BABCOCK l MllCflX INSULATICN-RffCTQRIB-USeiM6 MRTflfiS COMPARATIVE LISTIJG CONFIDENTIAL 4Y 3)1 5/ 6-29 Theraal Ctraaics High Teflo Kul-S#t F sa-so Air Sit 11 1 Pretirr lAIi1 tfrartorits 1 1 ------lli1 ! Suptr 3000 >1I1 ttorwl Mix) !-- ii ii 1 Suptr 3000 l1*1 Secoth Stt ! ti1* 11,11 11l>11>11 111 i i ii 111111I1at l I1a I i I tI J l lIii ------- lIiIIIiii iiii National i)i Plibrico i Hy-S*t ! Suotr ! Dcnon Millstt ! Suotr * 1l Dtfion Alutab Suotr TrodlRt TrcNlizt 111t ------1I Dtton 11i1 Air Sit 111I i 1iiii i iit i ii i i I i i41111111 I11114l 11}1111111 Trottlability of this product is unknown. Harbison A.P, Grsn Milker Mlxi-Kooo -- | T-36 Harttco Mastic Srttnat 90 Coral Bond Sairsit -- Hamace Bond -- i i .H. Francs National i Francitt y Hntset Hy-Stt ! uctrsastic i ____ Alutab 1 Franstt Hilostt I -- Trctlne ! ! I ! i CONFIDENTIAL BflBCDCX ( ILCQX IULftTlCW-R.-CTC8!G-J^6lHa CERAMIC BOflffl PEDUCI5 COTPflMT!^ LiSTI* 4Y i 7/ 6-29-89 Theraal Ctrui cs M Board S Board HS Board Kaoaool Block Millboard 822 Kaowool 12C Board `arbor imdua Buriboard U fluraboard ID aboard W> Ouriboard Hot Board -- -- ----------------- f i Johns Presisr Kami Ua Rafractcriis Typ* 103 Tbtrsotce Type 12S ID Bound Typt U3 -- -- -- Theraotec A Board -- Cirifibtr Millboard -- Typ* 130 Th*r*ot*c ST Board a Industrial relations ti 1 1 Indo-Fon i 2100 \i 11 Indo-Fon 2400 l111 1 1i \ t1 1 Indo-For* 2300 t1 1 l1 ......-- - Kaoaool Duraboard 14C Board 2500 Tharflotac HPX Board / 1| KaoMOol Duraboard 2O0 Board 2600 Kaoaool ISC Board 2300 XaoMool Duraboard 3000 Board 3000 Unifilt Board m Board XaoMool 17C Board 3100 -- -- -- -- ------- Tharttcttc HT Board -- -- -- Indo-For* 2300 Indo-fori 3000 > 1 1l t 1111 1 I 5t111 \1 \ tll 1t11 i 1 CONFIDENTIAL BABCOCK fc 0ILCOI INSUUAT t ON-REFRACTOR IES-LABSI NS PAPER PRODUCTS COMPARATIVE USTINS 4Y 2AI 9; 6-29 - I CONFIDENTIAL T?ier*il Ceraiics 1 irborundua 1i Rollboard 440 Rollboard Millboard 110 839 -- -- -- ------------- -- KaoMoob 2390 530 Kao*ool 2633 880 Kaowool Unifelt H grades (972/882H) Kaowool 3990 fiberiax HSA ------ -- -------------- -- -- CONFIDENTIAL ._ BABCOCK i V1LCQI INSULATIQN-REFRACTQRIES-LA66INS SPECIALTY CERAMIC PRODUCTS COMPARATIVE 11STW8 5' / 4Y 2A1 11/ 6-29-89 CONFIDENTIAL ! Thiritl Ceriiics. Carberundui 1 Ceiss-Fire LDS Holdablt -- Taupin Mi: FC-23 111111 i1)11 111111 ---- -- ----------------- -- mm. | -- i i i ii ___ i i i i n. i i -- ---- ------------- -- -- > i 1>ti111 aaaa-fwa mmma 111t1 1 >1> 1 -- -- CONFIDENTIAL 0 MAX , 10* - 0 M AX . '!0 - 0 MAX O0j z 0 zI -s i K Z 0 02"Sz t31 * Oi. t* WlU.uA LU/VU'ANY POWER GENERATION DIVISION Co A 12R INSULATIONt BRICKWORK `REFRACTORY APPLICATION SOOT BLOWERS Cask HO REVISIONS OATC OtiCAIFTlOH 0*10. / "a CHSP APPLICATION f r IN SUIATION AN0 OUTER 2o S5E k 3Z i* wu io otjixv :oi ! 5 2x i 50 5< 2- kO! c c. <a * ru : c1: LOCKED DRAWER DRAWING FOR PRESSURE OR SUCTION! BORES own iy S. A- 3. CHCB *A**EO *7 APP'Q DUPLICATED in 3Y-LA-IERI SOOT &LOWERS MEMBRANE WALL \f (eO CACl " ' oatz i 7- 7 Z ow. NO. \ o \ R) c> O A 1 fOM aOM tO7 A.t C O N D IT IO N T H A T IT r n1 (7 rr./ n i v u i r n n n A ts /iM p i*oam aow io*t *< a, ilwwa *-vJlVirANY POWER GENERATION DIVISION 6A 80 3 t/>a-/a*fc3 INSULATION BRICKWORK# REFRACTORY Revision 5 1 -n.fi APPLICATION! Sc^rt|oAre{ p&^aipHQA |i4. OOORS / *5> APPLICATION INSULATION AS SPcClFlCD 0 Hr !* L * J 5tfSo 33 cZC5 3tC34 ACCESS DOOR IN FLUE., DUCT OR PENTHOUSE. 35 INSIDE OR OUTSIDE INSULATED l l NO REFRACTORY, P1N5.AN0 EXPANDED METAL LATH REQUIRED FOR TEMP. ISO AND E>EL0\V. MAX. TEMP. WITH REFRACTORY LINING 833 ><iI2 z3 '0 INSULATION 0y az 2X < `d_ l v 52 l -xj - II CONFIDENTIAL i. 3 Z HI ACCESS DOOR hS MAX. TEMP. 1500' in * 3* ,,52*2; oyx i< z- ua * .< - sa Cr. O Co LOCKED DRAWER DRAWING / o <5.A 5. PASSED BY DUPLICATED IN4Y-&A-3U3 ACCESS DOORS GO oaTk I I t i a A -/Mwq, NO. 101355 P<3D raftt* ism io.t A'2 HIc e. :i POWER GENERATION DIVISION 8U3 NSULATlON BRICKWORK REFRACTORY ARPUICA TION DOORS CONFIDENTIAL KG.vibOKJ5 hiC 5*7^1 pe^ce\Prio^> VteilSCCC'FtoOXAlUMtNiA WAS PUSTlC CHROMC CKE [CHGO DOO* FOR %Z\TMP OVER Z200etH 's>i/.- I' *C**wuGf*rs} nW/Dff OinCr-A>Ff=Pp-9u. .C!. INSULATION . AS SPECIFIED KA0CRTE 5 FIELD APPLIED 1I D /) L) INSULATION SHOP APPLIED EXPANDED METAL LATH SHOP APPLIED ACCESS DOOR- REFRACTORY LIMED I e MAX. TEMP. 2200 z i, w BRICK IN OPENING SEE DWG JOJ997/4- X< CI SI il *I uXo zrz o5 KAOCRETE 3 field applied INSOLATION AS SPECIFIED wwz 0 "v0 3S>Z< >5* MS ; (. x 5*8 INSULATION Expanded metal lath : 5 S SHOP APPLIED shop applied -< A"2i 2;i xu0 ccess door - refractory l/ned i ^g sCC.S< FOR TEMP. OVER 2200 ' - OH 15*2/ WATER COOLED ACCESS DOOR DWG 32039E OPTIONAL own, av S A- 5 CHK'O ACCE55 DOOR5 AS1C0 IV apwd * >v "M t OJRUCATED IN SY'OA-SUS IFAS-U UIV, LOCKED DRAWER DRAWING .. . tCALC 8IWS. *o. . W o*re ) " ) 2" 7 2 toi 3 5t /A-3 - rOMM IOM 1067 A-l , On POR ANY OTHER PURPOSE DETRIMENTAL TO THE INTERESTS thc rn o riim or THE DAOCOCK & WILCOX COMPANY aho is loaned upon conoition that it is not to si ntPAotiucio C0 i0 J> POWER GENERATION DIVISION CoA\ &U3 3 //fi-J&tt INSULATION brickwork 4 refractory application DOORS Oa&h MO. ______________ -- GATE DESCRIPTION Plt-M OOIC. a OClSTZD REFTbCeOSJ*** 3 'C! :Gb TYPi Of=APPitCAnCN C0NF1E>ENTIAL ~Q -'^3 DO HOT SCALE--USE DIMENSIONS iQ 3'air cooled OBSR VVHBNl RQ WILCOX COMPANY. ANO IS TO RE RETURNED UPON REQUEST on IN PART, on USCO PON PUANI9HIN0 INFORMATION TO OTI OVilT FI A&OV. THISJ-LMEl W.HN 3 rsareD DO-Plg. 15 NCLUDn, N2 I FIREBRICK. (_KlOT REQ'D, OM -WATER ..COOLED ODOR.) VIEW ' FROM sect\om'A*A" N5[DE FURNACE. ^2.\854>E showki) IS'xZr'ACCESE DOOR WITH' REFR.RBTAlNER OWQ. 3EOA1E zS Q 0S = CI WHEN |5x 2.l" DOOR LoCAT\OK OVERLAPS STD. 3.Location for. " obsesr. door.-idbe ARR^t. 2\554CE OWN. ST l.H S. chx'o PASSCO ST A T\< APP'O ARRi^TIDF ISXdr.jQRKT. ACCB55 ' " SCALE S OATE (L-/5- l-' Door, with brick.iki OpenimGj :r lO\99"7 A-3 \ C|;A ../ IP^D * nc dmduUCK & WILCOX . COMPANY POWER GENERATION DIVISION INSULATION BRICKWORK 9 REFRACTORY APPLICATION AT SUCKSTAY I0 B3 TMK BAIJCOCK ft WILCOX COMPANY S- u* 0 Is X L0 |c 5t U * sS w > : ei c a'- rx 158 Jee e5. 8<e :: - :c w I" * FOR PRESSURE OR SUCTION E>LR u t..' 2 t wx r S-AS. '*nto *r CMK'O AAP'B 1N5ULATICN AT 5UCKSTAY scale e*rc 1 * "2 4c * 7 2.- STUDDED WALL ;r- I019&4A-1 D'JFl.ICATED IN 4Y~(pA-3Yl . _ ............ ^-?0 E IPGiDTMm *om ,C*T*'* ' Ihi pho dk or THC THE tIAIICOCK A WluCOK COMPANY A I01LEI DIVISION :-r-i 7`\ : 4Y OPGP) Z ROf 5 3 3 9 '//-2-A2-&3 BOILER 8 FURNACE WALLS INNER CASED BRICKWORK REFRACTORY INSULATION CONFIDENTIAL DURUCArD lUMERCASEtJ BLR 4.FUfcWACt WALLS WITH METAL LAGGING tlKISH .. iN "3Y-ZR07 NTS It A- ~ . J ' tk -  PM X POWER GENERATION GROUP 2R01 INNER CASED XZ PLASTIC FINISH REVISIONS 1 ACM KQ. OATt -- hic*ipti6 1 *H.N J oltlc f* U1s> Chp To ipsp ih wots " IO A N C D U P O N C O N D IT IO N T H A T IT I* f* -i Mia oe z CONFIDENTIAL Is c* oA C9 IC *0 z< o W IL C O X C O M P A N ' t` S* *- o ur o * o xo wi0 <zL z . 0 5U AX 53 FOR APPLICATION OF PLASTIC F\U\SH .d oJ REFER TO 3Y(lPD)-6A-3Y4. *3 o. <c LOCKED DRAWER DRAWING K.D. ..r T.P.S. 1/ INNER CASED BLR 4FURNACE T>. k.-s. WALLS WITH ^PLASTIC FINISH DPWC. NO. DUPLICATED IN 3Y- 2R0I ^irGD D yy ^9-?a-RO 205/02/)-/ ipgp FOAM ISM IOT *< i n r u r n i w w r o h p a m /in c m i ? waiving Lucked drawfp nPAu/iMn ftt.  rv wwmrAill POW OBflBUTtON DIVISION ~ 5 3 6 a SR i//2-ta^3 BR/COVORK REFRACTOR.y REVISION* ww APPlt CATION &AH HO. OATC soe*ifno oi4. 4 BURNED THROATS aoodflast/cMoL>: R)& pit i Gfics Firp. -a i KAOCRETE MOT REQUIRED ON PORTION OF WALL WITH MEMBRAMS CONSTRUCTION ? ^>he CK>0 PlfrejTC 3 % ktoTt PoR Cilt&IA FiRtt ti Si PCO T PUBK *CL0 tvp* QP*rru<*notf 8I i Ver 40COPCOtKROt+ALOX F TACK WELD Ui IE"CENTERS 003 X * IS SA. EXPANDED METAL LATH tK0 W I L C O X C O M P A N Y a n u I * l >a n i > u p o n C O M O IT IO N > M A T Burner support plate CO/1L FIRED OR COAL 4 OIL OR GAS FIRED 3Z 5S E< 8 OiL^AS s8 : 3J ; 2 2x 5 >* u o.. **< -* o. Hoa< w rw FIR-ElD e>4w kromalox p B4W PLASTIC CHROME ORE APPROVED 0G7o alumina, nr setting 3000h use limit plastic moldabl^s; >4w KROMALOX P PLIBRICO CO AB KAISER MONO-CO AiRSET PYRAMID CO (INTERPACE CORP') HW APACHE PLASTIC C5 *5 AOWN. Y CHICO AWO ^ BURNER THROATS membrane WALL "" i Jfv.'\fHiSb SZ/~--\ CALC Mwa. NO. ' . OATC l -2.0'lTr \0\ 3 <3 l A-4 M SOM 10*7 A>1  TH P R O P tR T V o r T H C B A B C O C K & W IL C O X C O M P A N Y A N D 1C L O A N ID U P O N C O N D IT IO N T H A T IT I * N O T T O * n c p n o o u c o ON . ON IN P A R T . OR O X O TO N P U N M IC M IN O IN rO N M A T IO M T O O T H C N C , O N TO R A N T O T H IN P U N P O C C O C T N lM B N T A L T O T H C IH T C N IC T C OP A W I L C O X C O M P A N Y , - A N O 1C T O N C T U R N C O U P O N H t U H T . D O N O T C C A L I-- UCB O IM K N C IO N C O N LY OWN. T *J TRiNO PACCV^NT _ -- enrs _ PV pp-# BURNER WALL INSULATION DETAILS INSIDE WINDBOX 2 1/2"0D. TUBES ON 3" CENTERS "" :r*......3 97 9 3-**1 f NORM.CON (OCT A-1 DRAWER DRAWING !{-(.*! I I CALC OATT L-lL BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK REFRACTORY rr- ^. FLUES & DUCTS &'f. T-! " r, LININGS ' 4Y(IPGD) HR 1/12-12-83 Zq `^ When carbon steel flues and ducts are used for temperature above 850F it is necessary to provide a refractory lining to protect the casing from the excessive temperatures. For material and reinforcement systems re fer below: Kaocrete HS is an acceptable refractory lining to protect casing for those areas where the flue gas or hot air does not contain excessive errosive particulate. For abnormal conditions contact Design Engineering. The refractory linings shall have a minimum thickness of 2". Linings shall be reinforced by several acceptable methods, when gas or air temperatures are below 1000F. 1. 2" x 2" x #12 B.W.G. wire mesh 2. 4" x 4" x 8GA. Road Mesh 3. Two or three tine self welded studs 4. Bent rod "V" Anchors Hand Welded 5. Self Weld "V" Anchors CONFIDENTIAL For conditions at 1000 F and above, gas temperature, stainless tines or anchors must be used as a reinforcement. Refer Below. GAS TEMPERATUREANCHOR MATERIAL Up to 999F. 1000F. thru 1600F. 1601F. thru 2000F. Carbon Steel Type 304 Stainless Steel Type 309 or 310 Stainless Steel The reinforcing mesh shall be held to the flue lining by suitable carbon steel supports such as Gateway Engineering Carbon Steel SS Slab spacers, T-slot self welded studs, nuts or drilled studs. The mesh shall be lo cated approximately 1 inch from the hot face of the refractory lining. The corrosion resistant lining construction details are the same as stack lining details which are shown on 3Y (IPGD)-13R, with exception to over head surfaces which shall have the mesh supports installed on 12" x 12" centers. All anchors for temperatures above 1000F shall be installed on 6" x 6" staggered centers. oAotuurv <x wILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY STACKS LININGS AY(IPGD) 13R 1/12-12.-83 9 When it is necessary to line the inside of a stack with refractory to pre vent corrosion, a minimum of 2 in. thick lining shall be made up by gunning a refractory mix composed of three parts of acid-resistance aggregate plus one part on Lumaite cement by volume. The acid-resistant aggregate may be acid resistant crushed firebrick, #4 x 0 mesh., or trap rock. Silica sand 95% or better is an acceptable aggregate for stack conditions below 400F. The sand must be of a coarse grade that approximately 99% will be retained on a 70 Tyler sieve and meet ASTM C40-79 for impurity limits. B&W KaocreteHS is an acceptable prepared refractory. This lining shall be reinforced by several acceptable methods, when stack gas temperatures are below 1000F. i: 2" x 2" x #12 B.W.G. wire mesh 2. Chicken wire mesh 3. Two or three tine self welded studs 4. Bent rod V anchors hand welded 5. Road Mesh 4" x 4" x 8 GA CONFIDENTIAL For conditions 1000F and above gas temperatures, only stainless tines or anchors must be used as a reinforcement. (Refer to Table below) The reinforcing mesh shall be held to the stack lining by suitable carbon steel supports such as Gateway Engineering Carbon Steel slab spacers, Tslot self welded studs, nuts or drilled studs. The mesh shall be located approximately 1 inch from the hot face of the refractory lining. For de tails refer to 4Y-13R, drawing 203099A. GAS TEMPERATURE ANCHOR MATERIAL 0 thru 999F 1000F thru 1600F 1601F thru 2000F Carbon Steel Type 304 Stainless Steel Type 309 or 310 Stainless Steel THE BABCOCK A WILCOX COMPANY 0z w X roAM o*< ot? * W IL C O X C O M P A N Y . AMO I* TO A T U A N *0 U fO N M O U IIC . . OO MOT iC A L -- U f O 'M fN ilO N * N L. *>W swiMvaa iOAwaa cbmdoi ML3 S M O IS IA 3W / i- oo 8$ j^28c tZ la-o-sl Cj vStoro**! it Hst a IsSfeSg! ti lligegfl i! slsicega ii - fl Sga5 S<^ 2*15 mWU" >* b '4=i S/CsB s a!e<c*>*: {5* vjtl v |P | w5 n h* " u*er 8335 z$%z J3jC 2S*2 5* 2s*# tti y5><C ocfcz P*2 <j&. *2-, P0<wOtt0fSJ.C< ,2,, oo=2hl3:<s>ui t -io O 5:& *&= 0|-e.0 ir.tfi *< *0 ? gK 2< =Sl! *?<*$ <^ii 5Sfl5 55 i*.? 2> * cdSfe i. i0- THE BABCOCK & WILCOX COMPANY POWER GENERATION CROUP *~t r \ir^D) //& ASH HOPPER REVISIONS --1 Kicao. FILM VERTICAL i SLOPIN& W/fCESO A*K . **( O DATS TS-X1 DC*C*IFTION Prf0-feOWWN* P. Apply One Coat Of MASTIC On a TW.H-DLETE.D VIEW" Insulation Block AT Z5 5q>. Ft. OF ExP. UT. t CH&'H Pee. Gallon coverage. WALL BRACKET M(n= (RAl mastic or. equal) T /h s KmiSEd WftU&CAfL-PY see,notes Ifi ,,. -- LINING) Anchors io /c ea. way Sta^Cjefled (on Vertical Walls) Cut Opening In Insulation Block appro*. 6"sgj. (To sive Additional c SlSPP'T To ReFRACioRy.) .5 Wall Bracket @ 24" /c (HW-6E3 4-026 OR EQUAL) 7l\T*XANGLE (A'LOtNO) @ cA" /c C Lining Anchors is" /c Ea- way Stasgered(On SloPin^ walls) Hopp^k Plate : 2b *o 0 1< 34. l\ xg r2 *E si; !o er :- FOR GENERAL NOTES U oz PS5. SEE DW&. I7295SC . 5> It 'd2 l W g ** =u E8S z i i xu0 i'i ce rw l" Kaocrete "d"or"hs" Hih Temp. Block CONFIDENTIAL SECTION-IZA -liW.H, CMK-e S ^ _/ INSULATION! DETAILS oawc. MO. A <20 I PGP OATC 1 " I 0 " *1 "1 A. z> ? r.FOAM IBM 1017 *< THE BABCOCK & WILCOX COMPANY POWER GENERATION GROUP AY (I FGD) HU 3/&'/J2-3 TTTT^ ASH HOPPER DETAIL OF EXP. JOINT pmao*.h EV1SIONS eoexmioN MlC0. pk.m V.i To 3 a* A/orr 2 'Sft/t C*C f^eVroBi^njT LZ a?B > 3 / K/3CWOOL BLANKET 5* *i5 4<U INSTALL TO A DENSITY of s *y co. Fr ij5 51 APPLY 2 COATS OF ro II R 41 MASTIC OR EQUAL ON INSULATION BLOCK 2- 0" W|DE/c OF EX O 0 PANSION JOINT ANCHORS SEE NOTES 1(2 KAOCRETE'D" or *HS" M* <s |Si HIGH TEMP. BLOCK si: HOPPER FE.- _0 *0u *<I 3,,H 12S TYPICAL EXPANSION JOINT 5I2 e 'z 2 XI* y5g je: a c- CONFIDENTIAL PS! Cl 0A * zO t FOR GENERAL NOTES SEE APPLICABLE DNNG'. " * X 8 17Z95SC = 55 !l< _ 2* 25*s0u 558 lit > iI U :- cu I>- SECTION -IZB own. mr 1 . W. H . CHK'O J M P a*Dssueof=*vcft5^-T1 INSULATION DETAILS paws. MO. ^LCCKD? hr-Apr DRAWING ip<5 fioO ? 32665.4 - Div.jhftFH'W THE BABCOCK & WILCOX COMPANY POWER GENERATION GROUP Sv *o ^. 4 Y ( tRGD) //yy ASH HOPPER DETAIL WATER SEAL TROUGH ^ O i-> EVISIONS SA.H MO. OATS cucxmioN ">C*o. OAic. M5v 225 gji lii .52 ih s? s- :0 m. o o .5' 9 0t 94 _C0NFIDEntial 50 5A >lM 50S si;2 t u,,5 2< *t6 0u I* 9 d22 e x xoi 2S U5 SI l': B C- u?O xil6 l `0 1 5U 4. 1,5 S0u sS o J " o' ?5 *u MS 5 5e DB : to HOPPER FEt FOR GENERAL NOTES SEE DW6. I72958C. REFRACTORY WALL ANCHORS 10"%. EACH WAY STA6SERED (TYR FOR ALL VERTICAL WALLS) KSM"SURELOCK"y& x5/s x7 RECTANGULAR REFRACTORY STUD ANCHORS WITH RIPPLED TINES (OR EQUAL) APPLY ONE COAT OF R.Z. MASTIC OR EQUAL ON INSULATION BLOCK SEE NOTES I $ E SECTION -I2.C OWN. IT H~ W. H. I cmk -0 u tA P ~D u-f-o ftS'p 6 v ' 4-i) A INSULATION DAT* DETAILS 131466ORWC. MO. 6,0 / PGii * 3 C ' 2J) a* O UltUNING THE BABCOCK & WILCOX COMPANY POWER GENERATION GROUP IIU 5//J-/J-23 ASH HOPPER DETAIL OF A-SH REMOVAL DOOR REVISIONS BAVH NO. &ATT BUCAIPTION NICNOPV.N ON!S. 1 >/f4/)5 rs YJau EK.KLx.it Z V.J/jt|J^tvi^in^>tALXCTNs fM- Lw-CSfi Fo i I# LO A N E D U P O N C O N D IT IO N T H A T IT IV N O T TO * NEPNO O UCED OK . O N P O N A N V O T N C N P U N P O H D K T N IM S N T A L T O I H I IH T E H B V T V OP" O O N O T C A U U O IH C H V IO N V O N LY . 1M I1 O N A W IN G I * TM PNO PRNTT OP T U B B A B C O C K a W IL C O X C O M P A N v c o n tti. IN W H O LE O N IN P A N T . O N U V C O P O N P U H N lV H IN O IN P O N H A T IO N TO O l T V IE B A B C O C K ft W IL C O X C O M P A N Y . A N D IV TO VC N ETU N N BO U P O N N E O IIE V T. TN INCLINED DOOR SHOWN VERTICAL DOOR SIMILAR CONFIDENTIAL FOR SELNERAL NOTES SSE DWG. 17Z95&C. pT.W.H. "VLPo-^ST PAtltO *Y . SECTION-IED JHP OATT 50**17- INSULATION. DETAILS onws. NO. I3Z667 a-2 &o i pg d j-JiTtT" rvnv  - rrU'-w/s. cum^ANY POWER GENERATION GROUP !lU ./ ASH HOPPER REVISIONS CASH MO. OATB OKBCBIPTIOM MICROFILM ORIS. TYPICAL LAYOUT FOR ! VuhR A KLOC*. IVATiM REFRACTORY ANCHORS B S IMPALE INSULATION BLOCK ON CLOSED H-.'-rt. tav*s>t. ,, H:\L. AP&i: KtTjf.NHt ^S89 i tI ANCHOR USING DABS OF BLOCK STICK MASTIC . OPEN ANCHORS AFTER BLOCK INSTALLATION $ COAT ANCHORS BLOCK WITH R..6T. MASTIC 0 * (OR'EQUAL') BEFORE INSTALLING REFRACTORY 2 < 3 SEE GENERAL NOTES. ANCHORS SEE NOTES O HOPPER PLATE o APPROX. Z A I* <|oe. ,c is*s 02* j|5S 0u I* 5_ dgS ANCHORS TO E WELDED m FIELD . GOc 0 v MOVE. ANCHORS TO CLEAR ,1* DOORS , WINDOWS, PIPES ETC. 0 S * WHEN NECESSARY s: Bc- s Lining ANCHORS TO B>E ANGLED KAOCRETE"D" OR HHS" AS SHOWN (BSPACIN6S CALLED !'i FOR. ON DETAIL DRAWINGS * I. o 1" E i<z *yo ty FOR GENERAL NOTES SEE APPLICABLE DWG *. CON^IdEN,T1AL w _J 0J 2< I72.95SC 5 2 *u 5*0 5 58 SeV-2 SEW ! C* UM SECTI0N-I2E rT.W.H OtFcR3*r F**to BY CHK-B JHP lL INSULATION DETAILS o*rt (o' 3 C> '71. PKWG. NO. I3Z668 a- + PGD FORM BOM IOB7 A*y \.T.;.......... . ttRUNlNG 26946 THE BABCOCK & WILCOX COMPANY POWER GENERATION GROUP a y (tPGDJ itu ASH HOPPER DETAILS OBSERVATION DOOR REVISIONS MICMO. OACM MO. OATS OCSCMIPTIOH o<ue. 1 3/-Y* R*Vl-C VJiLLS>C.,ct^T AO ") 9 2" H.T. INSULATION BLOCk(dIATOMACE.OUS 60 EARTH)IMPALE BLOCK ON CLOSED ANCHOR u ii USING A DAB OF BLOCK STICK MASTIC (J# PER BLOCK) u 7 KAOCRETE D OR ttttlHicSH Z0 ii a 4. 2cu * WALL BRACKET ABOVE OPENING (HW-6Z3 4 GE& OR EQUAL) \W\TH ZAEL^'x-A'LG SUPPORT ANGLE 0 6h FILL WITH KAOCRETE^D" or"HS" <L DOOR 02 oU * d? i2 HOPPER PLATE CUT INSULATION BACK 4" TO 6" AROUND CASTING TO GIVE ADDITIONAL SUPPORT TO REFRACTORY OPEN ANCHORS FOLLOWING INSTALLATION OF INSULATION BLOCK 4COAT ANCHORS AND INSULATION BLOCK WITH R.4X. MASTIC OR EQUAL BEFORE INSTALLING REFRACTORY SEE NOTES I 4 Z ANCHORS TO BE WELDED IN FIELD confidential ix it's FOR GENERAL NOTES SEE DWG. I72.958C. c <s V ts>- otu *Kl - SECTION-IZF VXi>siutsFtcv <?S t J.ri.p. INSULATION LCCTD Pn'tJ,T OA-r.^-50-m DETAILS SCM.C / onwe. MO. I3Z6G9 a- l (oO I PGj D j i> |9 L O A N E D U P O N C O N D IT IO N T H A T IT 19 H O T T O 9 9 A T P F O O U C tO O N O N PO N A N T O TH ER P U R P 0 9 9 D E T R IM E N T A L T O T H E IN TE R E 9T9 OP O O N O T 9 C A L *-- U 9C O IM E N 9IO M 9 O N L Y . THE BABCOCK & WILCOX COMPANY POWER GENERATION GROUP A Y ( IPGD) no . ASH HOPPER DETAIL S POKE HOLE REVISIONS &AM NO. BATE DC9CNIPTION NlCo. *11. M OHic. " o3 CONFIDENTIAL LINING ANCHORS IO"/c EACH WAY STAGGERED PI ' l l ftO P tA T T o r T H E B A B C O C K a W I L C O X C O M P A N Y OH IN P A R T . O K U 9C O PO P P U H N I9 H IN O IN F O R M A T IO N T O O TI W IL C O X C O M P A N Y . A N D 19 T O B E R E TU N N C O U P O N R E O U E 9T . HIGH TEMP BLOCK KAOCRETE "D OR "H5' FOR GENERAL NOTES SEE DWG. I7Z958C . CUT INSULATION BACK 4-" TO 6' AROUND OPEN IN&S TO GIVE ADDITIONAL SUPPORT TO REFRACTORY -APPLY ONE COAT OF R.4T. MASTIC _0R EQUAL ON INSULATION BLOCK SEE NOTES I % 2. S SECTION -12.6 s "g 3 z INSULATION DETAILSO W. H . JHPOWN, 9tT. CMA-O .H.bKpRsT DRWC. NO. DATt Gs" 3 O *"} "7 132670 a. O <,0 IPGD jonu 90M T097 *< <)Wi9Z ONlNfUIII THE EA&COCX & WH.COX COMPANY POWH OfNEIATICN DIVISION BRICKWhRK-REFRACWry .'__FASTENEffS 4 YfrfcpT 5W . y I //L '/*& R CVISION8 NO. o*rz KKIiniO* ie*37~ 6*15, 1 EFF. H - 5 3 ^ q o3 ' i a Za Va aa0 to 3a 3y 3z a< CONFIDENTIAL z o: i0 o5 "x S uoz 0u a 3o d$; 1i> FIGURE - u*Uo 5l5 STUD -GUM ANCHORS I. DOUttLE WOO< 4. SIGHT AUGIE BEND *2. 2-PRCnaSED STUD S/T' STUD 6. V v 3. UEfxDEt) STUD STUD fc 3 Z 9 i,,t:o SHWUP11-UJ&LD f\NCHOfcS SS 5Iyk T '`V" S.CUftlU-UWK FEJJCE s8 a .J B. LONGHOfcN i0f ss SLAB SPACER J e5 to , IN W H O ti own. ar **MC9 mr HK`0 LOCKED DRAWER DRAWING IP.GQ DIUM*.X BEfractory anchors . M1 NO, -- BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION REFRACTORIES MATERIAL ORDERING 4YCIPGD) 4Y2 4A2 1/ 12-12-83 When ordering material for use oa boilers, use the tables for specific material found in this section. All quantities shown include the proper percentage extra for rebound or wastage. To facilitate economical procurement by the Purchasing Department, each item of brick or tile except Insulating Firebrick on the shop orders should list the Pyroraetric Cone Equivalent (PCE) necessary for that item. The term PCE is a test of refractory materials per ASTM designation C-24. Specifically it is a number, assigned to a refractory materail which de signates the temperature at which the tip of a cone of refractory material being tested will melt and touch the supporting base. RECOMMENDED CASTABLE OVERAGES TYPE OF INSTALLATION 1. Casting and hand rodding involving minimum of waste OVERAGE - % 8-10 2. Vibrated installation - to allow for greater compaction Dense castables Insulating castables 15 20 3. Slap troweling and plastering 10 - 15 4. Gunning 15 - 100 Gunning losses vary widely according to a number of variables. A floor may have less than 10% loss and a roof might have as much wasted as that which adheres, in other words, a 100% overage might be required. Losses run less on the inside of a stack than on the outside of a vertical cy linder or tank. Losses will also vary according to wall thickness, type of nozzle, air pressure, water pressure, prewetting of castable, rate of ..feed., experience O'f operators, stickiness of material, type of surface, etc. For B&W gun mixes see 4Y(IPGD)-4Y2-4A2 page 8 showing various lightweight and dense castable rebound figures, material overages and necessary pounds required to place. CONFIDENTIAL BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION REFRACTORIES MATERIAL ORDERING 4Y(IPGD) 4Y2 4A2 3/12-12-83 Application Tube O.D. ! Inches ! Tube Centers Inches Plastic Moldables or Castables Weight Recovery Unit Furnace Bottom 2-31/32 2-31/32 4 5 21.3 #/sq. ft. 25.5 iffsq. ft. Cyclone Furnace 1-15/32 1-1/32 1-1/2 1-1/16 11.8 #/sq. ft. 11.5 #/sq. ft. Full Stud Furnace Walls 2-31/32 2-31/32 3-1/4 7/8 3 5 4-1/2 1-1/2 17.2 iffsq. 25.5 iffsq. 24.3 iff sq. 12.3 iff sq. ft. ft. ft. ft. Slag-Tap Furnace Floors (Full Stud tube flow without slag Monkey) 2-31/32 2-31/32 3-1/4 3 5 4-1/2 17.2 iff sq. ft. 25.5 iffsq. ft. 24.3 iff sq. ft. Slag Tap Furnac.e Floors (Slag Monkey) Furnace Screen Tubes of Slag Tap Units (Full Stud_and h?nd ; trowelled) Furnace Floor Full Stud Tubes -- 2-31/32 3-1/4 7/8 1-1/4 -: i 1-1/2 1-3/4 245 iffeu. ft. 1 8 #/ft. (length) 9 iff ft. (length) 23.4 iff sq. ft. 24.5 iff sq. ft. Above quantities (except for screen tubes) include extra 40% for rebound losses. For screen tubes quantities include extra 20% for tube bends, wastage, etc. confident^ 4Y(IPGD) 4Y2 4A2 4/12-12-83 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION REFRACTORIES MATERIAL ORDERING For additional material beyond the face of the tube add the following: WEIGHT PER INCH OF THICKNESS PER SQ. FT. (HAND APPLIED), LB. B&W KAOLITE AGGREGATE B&W KAOCRETE-B 4.11 9.44 (allowing 20% overage) (allowing 10% overage) Example: For weight of refractory 1" beyond the face of the tubes using Kaocrete-B for 2-31/32" tubes on 6'* centers From 4Y-4Y2-4A2 Flush with tubes 8.02 ///ft2 1" Additional 9.44 ///ft2 TOTAL 17.46 ///ft2 NOTE: For export jobs where B&W supplies the High Early Strength Portland Cement for the Kaolite materials. Quantity of cement 0.52 x pounds of Kaolite Aggregate. confidentia: BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION REFRACTORIES MATERIAL ORDERING 4Y(IPGD) 4Y2 4A2 5/12-12-S3 MATERIAL Kaocrete-A Kaocrete-B Kaocrete-D Kaocrete-HS Kaocrete-28 LI Kaocast Kaocrete-30 Kaocrete-32C (Cast) Kaocrete-32G (Gun) Kao-Tab-93 Kao-Tab-95 (Cast) Kao-Tab-95 (Gun) Kaogun-BF Kao-Phos-93 (Ram) Kao-Phos-93 RG (Gun) Kao-Tuff-C (Cast) Kao-Tuft-G (Gun) Kromalox-P (Ram) . Kromalox-G (Gtm)' Kaolite-2000 HS Kaolite-2200 Kaolite-2200 HS Kaolite-2300 LI Kaolite-2500 LI Kaolite-2500 HS Kaolite-2800 Kaolite-3300 Plastic Chrome Ore DRY MAT'D. REQ'D/CU. FT. CAST IN PLACE (POUNDS) NO ALLOWANCES MADE FOR LOSSES 125# 100# 128# 123# (Cast) 125# (Gun) 126# 123# 135# 144# 135# 150 # 165# 165# 126# 170# 168# 138# 130# 175# 154# 58# 58# 71# (Cast) 82# (Gun) 54# 74# (Cast) 60# (Gun) 78# (Cast) 85# (Gun) 84# (Cast) 86# (Gun) 68# 208# SHIPPING UNITS 100# Bags 100# Bags 100# Bags 100# Bags 100# Bags 100# Bags 100# Bags 100# Bags 100# Bags 100# Bags 100# Bags 100# Bags 100# Bags 50# Bags 50# Bags 100# Bags ' 100# Bags 100# Boxes 100# Bags 40# Bags 40# Bags 50# Bags 40# Bags 50# Bags 75# Bags 75# Bags 50# Bags 200# Drums For B&W gun mixes see 4Y(IPGD)-4Y2-4A2 page 8 for rebound loss and pounds required to place/per cu./ft. CONFIDENTIAL BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION REFRACTORIES MATERIAL ORDERING 4YCIPGD) 4Y2 4A2 7/12-12-83 MORTAR '-QUANTITIES LBS./1000 BRICK High Temp. (Heat Setting) SR-90 (Dry) (Air Setting) Mul-Set F (Wet) (Air Setting) Mul-Set F (Dry) (Air Setting) Air-Set (Wet) **(Air Setting) Air-Set (Dry) **(Air Setting) Smoothset (Wet) (Air Setting) Smoothset (Dry) (Air Setting) I.F.B. (Dry) (Air Setting) I.F.B. (Wet) (Air Setting) 240-300 375-475 300-350 180-300 360-400 275-300 220-330 160-240 220-330 160-240 REQ'D LBS. BRUSH C0AT/100 SO. FT. 20 25-35 22 20 22 20 22 20 22 20 SHIPPING UNITS (CONTAINERS) 100# Bags 100# Bags 100# Drums 100# Bags 1Q0# Drums 100# Bags 100# Drums 100# Bags 100# Bags 100# Drums * Quantities, vary according to type of brick laid up. Lower values are for dipped joints, higher values for trowelled joints. **Order Air-Set Mortar (Dry) for all domestic applications. Order Air-Set Mortar (Wet) for export jobs. CONFIDENTIAL 4YCIPGD) 4Y2 4A2 8/12-12-83 BABCOCK Sc WILCOX INDUSTRIAL POWER GENERATION DIVISION REFRACTORIES MATERIAL ORDERING B&W GUN MIXES REBOUND PROPERTIES The following is a table showing the various lightweight and dense rebound figures, material overages (attributed to rebound loss alone), and necessary pounds required/of to place: Lightweight % Rebound Resulting Overage Figure Pounds Required/Of ________ Gunned Kaolite 2000 HS Kaolite 2200 Kaolite 2200 HS Kaolite 2300 LI Kaolite 25Q0 HS Kaolite 2500 LI Koalite 2800 10-15 10-15 15-20 10-15 5-10 10-15 10-15 1.11 - 1.18 1.11 - 1.18 1.18 - 1.25 1.11 - 1.18 1.05 - 1.11 1.11 - 1.18 1.11 - oo 62 62 85 57 84 70 84 Dense Kaocast 4M Kaocast 6M Kaogun BF Kao-Tuff G Kao-Tab 95-G Kaocrete 28-LI Kaocrete 32 G Kaocrete HS Kaocrete A Kaocrete D 13 16 10-15 12 18 13 18 10-15 23 28 1.15 1.19 1.11 - 1.18 1.14 1.22 1.15 1.22 1.18 1.30 1.39 126 126 128 138 165 134 136 124 132 133 NOTE: Gunned onto vertical wall by experienced operator under optimum conditions. Total overage figure should include a 10% contingency factor. CONFIDENTIAL BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY FIREBRICK ` AY(IPGD) 4Y21 1/12-12-S3 The industrial boilers of Babcock & Wilcox may require firebrick for the following applications: 1. .Pulverized Coal Unit - Ash Hopper (4A-11U) The standard refractory is Kaocrete D (trowelled) or Kaocrete HS (gunned). If customer specifies firebrick on the floor (or slope) of the hopper, B&W Firebrick 80 is recommended with B&W MUL-SET F (air-setting) mortar. 2. #1 Firebrick Access door protection (4Y-6A-8U3) Lower drum hopper (stoker fired unit) (1K2542-3Y) 3. i\2 Firebrick ;/ Ash hopper (stoker fired unit) (1K2542-3Y) CONFIDENTS 4Y(IPGD) 4Y21 2/12-12-83 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY FIREBRICK AVERAGE PROPERTIES OF B&W FIREBRICK CONFIDENTIAL firebrick series Melting point F Density avg (ASTM C 134-70} LD/9" straight Lb/Cu ft Hot modulus oi ruoture.-psi CASTM c 583-76) ; noon-, temperature 2000? 2300? 2600? 2800? CotC crushing strength, psi . (ASTMC 133-72) Permanent linear change. % (Per ASTM C 113-74) 5 hr2912? 5 hr3200? 2? hr3200? Tnerrr.ai conductivity. Btu*in./htl*F (ASTM C 202-75) Mean temperature 500?; ;-r .* 1000? k ` ' 1500? 2000? 2500? Deformation under hot load. % 25 psi (ASTMC 16-77) 1H hr2640? l>i hr2900? 1^ hr 3000? l hr 3200? 150 hr 3200? Pe'meabi'iTy ftJ/hr ttJ in./DSi Relative abrasion resistance vo' loss when abraded cc's (ASTM c 704-76) Porosity %(ASTM C 20-74) Pane- soa'i loss. % (Per ASTM c 122-76) 12 cycles 2550? 24 nr preheat 3000? 2? hr preheat 3100? Static corrosion resistance to molten glass, corrosion. S (ASTM C 621-68) soda, lime silica cuet~one inch cylinder 72 hrs 2250? Chemical analysis. % (ASTM C 573-70) Alumina Al,0, S'l'ca S*0, Zirconia ZrO; Ferric once Fe,0, Titanium Oxide TiO} Calcium oxide CaO Macnes>um oxide MgO Amalies as Na?0 Firebrick 80 3190 81 189 1700 -- -- -- -- 4000 -1.0 -- -- 160 16.0 15.9 15.6 15.2 -1.0 _ _ -- _ 1000 11.0 17 30 -- _ 45 52 _ 14 1.7 01 Trace 03 *Noi recommended lor severe soaiimg conditions Firebrick 80-0 3190 ee 151 3500 _ -- _ 10.000 -0.8 -- 20 8 20 6 20.3 19 9 19 5 -0.5 -- -- - 100 52 8 NR* -- - 45 ' 52 -- 14 1.7 01 Trace 03 Glass tank paver 3100 Special reflectory brick SR`-90 Sfi-99 3480 3660 11.1 190 10.6 183 11.3 ' 193 3000 1900 1000 800 700 12.000 3600 4S00 4200 2900 2100 12.000 3800 2900 1600 800 650 10.000 +01 - - - + 1.5 - - + 03 130 12.3 12.1 11.9 - 26.5 22.8 20.6 19.5 16.6 47.5 31.5 24 0 20.5 . 175 -0.0 - +0.1 - +0.1 - <0.25 13 35 5.6 7.3 16 18 - -03 - - 30 13 5 17 - -- 0 2.6 12 57 14 26 0.3 0.2 05 01 1 09 -- 90 10 * 01 Trace 0i 01 01 99 4 04 - 01 Trace Trace Trace 0t* BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY FIREBRICK f *' 4YCIPGD) 4Y21 3/12-12-83 RECOMMENDED INITIAL CURING AND FIRING SCHEDULES OF FIREBRICK f 1. Firebrick Structures: to 13-1/2" thickness, 75F per hour to operating temperature above 13-1/2" thickness, 50F per hour to operating temperature or: 75F per hour to 1200 F Hold 8 hours at 1200 F 75F per hour to 1800 F Hold 8 hours at 1800 F 75 F per hour to operating temperature CONFIDENTIAL 2F15 THE BABCOCK & WILCOX COMPANY OILER DIVISION REFRACTORIES - TlfcBS . I ,, ^ Q g AYfrfco) 4YZII y ^'Z-/2-t3 "C" TILES FOR 3'', 4", 6 4i WALL TUBES Mat MCVWONI EOCnriM 1 . I r THK BABCOCK A W IIC O X CO. it io an io i m m eoHom oN tmai f a moi iq m tv a to o a c m q* c o ru . m sii! p Mi ll t OF RADII C is;i m Lu ll6l il Hill SECTION X-X / USED FOR TUBES DIA. [ CTRS. 3* 6" PATTERN NO- 45211 4` r 45212 4* 8* 45213 4' 9' 45214 * 45215 *( 9* 45216 c A B MM. r 2p; D F E MAX. VOLUME 2i" *1' 70 CU.IN. r 2fc 'f 3" * r 2-1" *16 r r 3` *r 69 CUM. 108 CU.M. r 127 CU.M. -r *r 8* MO CU.M. 8s *s 8" 130 CU.M. SECTION Y-Y CONFIDENTIAL NOTE - A TOLERANCE OF 2V. PLUS OR MINUS WILL 8C ALLOWED ON ALL DIMENSIONS OF 4* AND OVER, AND 3% PLUS OR MINUS ON ALL DIMENSIONS UNDER 4* WLESS OTHERWISE NOTED. JK Mtx 3-26-59 E8S REL INSULATION DETAILS *aUi NTS moo " i rrxrr 284 26 A- IPGD DIV-.--LOCKED DRAWFR--n5MwiMfl-~ -fc PGD *nt BABCOCK & WILCOX COMPANY BOILER DIVISION 4YCrfi&O % ?; REJRACTC'KIES - TILES ` 4YZII o 8r 'T" TILES FOR 2^ WALL TUBES fcvarars COOVTXM HlO> one. USED FOR TUBE CTRS. 6' 7* 6' 9' PATTERN NO. 45201 45202 45203 45204 A B VOLUME *r !' 60 CU. K. V 4' 72 CU. IH. 5i" 85 CU. IN. rr 97 CU. 9i. .CONFIDENTIAL NOTE - A TOLERANCE OF 2*f, PLUS OR MINUS WILL BE ALLOWCO ON ALL DIMENSIONS OF 4* ANO OVER AND OR MINUS ON ALL DIMENSIONS UNDER A* UNLESS OTHERWISE NOTEO. PLUS turn, rr J* dt 3-30-59 EBS INSULATION DETAILS REL ^AWINii liHau.-UtV*-- .... <u>o NTS_____ imo - i roct 28427 A-0 -.^SD CONFIDENTIAL USED TOR TUBES DIA. CTRS. 4" 7" 4" 12" 3* 12* 3" 12' 3" 6" c" P" 5" PATTERN NO. B-65100 B-65606 B-65607 B-656B6 B-65687 B-65688 4124 SA A B C 0 E VOLUME CD f 2* < 43 5* 2* 'h f. 71 CU. IN. BO CU. IN. 112 CU. IN. *f 8$ r *r 4 4 ISO CU. IN. 4* 0* SB CU. IN. 4r 5* 2* ` 73 CU. M. A A. A2^ 0* 40 CU. IN. NQTE- A TOLERANCE OF 2% PLUS OR MINUS WILL BE ALLOWED ON ALL DIMENSIONS OF 4* 6 OVER, AND 3% PLUS OR MINUS ON ALL DIMENSIONS UNDER 4* UNLESS OTHERWISE NOTED. own. rr J* cmtt 3-30-59 oicb. CBS Afrs. REL INSULATION DETAILS CALX NTS HOB -- 1 FOOT __ ^ \ 284 2 8 A- 0 " LU u\lu dkkwhk 1 H<5C? THE BABCOCK & WILCOX COMPANY BOILEK DIVISION * RZFRACTChlES - TILES T" TilES TOR 2i, 3", 4", a 4^ DOOSLE. ROW WALL' TUBES auH AYCrfisz) 4YZII 4//JL-/2-S3 Rsvmow-s ***="'' |1 "H<olXo. I o*. EFF. R ~ 5 y CONFIDENTIAL *82 Hill USED FOR TUBES OlA. CTRS. 3" 6" 3" 8" 4" 7" A" A" Ai f 2i" L. 8' 9" e" 9* 8" PATTERN NO. C B MIN. 45217 r 2S" 16 -I' 45224 7-r 3f 5i" 5|* 45218 6l 2re e2 45219 2 4 45220 45221 45222 45225 r 6i' r al5* ' 16 ?fc 7* r < 2ll r i' sf i' 5' r MAX. 6 VOLUME * *r 58 CU. IN. f r r 86 CU. N. * 2" *r 2| 73CU.N. 2" r * 69 CU. N. r r 42* 4 105 Cu.m. 2i 3i 90 CU.W. *s 107 cu.m. f Lr 83 CO.IN. NOTE - A TO:_ESAr<CC Cp 2% eeuS OR MINUS will BE AlLOWEO ON Awl OiMENSlOhS C* 4" AND OVER. AND 2% P.US OR Mi\uS ON AwL OMENSiONS UNDER 4* UNLESS OTHERWISE NOT0. tmrw. rr J* M-n 3-26-59 chk*o. E 8 S mt"o. REl INSULATION details tuUKED DRAWER DRawimd 6,0 tcxix NTS oa -- i net Z8AZ9 &-0 IP.Qnv p.izgB. THE BABCOCK A WILCOX COMPANY BOILEK DIVISION eZ?K-.CZZ?lZC- - TILES 'T" TILES FOR y,-4", a 4^ wall TUBES MK 4Y'*s>J 4YZU 5/'2S3*3 RSVtSIOMS caonnw *6. me. 1 !ii! I! 5 lift ill fjli i i! fU >w y . it l i < *||pg 8 si g 8 Mils! SKi* |55gf I&sEi UnlhS C RADIUS USED FOR TUBES DlA. CTRS. 3' 6' 4' 7" 4" 8" 4" 9' `f 8' aC 2 9' X 8' PATTERN NO. A 8 C D E ' VOLUME 45205 5i; *r *F f 60 CU. IN. 45206 45207 45208 45209 L H' *r *4' f zii" 6f F F *f * *s 7" 2* 75 CU. IN. 2' 91 CU. IN. 2* 107 CU. IN. 92 CU.IN. 45210 ' 45223 r r *s 7r ^ 2" s 6 '8 7' 109 CU. N. F 88 CO.IN, ^369 S. ** CONFIDENTIAL LOCKED DRAWER DRAWING n;?; - A TOLERANCE or 2% PLUS OR MINUS WILL 8 ALLOWED ON AlL DIMENSIONS Of 4* ft OVER. AND 3% PLUS OR MINUS ON ALL DIMENSIONS under 4' UNLESS OTHERWISE noteo. nn, rr JK d*tt 3-27-39 oocfi. E6S REL IN SUL ATION DETAILS iPGD D1V. CAUC NTS p>4B " 1 root-- 28430 -0 I PC o BABCOCK & WILCOX . INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY INSULATING FIREBRICK 4Y(IPCD) 4Y22 1/ 12-- 12 --S3 The industrial boilers of Babcock & Wilcox may require insulating firebrick for the following applications: 1. Gas and Oil Fired Units - Ash Hoooer The ash hoppers of a gas and oil fired units are lined with 2 layers of insulating firebrick (B&W K20 or equivalent) which, in turn, are covered with 1 layer of #1 Firebrick (B&W Firebrick PCE 31-32 or equivalent). CONFIDENTIAL hY(IPGD) 4Y22 2/12-12-83- BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY INSULATING FIREBRICK ntilcor* 3250 3250 500 73 0.4 o o -- 0 T C<EM nn o c ra to 5 o onoo sc 00 00 0 0 0 V O vCnO mO CM in CM > 90 C9 09 0001 1 l 1 1 1 1 re O l/) re 1 i tO K. eg 1 c 6 d CXO 1 0 Z 1 1 1 1 1 l 1 *CM" TPSJ PM re re | 1j l1 re 9 n O 9 0re b re ? K CM 0 C3L 15 co rj MS 00 Z5 Cl C o To 3 to ic c c .9* u; oo *= m G) c\j 3 _ CO o~ <f*0g >. -- JC i OCOM 0 0 C0M O cCM COOM OO1CCM OVCOOM vn OO' r> CM CmM 0 *n O0' CM CCMM CM e O' VO 1 l 1 1O 1 1 1 O O PM fsi rj | 1 1 1O 1 1 1 1 P. p n rv CM CM I 1 16 1 1 1 1 1 P. O CM p. Pm CM ! J CM 6 1> 11 re eg tn 0 6 re b T X JOrCe 3 CM | CM 1 | ? re eg - - X cre CM O | cm 6 1 | re eg 0 ? c S 6 0 X 0kx CD o 3O o D C O o w <N , L. 1C CO O 0) **" JC OO OO PM OCC"M> O O in CM re " mre i 1 1 I 1 t O I | _ 1 | ? -- re re _ re 6 O X 0 8 Cl > to o~ L CO <oN * v. g> JC 2 co OO OO O PM OCM /*. OCM' m|v- CM 01 l 1 1 1 1 O CM O 1 1 O1 1 1 K p. d - O 0 f 0 X O c 1 0 Ow ^Q .uy. >: .O c U .b > ~ .Q o c:cn c '= CO 2F o 3 -C O) c --1c/5 a*, 5 * O n *3 b (J 53 w c oS m C2 H b 91 Mu O'- G> A 0 Q |5 > to bo ee * ea* 0c1 .5*5 -j 3et j l OC u; O 3 JC Cre 2 CO < z re > 7i It >L O' 0 ca> _i O lb /c u It Alumina PpM. PeM ** O 2 1- a 10 < u. c K. VC 0 <c O 2 CM O 2 O 2 to < to < 10 * < c 4; 5c re J cOre u. c cc c 03 O vn vn c m 3 G rrcee crcree re 2 rc 2 G e aS.* u. 0 5 OD ix VC c MCCMMl e lL O<n A % ix 0 PM OfCfMl <& U. CM <r u. PcV CO w2 to < u. C D S > 0 c6 cu "re >4-1 u. c O re c c 6c rce 0 2 tx C a. 0 <. U. c CL Ore re id C Cre c scc c 0 re E 6 41 O ICX cc UCOM. z. 0 IL re u. OOiK. 0 2- O <3. r < < scr vT< 5a> v> iS> re rg cre re V Ere u O n 0 ch O u41. re X 0 y re IX C 9 0 "5 O E 3 cre Ore O rDe O E 3 y re U O O 2z 0 0 S O E 3 irne rce VC) jt 2< c c 0 VCrei OX 0 re E 3 rr>ee 0 rce C re 0 O 0 0 0 0 4 H Z W QPm 3 8 a e *8 2-F17 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY INSULATING FIREBRICK 4Y(IPGD) 4Y22 3/12-12-S3 RECOMMENDED INITIAL CURING AND FIRING SCHEDULE OF INSULATION FIREBRICK 1 Insulating Firebrick Structures: to 13-1/2" thickness, 75F per hour to operating temperature above 13-1/2" thickness, 50F per hour to operating temperature or: 75F per hour to 1200 F Hold 8 hours at 1200 F 75F per hour to 1800 F Hold 8 hours at 1800 F 75 F per hour to operating temperature Qt ' CONFIDENTIAL } 2F18 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY INSULATING CASTABLES 4Y(IPGD) 4Y23 1/12-12-83 Insulating castables may be used for special cases where insulating firebrick does not conform to the desired curvature or shape. In formation is supplied to assist anyone considering a special applica tion of these materials. 1. Kaolite 2200 HS & Kaolite 2200 Stoker extension (1K2542-3Y) Protection for observation doors (4Y-6A-8U3) A.H. at tube ferrules 2. Cease Fire 2000 CONFIDENTIAL Normally used for replacement of block insulation or castable. RAPID FIRE TECHNOLOGYTM *- 2 RFT can be incorporated in a number of insulation castables. See ) * 4Y(IPGD)4Y26 for a brief description of RFT. Contact B&W Insulating Products Division for additional information. See 4Y(IPGD)-4Y26 for recommended water additions, castable averages, and quantity of metal fibers (when used). BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY INSULATING CASTABLES 4Y(IPGD) 4Y23 3/12-12-S3 INSTRUCTIONS FOR USING B&W KAOLITE 2000-HS, KAOLITE 2200 & KAOLITE 2300-Ll These materials are recommeaded for casting, gunning and plastering. Highest strength, is obtained with refractory castables by using the least amount of mixing water which will allow thorough working of the material into place. 1 Hand Rodding, Tamping and Casting .CONFIDENTIAL Best results will be obtained by using a mechanical mixer. VTben machine mixed (paddle typ mixer best suited) , add one-half recom mended amount of water to mixer before adding dry material.- Place contents of bag (40 lbs.) directly in mixer and add remaini-ng`..wa'ter} immediately and mix 6 minutes. When hand mixed, contents of bag" ^ should be dry mixed on a clean dry surface before adding_water. Place materail within 30 minutes after mixing. Forms may be re moved eight hours after placement. Additional water will be required to achieve satisfactory consisten cies with shorter mixing times, and correspondingly lower strengths can be expected. No more than 12 U.S. quarts of clean water should be used under any conditions. Strengths will be reduced substantially if 13 U.S. quarts.:of mix water are used. The following amount of clean water is recommended for this method of placement: HAND RODDING, TAMPING AND CASTING: 11.5 to 12 U.S. qts./bag (40 lbs.) INTERNAL VIBRATION: 11.5 to 12 U.S. qts./bag (40 lbs.) 2. Gunning Follow regular approved methods. To reduce rebound .and dust, castable should be dampened uniformly with not more than 4 U.S. quarts of clean water per bag (40 lbs.) by machine mixing (paddle type mixer best suited) or by hand before placing in gun. Add required water at nozzle for effective placement. Suggested air pressure at nozzle should be 15 to 20 psi. 3. Plastering Add sufficient amount of water for proper consistency. Follow recom mended mixing instructions. Use watertight forms. When placing against porous surfaces, waterproof the surface. For maximum strength, allow 24 hours curing in damper atmosphere be fore first heat up. Heat slowing the first time. BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY INSULTING CASTABLES AY(IPGD) 4Y23 5/1-212-83 INSTRUCTIONS FOR USING B&W KAOLITE 2200-HS (CONT'D) 3. Plastering Add sufficient' amount of water for proper consistency. Follow '.recom mended mixing instructions. Use watertight forms. When placing against porous surfaces, waterproof the surfaces. For maximum strength, allow 24 hours curing in damp atmosphere before first heat-up. Heat slowly the first time. __ __ _ CONFIDENTIAL 4. Caution Store in warm, dry place. Keep freshly placed castable warm during cold weather. For details on temperature requirements and on other questions related to placement, contact the B&W Insulating Products Division. INSTRUCTIONS FOR USING B&W KAOLITE 2500-LI B&W Kaolite 2500-LI is;a 2500F, low iron, insulating castable recommended for casting, gunning and plastering. Highest strength is obtained with refractory castables by using the least amount of mixing water which will allow thorough working of the material into place. 1. Hand Rodding, Tamping and Casting Best results will be obtained by using a mechanical mixer such as a mortar mixer. When machine mixed (paddle type mixer best suited), add one-half recommended amount of water to mixer before adding dry material. Place contents of bag (50 lbs.) directly in mixer and add remaining water immediately and mix for 6 minutes. When hand mixed, contents of bag should be dry mixed on a clean dry surface before adding water. Place material within 30 minutes after mixing. Forms may be removed eight hours after placement. Additional water will be required to achieve satisfactory consistencies with shorter mixing times, and correspondingly lower strengths can be expected. No more than 12 U.S. quarts of clean water should be used under any conditions. Strengths will be reduced substantially if 13 U.S. quarts of mix water are used. BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY INSULATING CASTABLES 4Y(IPGD) 4Y23 7/12-12-83 INSTRUCTIONS FOR USING B&W KAOLITE 2500-HS (CONT'D) 1 - Hand Rodding, Tamping and Casting Best results will be obtained by using a mechanical mixer such as a mprtar mixer. When machine mixed (paddle type mixer best suited), add one-half recommended amount of water to mixer before adding dry material. Place contents of bag (75 lbs.) directly in mixer and add remaining water immediately and mix for 6 minutes. When hand mixed, contents of bag should be dry mixed on a clean dry surface before adding water. Place material within 30 minutes after mixing. Forms may be removed eight hours after placement. Additional water will be required to achieve satisfactory consistencies with shorter mixing times, and correspondingly lower strengths can be expected. No more than 14 U.S. quarts of clean water should be used under any conditions. Strengths will be reduced substantially if 15 U.S. quarts of mix water are used. The following amount of clean water is recommended for this method of placement: V HAND RODDING, TAMPING AND CASTING: 13 to 14 U.S. qts./bag (75 lbs.) INTERNAL VIBRATION: 13 to 14 U.S. qts./bag (75 lbs.) 2. Gunning Follow regular approved methods. To reduce rebound and dust, the castable should be dampened uniformly with not more than 3 U.S. quarts of clean water per bag (75 lbs.) by machine mixing (paddle type mixter best suited) or by hand before placing in gun. Add required water at nozzle for effective placement. Suggested air pressure should be 15 to 20 psi. 3. Plastering CONFIDENTIAL Add sufficient amount of water for proper consistency. Follow recom mended mixing instructions. Use watertight forms. When placing against porous surfaces, waterproof the surfaces. For maximum strength, allow 24 hours curing in a damper atmospher be fore the first heat up. Heat slowly the first time. BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY INSULATING CASTABLES 4Y(IPGD) 4Y23 9/12-12-83 INSTRUCTIONS FOR USING B&W KAOLITE 2800 (CONT'D) 3. Plastering CONFIDENTIAL Add sufficient amount of water for proper consistency. Follow recom mended mixing instructions. Use watertight forms. When placing against porous surfaces, waterproof the surfaces. For maximum strength, allow 24 hours curing in damp atmospher before first heat up. Heat slowly the first time. 4. Caution Store in warm, dry place. Keep freshly placed castable warm during cold weather. For details on temperature requirements and on other qeustions related to placement, contact the B&W Insulating Products Division. INSTRUCTIONS FOR USING B&W KAOLITE 3300 B&W Kaolite 3300 is recommended for casting and plastering only. It is not recommended for gunning. Highest strength is obtained with refractory castables by using the least amount of mixing water which will allow thorough working of the material into place. 1. Hand Rodding and Tamping Best results will be obtained by using a mechanical mixer such as a .i. ; ;n)Qvrtar mixer. When machine mixed (paddle type mixer best suited), add one-half recommended amount of water to mixer before adding dry material. Place contents of bag directly in mixer and add remaining water immediately and mix for 3 minutes. When hand mixed, contents of bag should be dry mixed on a clean dry surface before adding water. Place material within 30 minutes after mixing. Forms may be removed eight hours after placing. Additional water will be required to achieve satisfactory consistencies with shorter mixing times, and correspondingly lower strengths can be expected. No more than 5 U.S. quarts of water should be used under any conditions. Strengths will be reduced substantially if 6 U.S. quarts of mix water are used. BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY INSULATING CASTABLES 4Y(IPGD) 4Y23 11/12-12-83 B&W CEASE-FIRE 2000 (CONT'D) Chemical Analysis Alumina Silica Ferric Oxide Titanium Oxide Magnesium Oxide Calcium Oxide Alkalies, As Phosphorous Pentaoxide Loss in Ignition Al23 Si3.3 Fe263 Ti 3 MgO^ CaO Na 08K 0 PS 2 L70:I. 31.0 31.0 0.8 1.2 0.2 11.0 0.1 14.7 10.0 Average Foam Characteristics Rise Time, Seconds Set Time, Seconds Volumetric Expandion, % 30 . 90 30 - 120 125 - 150 .CONFIDENTIAL B&W Cease Fire 2000 is a unique two component inorganic refractory foam that permits repair or replacement of backup insulation while a unit is still operating, thus reducing downtime and saving energy. In one of the components a dry powder is mixed with water to form a slurry mixture which when mixed with mild phosphoric acid reacts and forms an insulation inor ganic .foam.. ; ' .. /. V's The foam rise time is 30 to 90 seconds, and sets between 30 and 120 seconds, while expanding to more than twice its original volume. There is no need to allow for drying or curing time. Should forms be required, they can be removed almost immediately because Cease Fire sets so quickly. The structure of Cease Fire results in low thermal conductivity. And its inherent semi-resilience lets it "give" as temperature fluctuate, instead of cracking. It is pumped from a specially designed placing maching through nipples located on the furnace casing, filling all cavities. Although Cease Fire was introduced for replacement of damaged refractory or insulation, it can also be used on new units in hard to get at areas which require an insulating protection. TM B&W CEASE-FIRE FAST AIDE KIT The Cease-Fire Fast Aide Kit is a quick fix inorganic foam designed for small industrial hot spot repa.ir. The Cease-Fire Fast Aide Kit is a two component product consisting of enough material to place approximately 1.3 cubic feet of Cease-Fire 2000. The product comes packaged in 6 gallon 4Y(IPGD) 4Y23 12/12-12-83- BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK ' REFRACTORY INSULATING CASTABLES B&W CEASE-FIRE TM FAST AIDE KIT (CONT'D) mortar drums, the two components are first removed from the drum which then acts as the mixing vessel. Water is added to the appropriate level and then the dry component is mixed to form a slurry. The second com ponent, 75% phosphoric acid, is packaged in a one gallon cube. The components are then automatically metered in the appropriate ratios through a specially designed peristaltic pump, the Cease-Fire Fast Aide Pump. This pump weights only 42 pounds allowing for easy transport from location to location. The Cease-Fire Fast Aide Pump comes with a standard "hand crank" drive. An optional bolt on motor assembly is also available. This pump is capable-of delivering up to 1/2 gallon of foam per minute. A mixing blade suitable for use with an electric drill as well as all hoses and nozzles come complete with the Fast Aide Pump. The Cease-Fire Fast.Aide Pumpjis sold as a separate item which is capable of delivering several of the Fast Aide Kits. The Cease-Fire Fast Aide System is designed for those jobs where material requirements are low and it becomes cost prohibitive to bring in a con tractor or dealer with larger scale placement capabilities. Areas such as burner block repair, door leaks, or other small hot spots in industrial furnaces are ideal for the Fast Aide.Kit. This produce fits best the jobs in 1 to 30 cubic foot range. 4Y(IPGD) 4Y24 2/12-12-83 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY MORTARS AVERAGE PROPERTIES OF MORTARS Mortars are used to bond firebrick into place or to patch. An acceptable mortar for boilers is B&W Mulset-F (wet & dry) . Recommended Use Limit, F 3200 Quantities Required Lbs. per 1000 Brick Lbs. Required to Brush Coat 100 Sq Type of Brick Ft. 180 - 350 20 - 22 Heavy Firebrick Refractoriness, ASTM C-199 Fired (3 3200F instead of the 2910F specified, 5 hrs., soak Modulus of Rupture, psi (ASTM C-198) Using B&W Ailraul Brick Dried <5 230F Fired (& 1000F, 5 hrs. Fired $ 2000F, 5 hrs.. No fusion, bloating, or cracking + 1000 psi at all temperatures up to 3200F Resistance to Slag Attack (USS ARL 1 S 64) Excellent Typical Chemical Analysis, % (Fired Basi ) A! 0 : SiO 3 o Fe 0 TiS/ Alkalies 70.8 23.4 1.7 3.0 1.1 CONFIDENTIAL Data are average results of control tests conducted under standard pro cedures artd are subject to normal variations. Results should not be used for specification purposes. AVERAGE PROPERTIES OF B&W MULSET-F MORTARS (WET & DRY) B&W MULSET-F MORTAR is an airsetting mortar mix designed for use at tem peratures up to 3200F. It has, in addition to this unusually high use limit, excellent troweling charcteristics, exhibiting a ''buttery'* work ability. Even at consistencies considered to be at the upper limit for troweling, it will not drip or run off until the trowel is turned. De spite this characteristic, however, Mulset-F spreads easily with a minimum of loss due to run down the side of the brick. Cleaning up, or pointing time, is thus minimized. BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY MORTARS 4YCIPGD) 4Y24 3/12-12-33 AVERAGE PROPERTIES OF B&W MULSET-F MORTARS (WET & DRY) (CONT'D) '' Mulset-F has shown superior resistence to attack by slag (U.S. Steel Tests) ranking above all competitive mortars tested in this respect. Mulset-F Mortar (Wet) is furnished at a consistence suitable for troweling. Additional water, to give a dipping consistency, can be easily worked into the mortar. Mulset-F Mortar (Dry) is supplied in bags for those who prefer the material in this form. The desired consistency can be attained by hand or machine mixing with clean water. It is not necessary to use hot or heated water for this purpose, and strength properties are developed without the neces sity of having the tempered mortar stand over-night before using. B&W SMOOTHSET MORTAR (WET & DRY) This mortar is recommended for field mortaring of insulating firebrick suspended roofs because the very nature of this operation calls for a material which will be workable for several minutes after it is buttered on the side of the brick. Actual observation of a number of field in stallations, both with B&W Air-Set Mortar and with B&W Smoothset Mortar, has indicated that the Smoothset is definitely superior to the Air-Set from the standpoint of permitting an easier and better job to be per formed. BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY PLASTIC MOLDABLES 4Y(IPGD) 4Y25 1/12-12-83 PREFERRED PLASTIC MOLDABLES* B&W Kromalox P (rammed) B&W Plastic Chrome Ore (rammed) Kaiser Kromight Gun (gunned) APPLICATION OF PLASTIC MOLDABLES B&W Kromalox P - General patching material - Chemical recovery boiler walls and floor * Water cooled burner throat - Industrial and marine boiler studded tube walls B&W Plastic Chrome Ore - Water cooled burner throat - General patching material Kaiser Kromight Gun - Chemical recovery boiler walls & floor -'ACCEPTABLE REPLACEMENT: 3000 60% Alumina plastic (air setting) - H-W Apache plastic CS (Harbison Walker) - Plibrico 60' AB (Plibrico) - Mono-60 Airset (Kaiser Refractories) - Pyramid 60 (Interface Corporation) Diamond Shamrock (Didier-Taylor) Jade Plastic (A. P. Green) CONFIDENTIAL B&W KROMALOX P 3200F Chrome alumina phosphate bonded plastic Recommended Use Limit Lbs. required to place one cu. ft. Density, Lb/cu. ft. (fired 2700F) o 3200 F 175 160 Condition (Treatment) Fired 5 Hours @ 600F @ 1000F @ 1800F @ 2400F @ 2700F Module of Rupture, Psi (ASTM C268-70) 1480 - 2160 2240 - 3360 2640 - 3960 3280 - 4920 3840 - 5760 Permanent Linear Change, % (ASTM C269 + 0.3 + 0.5 + 0.7 + 0.9 + 1.2 4Y(IPGD) 4Y25 2/12-12-83 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORIES PLASTIC MOLDABLES B&W KROMALOX P (CONT'D) Chemical Analysis, % (Fired Basis) (ASTM C 573-70) Abrasion Loss, C.C.'s (ASTM C 704) 5.5 - 7.0 Alumina Chrome Oxide Silica Ferric Oxide A,, l-20^3Cr^0,, Si6 3 Fe23 83.4 9.8 2.3 0.3 Phosphorous Penta-Oxide Alkalies, as P,0 n!2 1. Instructions for Using: 3.7 0.5 CONFIDENTIAL B&W Kromalox P is a high alumina refractory plastic combined with high purity chrome oxide. Kromalox P is designed for areas of ex cessive erosion and slag attach in the high temperature areas of cyclone fired boilers and chemical recovery boilers. 2. Application: B&W Kromalox P is suitable for pneumatic ram placement. The ideal temperature range to place Kromalox P is above 70 F with ventilation for moisture removal. Store in a cool, dry location. Keep from freezing. Storage over 6 months is not recommended in order to maintain optimum workability characteristics. 3. Warning: B&W Kromalox P contains polyphosphoric acid which can cause irritation to skin and severe burns to the eyes upon contact. Avoid direct con tact with skin and eyes. If the content does come in contact with the skin or eyes, flush with water for 15 minutes and consult a physician for eye care at once. 4. Heat Up Rate: For specific heat up rate or additional information consult B&W In sulating Products Division. AVERAGE PROPERTIES OF B&W PLASTIC CHROME ORE Recommended Use Limit, F Bulk Density (Rammed) Lbs./Cu. Ft. Water Content, % 3200 205 - 210 7 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY PLASTIC MOLDABLES 4Y(IPGD) 4Y25 3/12-12-83 AVERAGE PROPERTIES OF B&W PLASTIC CHROME ORE (CONT'D) Modulus of Rupture, PSI Fired 5 Hours @ 1SOOF 2500F Permanent Linear Shrinkage, After Firing @ 1500F 2550F % 1. Composition 708 1600 1.1 1.5 CONFIDENTIAL B&W Plastic Chrome Ore is composed primarily of high grade refractory chrome ore which is especially selected for its outstanding chemical stability and refractory properties. During processing, certain addi tions are made to the chrome ore to provide the proper workability and plasticity required for good ramming properties and maximum density. The additions also impart a high air-setting strength and provide strong heat-setting ability. Proper installation is essential in order to obtain best service results. 2. Packaging B&W Plastic Chrome Ore is shipped in either 100 pound or 200 pund airtight steel drums to preserve the plasticity which is developed during manufacture. 3. Setting Characteristics B&W Plastic Chrome Ore contains air-setting bonds that function as the product is dried. These bonds retain their strength throughout ;th$ .vlpwer temperature range until ceramic bonds being to form. B&W Plastic Chrome Ore develops strong ceramic bonds at temperatures above 2400F. These ceramic bonds give B&W Plastic Chrome Ore a strong monolithic structure which is permanently retained through all subsequent temperature fluctuations. 4 . Shrinkage and Expansion B&W Plastic Chrome Ore shrinks during drying and expands during firing The drying shrinkage and firing expansion compensate each other making it unnecessary to provide expansion joints during installation. This feature of the Plastic Chrome Ore makes possible the installation of large or small areas which will retain truly monolithic surfaces. 5. Slag Resistance B&W Plastic Chrome Ore, which is properly installed and burned-in, is highly impervious to slag penetration and erosion. Its chemically neutral character retards reaction with all types of acid or basic slags under oxidizing or reducing conditions. 4Y(IPGD) 4Y25 6/12-12*83 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY PLASTIC MOLDABLES o AVERAGE PROPERTIES OF B&W PLASTIC CHROME ORE (CONT'D) 15- Furnace Walls of Stud Tube Construction (Cont'd) CONFIDENTIAL the Plastic Chrome Ore be applied in such a way as to grip the studs and tubes tightly and also that it is thoroughly bonded together. This means that the material must be densely packed down between and behind the tubes. After B&W Plastic Chrome Ore is applied, the vent ing may be done with a stiff wire brush. It is to be noted that the ends of the studs are visible when the job is completed. 16. Patching Floors should preferably be allowed to wear thin and be replaced altogther. However, should a floor of sufficient original depth wear down, it may be rebuilt it if is possible to add 3'* to 4" of material to the entire surface. All slag and spalled or cracked portions should be cut away and removed to a point where the material is in sound condition. Before installing a patch, a coating of a chrome bonding mortar with good air setting qualities should be applied to the old Plastic Chrome Ore. . AVERAGE PROPERTIES OF K/R (EX B&W) - KROMIGHT-GUN (TEMPERATURE LIMITE 3100F) Kromight-Gun is a dry plastic similar to Plastic Chrome Ore in its air setting properties. Its chemical composition is chromium oxide. It is black in color and has sodium silicate additive for air-setting. KromightGun is especially designed to cover irregular surfaces. In most instances it will be used in place of Plastic Chrome Ore on furnace walls, screens, floors, seals, and cyclones. Its adhesive power is not quite as great as that of Plastic Chrome Ore when hand applied. However, when properly mixed with the correct amount of water, it may be pounded into place with the same application rules as with Plastic Chrome Ore. It also permits sub stantially reduced installation costs. 1. Instructions for Using Kromight-Gun Kromight-Gun is normally applied by means of a gun or by slap trowel ling in a manner similar to a castable. When gunning this material, it should be placed with as much water as the material will absorb without slumping with the use of an extended vater-Kromight-Gun mix ing period as provided by the 1-1/4" nominal pipe extension detailed on B&W drawing RR4146. This way severe dusting problems will be avoided. Also, for a slap trowelling mixture, it is desirable to have it on the wet side rather than the dry side. BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY PLASTIC MOLDABLES 4Y(IPGD) 4Y25 7/12-12-83 AVERAGE PROPERTIES OF K/R (EX B&V) - KROMIGHT-GUN (TEMPERATURE LIMIT 3100F) (CONT'D) CONFIDENTIAL1- Instructions for Using Kromight-Gun (Cont'd) A furnace lined with Kromight-Gun must be protected before firing as follows: K/R Kromight-Gun will air set and the top surface will dry in a com paratively short time after installation but the portion beneath the surface will remain plastic for quite some time. Under normal condi tions the material should crust up and be relatively firm in 12 hours; however, it is not unusual to take longer. Walking or resting tools, ladders, etc., on the dried surface while in this condition will pro duce cracks and depressions in the upper surface which will permit slag penetration, shorten the life of the installation, and close off the vent holes causing the surface to peel upon heating. Even placing boards on the floor will not protect it if traffic over the floor is permitted before it has deeply air set. Firing a furnace with a Kromight-Gun lining should be as follows: Provided that a refractory has been thorough vented, the best instal lation will result if heat is applied immediately upon completion. Since on most jobs this is impossible and the refractory is allowed to stand for a considerable length of time, shrinkage cracks will develop. If these cracks are large (over 1/8"), it is necessary to fill them before applying heat with a chrome bonding mortar having good air-setting qualities. Smaller cracks (under 1/8") may be neglected since they will close up when heat is applied. The furnace temperature should not be increased too rapidly. If the moisture in the refractory changes into steam too rapidly, it will not be able to escape through the vent holes quickly enough, resulting in a blistered or bloated surface. For the average furnace, the refrac tory should be thoroughly dried out if the temperature is brough up to about 500F and held there for 6 to 8 hours and then raised to about 1200F and held there for 3 to 4 hours. After drying out by the above procedure the refractory must be "burned-in" at the final operating temperature of the furnace. The period of the "burning-in" process should be a minimum of 5 hours. The Kromight-Gun cannot be overfired by increasing the "burning-in" temperature. Actually the structure of the refractory is improved if "burned-in" at temperatures somewhat above the maximum operating temperature of the furnace provided other components and material in the boiler will permit this overfiring. 4Y(IPGD) 4Y25 8/12-12-83 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY PLASTIC MOLDABLES AVERAGE PROPERTIES OF K/R (EX B&W) - KROMIGHT-GUN (TEMPERATURE LIMIT 3100F) (CONT'D) 2. ' Gunning Follow regular approved methods. To reduce rebound and dust, castable may be dampened uniformly with not more than 1/2 quart of water per bag by hand or machine mixing before placing in gun. Add required water at nozzle for effective placement. 3. Patching or Slap Trowelling Add approximately 3 U.S. quarts of water per 100 lbs. A machine mixer should be used, mixing only enough material for work immediately at hand. This is an air setting material. When applying by hand, avoid slicked surface. Stipple with stiff wire brush to leave rough surface. Store only in dry place. CAUTION .CONFIDENTIAL During cold weather, keep installed material from freezing until thoroughly dried out. BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY CASTABLES AY(IPGD) 4Y26 1/12- 12-S3 Refractory castables are used on industrial boilers to serve as a seal where gas flow is not desired or to serve as an insulator where high heat absorption may overheat metals. The following areas may require refractories as noted: 1. Kaocrete B Behind flat stud tube walls (4Y-2R01) Thermal barriers on flat stud tube wall or membrane walls (4Y-2R03) (4Y-6A-3Y1) Seal between roof and S.H. tubes (4Y-2R06) Burner seals (4Y-5R) (4Y-5R-4Y2) Access doors (4Y-6A-8U3) Vestibule seals Furnace arch seals (4Y-2R03) Seal between furnace S.W. and roof (1J21-3Y) Wall boxes - access doors - soot blowers (4Y-6A-8U) (4Y-6A-8U3) (4Y-6A-12R1) 2. Kaocrete D Ash hopper lining (4Y-11U) (Also see 4Y-4Y21, Page 1) (Trowelled Penthouse roof seals or Furnace roof seals casting) Stoker front (1K2542-3-3Y) 3. Kaocrete HS - Ash hopper lining (4Y-11U) (Also see 4Y-4Y21, Page 1) (Gunned or - Furnace roof seals casting) - Stack lining (low acid) (4Y-13R) - Flue and duct lining (4Y-11R) 4. Kaocast - Burner throat in refractory wall TM RAPID FIRE TECHNOLOGY CONFIDENTIAL Allows refractory castables to be heated safely from the cured state to operating temperatures without the risk of explosive spalling. This allows boilers to be brought on line much quicker. RFT is available in most B&W dense castables and a number of insulating castable for both casting and gunning, and is installed as ordinary cast ables. Those formulated for casting normally have a slightly lower placed density than that or ordinary castables, while the density of those for gunning is slightly higher. RFT has a maximum temperature of 3300 F. 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I i- '* *o ' a i s;22 S3 3 i :,i, n niiii'ii" S??1???'??'1 " 5 5 5 2 : S 6 1 1 1 `2 ii'-'i"!: 2 3. i : i : i nn il1 *i1 * 1ii i?''f'ifi<5?s 2522233 , mi ui | | 5 !;Ii III! m 11 iii'ii'ffi' sIMM"" 2?'??'???' ' " 2?T'T?'j"M i 5:2::;: . 5 2 s:: 2: :::: 3jS ! 1 S 1SS.Z2.|..,, SIMM".. 2??'??'?""' 5 2 2 :: 5: 3=33 s|- llMIMSii 2??' ???'?? = ?' 2523 ilMSMill s??'5?5'?;?5' 5 s: 1: |: i till SSMIMlii 35?'???'??55s 8 3 2 2 2 | 2 1 -SsS I11I11I111II 1 1 1 ? l 1 y 1 M f S 1 -- , :::: *2 II >11 1 1 1 1 1 y 1 1 1 O ~ 1 *"52223 , IIMIMli. 2S?'f??'5?=' 1 8 2: s: s: i Ill'll! il!' 2 5: s::: 1 2333 i! IIMIMf.. 2??'???i9" s 5 " t: 2 >: . 3533 5 I l 5 |l!.!g|i iimii......... 2?5'f?i......... 2 3:: 5 3 ] 2 i `33: I sis I 5 2 HS.H,, |!li................ S?T' Tf 1 " ' 1 ' ' 5 3 s: s:: . 111* is = :*2 i M IS3-M1 Ip'!!*" " 52??'7?.............. ;Uiiiiiii!ii jniililiiiii iniillllilll i r . i;2 2 I! <1 Jill Hi t ni] M: jUiit i 3 !S` .3 .?... nr !! U iii IS ilu I'* iliii BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY CASTABLES 4YCIPGD) 4Y26 3/12-12-83 B&W KAOCRETE B B&W Kaocrete B is a 2300F castable suitable for casting, gunning or plastering. 1 Instructions for Using Casting Highest strength is obtained with castable refractory by using the -least amount of clean mixing water which will allow thorough working of material into place with a vibrator or by rodding. A,mechanical mixer is required for proper placement (paddle type mortar mixer best suited). After adding the recommended amount of water to achieve a ball-d.n-h.and consistency, mix for 3 minutes. Place material within 30 minutes after mixing. 2. Gunning CONFIDENTIAL Use suitable gunite equipment. To reduce rebound and dust, material should be predampened uniformly with approximately 2 U.S. quarts of clean water per 100# bag in a mechanical mixer before plaing into gun. Add required water at nozzle for effective placement. 3. Precautions Use watertight forms. Waterproof porous surfaces. For maximum strength, cure 24 hours under damp conditions before initial heat-up. Keep freshly placed castable warm during cold weather, ideally between 70 F and 80 F. TM For standard castables, heat slowly the first time. RFT castables can be heated initially at much faster rates than standard castables. Consult B&W Insulating Products Division for any specific heat-up schedule. Store bagged castables in a warm, dry place. B&W KAOCRETE D B&W Kaocrete D is a 2500F castable suitable for casting only. 1. Instructions for Using Casting Highest strength is obtained with castable refractory by using the least amount of clean mixing water which will allow thorough working of material into place with a vibrator or by rodding. A mechanical mixer is required for proper placement (paddle type mortar mixer best suited). After adding the.recommended amount of water to achieve a ball-in-hand consistency, mix for 3 minutes. Place material within 30 minutes after mixing. 4Y(IPGD) 4Y26 4/12-12-83 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY CASTABLES B&W KAOCRETE D (CONT'D) 2. Other Material can be rammed into place by adding a sufficient amount of water for proper consistency. 3. Precautions Use watertight forms. Waterproof porous surfaces CONFIDENTIAL For maximum strength, cure 24 hours under damp conditions before initial heat-up. Keep freshly placed castable warm during cold weather, ideally between 70 F and 80 F. TM For standard castables, heat slowly the first time. RFT castables can be heated -initially 'at much faster rates than standard castables. Consult B&W Insulating Products Division for any specific heat-up schedule. Store bagged castables in a warm, dry place. B&W KAOCRETE HS B&W Kaocrete HS is 2600F castable suitable for casting and gunning 1. Instructions for Using Casting Highest strength is obtained with castable refractory by using the least amount of clean mixing water which will allow thorough working of material into place with a vibrator or by rodding. A mechanical mixer is required for proper placement (paddle type mortar mixer best suited). After adding the recommended amount of water to achieve a ball-in-hand consistency, mix for 3 minutes. Place material within 30 minutes after mixing. 2. Gunning Use suitable gunite equipment. To reduce rebound and dust, material should be predampened uniformly with approximately 1 U.S. quart of clean water per 100# bag in a mechanical mixer before placing into gun. Add required water at nozzle for effective placement. 3. Other Material can be rammed or plastered into place by adding a sufficient amount of water for proper consistency. BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY CASTABLES 4Y(IPGD) 4Y26 5/12-12-83 B&W KAOCRJETE HS (CONT'D) 4. Precautions CONFIDENTIAL Use watertight forms. Waterproof porous surfaces. For maximum strength, cure 24 hours under damp conditions before initial beat-up. Keep freshly placed castable warm during cold weather, ideally between 70F and 80F. For standard castables, heat slowly the first time. RFTTM4 castables can be heated initially at much faster rates than standard castables. Consult B&W Insulating Products Division for any specific heat-up schedule. Store bagged castables in a warm, dry place. B&W KAOCAST B&W Kaocast is a 3000F castable suitable for casting and gunning. 1 Instructions for Using Casting Highest strength is obtained with castable refractory by using the least amount of clean mixing water which will allow thorough working of material into place with a vibrator or by rodding. A mechanical mixer is required for proper placement (paddle type mortar mixer best suited). After adding the recommended amount of water to achieve a ball-in-hand consistency, mix for 3 minutes. Place material within 30 minutes after mixing. 2. Gunning Use suitable gunite equipment. To reduce rebound and dust, material should be predampened uniformly with approximately 1 U.S. quart of clean water per 100# bag in a mechanical mixer before placing into gun. Add required water at nozzle for effective placement. 3. Other Material can be rammed into place by adding a sufficient amount of water for proper consistency. 4. Precautions Use watertight forms. Waterproof porous surfaces. BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY CASTABLES 4Y(IPGD) 4Y26 7/12-12-83 B&W KA'OGUN - BF (CONT'D) 4. Curing - For maximum strength, material should be cured for 18 - 24 hours in a damp atmosphere. 5. Heating - Heat slowing the first time. 6. Caution Store in warm, dry place. CONFIDENTIAL During cold weather keep wet castable warm. FACTORS AFFECTING THE USE OF CASTABLE REFRACTORIES This Product Information Sheet has been prepared in order to cover in one place for ready reference the majority of information affecting the proper use of castable refractories. Failure to .understand some of the fundamental facts about castable re fractories has led to installations in which the material has failed to perform as expected because basic considerations were ignored or violated. Those factors which are; considered to be of prime importance are covered in this Product Information Sheet. 1. Water Content Of all the variable factors involved in the placement of castables, proper control of water content with prompt thorough working into place is probably of greatest importance. Appendix A gives recom mended water additions for our complete line of castables. 2. Forms Watertight forms, suitably braced, should be used whenever it is de sired to contain the refractory castable until it take its hydrualic set. Either metal or wood may be used for the forms. The forms should be lubricated with a form-oil developed for use with wood or metal forms. Because of ease of installation it is suggested that sectionalized forms be used of type which will permit the height to be built up in successive convenient increments as the work proceeds. Particular care should be taken during the placement behind forms to insure that all irregular sections or corners are completely filled, by adding all fresh material from one side of an obstacle and working under and around it the tendency towards forming air pockets under the obstacle is reduced. 4YCIPGD) 4Y26 8/12-12-83 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY CASTABLES CONFIDENTIAL FACTORS AFFECTING THE USE OF CASTABLE REFRACTORIES (CONT'D) 3. Anchors and Reinforcement. Various methods and arrangements of anchors are used with castable constructions. These may consist of fired refractory anchor tile, various designs of straight or bent studs and rods and internal re inforcing such as chickenwire, woven wire mesh or metal fibers. Fired refractory anchor tile should be held firmly in place during placement of the castable refractory. This may be done by means of wooden wedges or by clamping the holders to the tile with a light hammer blow. Anchor tiles are placed vertically with castables to minimize the tendency towards air pocket formation under the tile. When metallic anchors are used they should be coated with a high melt roofing asphalt or paraffin. The purpose of this coating is to pre vent bonding of the castable to the metal anchor and to provide a space for differential expansion since the coating will volatize or melt when the anchors get hot. If a coating material is not avail able the metal anchors may be wrapped with a few turns of oiled paper, waterproof paper, polyethylene sheets or a cellophane type tape. It is particularly important to coat the ends of the anchors to provide expansion space. Studs on boiler tubes should not be coated in this manner. The use of internal metallic reinforcing such as expanded metal lath and welded wire road mesh is often undesirable. There is no cooling of this reinforcing material and it achieves the same temperature as the surrounding castable. Since the expansion coefficient of the metal is normally at least twice, and in case of stainless steels, perhaps four times as great as that of the castable its expansion builds up stresses which tend to form cleavage planes. As the ser vice temperature increases the differential expansion becomes greater. A perferred method is to carry anchors from the furnace casing (or equivalent) into the castable. The castable is then tied to a metallic surface exposed to cooling air having a total expansion comparable to that of the main portion of the castable itself. If an internal mesh is required for a specific reason, such as a thin duct or stack lining, chickenwire or woven wire mesh is recommended with a 1-1/2 inch - 2 inch mesh of approximately 18 gauge. Such a mesh is so formed that it is not able to exert the same type of positive expansion stresses as expanded metal lath or welded road mesh and therefore does not have a pronounced tendency to form a cleavage plane. When metal fibers are used refer to Appendix E. 2F49 4Y(IPGD) 4Y26 10/12-12-B3 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY CASTABLES FACTORS AFFECTING THE USE OF CASTABLE REFRACTORIES (CONT'D) 4. Mixing 4.4 Hand Mixing (Cont'd) done in a wheelbarrow or on a clean flat surface. The dry castable should first be dry mixed before water is added to overcome the effects of segregation which may have taken place in handling and storage. After thoroughly dry mixing the water should be slowly added and the material should be mixed sufficiently to obtain a uniform consistency. y 4.5 General Required water quantities for the various B&W castables are printed on the bags. Some variation may be observed from batch to batch because of variations in fineness. This affects total surface which in turn affects total water requirements. A good guide to follow is the "ball in hand" test. Make a small ball of castable and toss it 12 inches into the air several times, catching it on the flat, palm of the hand. It if breaks apart when it hits the palm, it is too dry. It if flattens out it is too wet for a dense castable but satisfactory for an insu lating castable. It if flows between the fingers it is too wet for either. For a dense castable the ball should retain its size and approximate shape. To avoid affecting the set and strength of the castable use clean potable water. Mixing should be from 3 to 6 minutes after all water is added. Longer mixing tends to speed up setting and reduce the final strength. Mixing insulating castables for 6 minutes yields the best consistency for casting and the best strengths. Under normal temperature conditions water temperature should be on the order of 60 F to 70 F. For cold weather precautions see the TEMPERATURE SECTION. Do not mix more material than can be placed in 20 minutes. In hot weather it should be placed in 10 minutes. Longer delays result in reduced strength of the castable. If longer working times are required check your local B&W representatives for suitable retarders.. Do not resume mixing action after it has once been stopped. This adversely affects strength. 2F51 2F52 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY CASTABLES 4YCIPGD) 4Y26 11/12-12-83 FACTORS AFFECTING THE USE OF CASTABLE REFRACTORIES (CONT'D) 5.; /; - Casting All the castable should be thoroughly worked into place and internal air bubbles removed by rodding. 5.1 Casting by Vibrating Means .CONFIDENTIAL An effective method of placement is by vibrating, either internal or external. The action of vibration sets the particles of the fresh castable in motion reducing friction between the particles and thus giving the mixture the mobile qualities of a thick fluid which flows easily into place. The vibratory action permits placement of a thick heavy mixture which is not practical with hand placement and rodding. It insures filling of all irregu larities, corners and voids. 5.1.1 Internal Vibrating The efficiency of an internal vibrator is a function of diameter and vibrating speed. They may be obtained in^sizes from 1 inch up. For the smallest size the speed should be 12,000 - 15,000 VPM. For a 2-3/4 inch vibrator the speed should be a minimum of 9000 VPM. Intermediate sizes should have proportionate speeds. A vibrator cannot be considered satisfactory which will not efficiently place a castable with the re commended water contents. A vibrator with a 1-3/4 inch diameter is the most common size used for placing 3-4 tons an hour. A 2-3/4 inch diameter vibrator will about double this rate where sections are 6 inches or more thick. When vibrating around cores, anchors or other obstruc tions add all fresh material from one side and vibrate the castable under and around the obstacle to avoid air pockets. Continue virbrating until the mass has settled into place and the surface gives an appearance of "wetness". If water collects on surface reduce the amount of water. An internal vibrator should be moved about 1-2 inches per second.' When removed from the mass the speed should be reduced to avoid formation of holes. Vibra tion should not be continued longer than necessary. 4Y(IPGD) 4Y26 12/12-12-83 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY CASTABLES FACTORS AFFECTING THE USE OF CASTABLE REFRACTORIES (CONT'D) ^ 5.1.2 External Vibrating CONFIDENTIAL External vibration will produce the benefits of internal '.vibration. The simplest method is to tap the outside of the form with a hammer. The efficiency is improved by an external vibrator. External vibration can be improvised by using a chipping hammer, air rammer to ..any pneumatic tool which produces a vibrating action. Merely place the tool against the outside form and move the tool to get a uniform setting. To get rid of air bubbles, augment with internal rodding parti cularly along the forms. 6. Placement by Pneumatic Methods Applying castables by means of pneumatic guns is widely practiced. This method offers particular advantages when it is necessary to handle large quantities of material through a small access area. In an ash hopper, for example, the physical problem of handling the castable through small doors poses many problems under con ventional mixing techniques and can be expensive in terms of manpower. If a gun is used for material can be charged at a con venient location a hundred feet or more from the point of place ment and carried there through a hose by air pressure. Pneumatic placement guns are generally classed as a dry run or a wet gun depending upon the manner in which water is added to the dry castable. 6.1 Dry Gun The dry gun operates on the principle of pressure forcing the dry material from the charging chamber through a hose to the point of placement. Water is added at the discharge nozzle. Prewetting of castables is recommended to reduce rebound losses and dusting. Instructions for suitable amounts of water for pre wetting are shown on the bags of B&W castable refractories. Experience has shown that dense.castables are best placed using a nozzle pressure of 25 - 40 psi. Insulating castables should be placed at 20 - 30 psi. 2F53 BABCOCK & WILCOX industrial power generation division BRICKWORK - REFRACTORIES CASTABLES 4Y(IPGD) 4Y26 23/12-12-S FACTORS AFFECTING THE USE OF CASTABLE REFRACTORIES (CONT'D) 6. Placement by Pneumatic Methods (Cont'd) 6.1 Dry Gun (Cont'd) The water pressure at the no22le should be about 10 psi higher than the air pressure. Allow a pressure drop between chamber and nozzle at 5 psi for each 50 foot length of material hose and an additional 5 psi for every 50 foot elevation of the nozzle above the machine. 'Also see Item 9, (Hand Rodding). 6.2 Wet Gun CONFIDENTIAL These guns mix the castable in the charging chamber to the de sired consistency. The wet mix is then forced through the material hose by air pressure. An additional jet of air is introduced at the nozzle to impart greater velocity to the wet castable. Wet type cement guns may also be used for mixing and transport ing castable with the placement behind forms accomplished by conventional methods. Also see Item 9, (Hand Rodding). 7. Ramming Castable refractories may also be rammed effectively. Under such circumstances less water is used than for the other means described. The amount required is printed on the bags of the various B&W cast ables. Ramming should be accomplished by means of pneumatic ramming tools. To reduce the tendency towards laminations a ramming head not over 2 inches in diameter should be used. Equally suitable are rectangu lar heads of not more than 4 square inches impact surface with a rough face. The action of such a head produces a rough surface when ramming the castable into place. Fresh material then has some thing to which it can knit without forming a smooth cleavage plane. 4Y(IPGD) 4Y26 14/12-12-8-3 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY CASTABLES FACTORS AFFECTING THE USE OF CASTABLE REFRACTORIES (CONT'D) 8. Slap Trowelling CONFIDENTIAL This method is particularly effective for thin lining or for places not readily accessible for ramming or gun application. It does not result in high rebound losses usually associated with the use of a gun. For this reason this method is preferred by some contractors over the use of a gun. When applying a castable in this manner small portions are picked up on the trowel and are then thrown against the surface being covered. Excess amounts are trimmend immediately. The amount of water required for mixing a castable to a consistency suitable for slap trowelling is best determined on the job. 9. Hand Rodding \ Probably the majority of small and medium sized installations are made without special vibrating or pneumatic equipment. Under such circumstances it is necessary to thoroughly work the material into place by hand whether it is a flat surface or vertical surface be hind forms. The water contents should be as specified in 4Y-4Y24. After the wet castable is placed in position, it should be rodded or tamped into place. Tools for such purpose may be any suitable implement. The foregoing will work well with a mixture which has fairly free flowing characteristics. For a stiff mix, it is necessary to use a tool with a large surface, which will permit the material to be pushed and tamped into place. Refractories may be hand applied or gunned on the walls. For either method the refractory should be packing behind tie bars and similar structural attachments before the major portion of the wall is done. It is advantageous to install refractory behind these attachments be fore the metal lath is applied. When hand applied, the refractory should be thrown through the lath with enough force to fill all the voids behind the lath, the material being built out until the lath is covered and the desired thickness is reached. If block insulation is to be applied to this surface, the refractory should be trowelled to a smooth straight surface. If plastic insulation is to be applied, the surface should be straight but left somewhat roughened. Around doors and soot blower openings on inner cased jobs, the re fractory should be packed in the metal seal box taking care to fill all voids. This is essential to prevent gas bypassing. 2FS5 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY CASTABLES 4Y(IPGD) 4Y26 15/12-12-83 FACTORS AFFECTING THE USE OF CASTABLE REFRACTORIES (CONT'D) 9'. , Hand Rodding (Cont'd) At the junction of walls at some locations on boilers a mound of re fractory is used to seal against gas bypassing. This seal is applied in two layers. The first layer at these locations should be installed before the remainder of the area is covered. After the first layer is thoroughly dry, the second layer should be installed; making this second layer a part of the refractory covering the remaining portion of the surface to be covered. Special care should be exercised to insure that these seals are installed exactly as the drawing as they-prevent gas bypassing and flyash leakage. 10. Temperature 10.1 Cold Weather CONFIDENTIAL It is of more than casual interest that complaints on castable refractories seem to be more numerous for material placed in the winter and early spring when the weather is cold than is the case during the summer and early fall. In cold weather the strength of a castable will be adversely affected if the dry material used is in the freezing range of temperatures and if mixed with cold water. It is desirable that both the dry material and the water be in a temperature range of 60-70 F if-maximum strength is a consideration. Provisions should be made to maintain a minimum ambient air o temperature of 50 F when placing castable refractories. At the same time any steel that will come into contact with the refractory should be maintained at a temperature not lower than 50 F. The freshly poured castable refractory should be protected against freezing for a minimum of 48 hours or until thoroughly dried. When the temperature is below 50 degrees the maximum strength of the material can be improved by heating the mixing water. The following formula may be used for estimating the temperature of fresh concrete: Wt. + .22 W't1 W + .22 W' where W W t t` X = Weight of water = Weight of dry castable = Temperature of water = Temperature of Solids = Temperature of mixed castables 4Y(IPGD) 4Y26 16/12-12-83 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORIES CASTABLES FACTORS AFFECTING THE USE OF CASTABLE REFRACTORIES (CONT'D) 10. Temperature (Cont'd) 10.1 Cold Weather (Cont'd) For example, assume that B&W Kaocast at a temperature of 45F is to be mixed with seven quarts of water per bag. A desirable mix temperature would be 70 F. 7x2.08t + .22 x 100 x 45 then 70 * 7x2.08 + .22 x 100 14.56 t * 990 70 = 14.56 + 22 t = 108 (temperature of water) For maximum strength development the dry castable should be heated if below 50 F. To eliminate this necessity it is sug gested that the material be stored in a heated enclosure several days before use. After placement maintain ambient temperature at 50 F minimum. 10.2 Hot Weather It is desirable to protect the freshly placed castable against excessive temperatures just as it is desirable to protect against freezing temperatures. In the event of excessive heat the strength will be improved by cooling the material by water or other means during the first 24 hours after it is placed. The water should not be applied until the material has set. 11. Finishing When finishing off a castable lining or trimming excess material as gunned or slap trowelled care should be taken to avoid overtrowelling the finished surface. Normally it is preferred to leave a slightly rough surface. Where a smooth surface is necessary it should be given only sufficient trowelling to make it smooth without slicking. Use a wooden float rather than a steel trowel. If overtrowelled, excess cement is brought to the surface. This has the effect of sealing it thus restricting the escape of water vapor during drying or initial firing-in of the lining. It can also have the effect of creating a thin crust of pure cement which is readily dislodged under alternate heating and cooling. 2F57 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY CASTABLES AY(IPGD) 4Y26 17/12-12-83 FACTORS AFFECTING THE USE OF CASTABLE REFRACTORIES (CONT'D) 11.' Finishing (Cont'd) CONFIDENTIAL The possibility of bringing water and fines to the surface is reduced by waiting for the material to initiate a set before trowelling is commenced. Too long a delay will result in a surface that is too hard to finish with a trowel. The tendency in a great majority of cases is to trowel while the material is too soft and plastic. 12 . Curing The term "curing" as applied to a castable refractory, means keeping the material wet or the surrounding atmosphere humid. The primary purpose is to create the most favorable conditions for the completion of the chemical reactions of the cement. Curing results in improved strength. Normally a period of 24 hours is suggested to permit strength development before starting air drying or application of heat. There are certain instances where the realities of the situa tion prevents taking this much time and where achievement of the last degree of strength is unimportant. Under such circumstances the curing period can be abbreviated. Good judgement must be exercised in such decisions. The basic con sideration being whether the last degree of ultimate strength is essential for proper performance in service. During the curing period the primary object is to prevent the loss of moisture from the castable. Three methods are in common use: 12.1 Cover surface with polyethylene or damp sacks. In this case do not place overing directly on the castable until the initial set has taken place. Block up the covering to avoid contact. Sacks should be kept wet for 24 hours. 12.2 Spray or paint yith concrete curing compounds. A list of resin base compounds (Appendix C) is attached which have been tested for castable refractories and found to be satisfactory. Other resin base compounds as well as compounds of asphalt are equally suitable. Their use insures proper curing without 24 hour super- vision. 12.3 Spray with water either continuously or frequently enough to prevent drying of exposed surface. 4YCIPGD) 4Y26 . 18/12-12-83 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORIES CASTABLES FACTORS AFFECTING THE USE OF CASTABLE REFRACTORIES (CONT'D) 12. Curing (Cont-.'d)'- CONFIDENTIAL According to Wygant* and Crowley, a rise in internal temperature of the castable during curing is not harmful so long as the moisture is not lost from the mass. Air drying will not take place until the impermeable barrier formed by the curing compound is burned off. For a structure subject to long slow heating this will take place at lower temperatures and the moisture can then leave the mass on further heating. For a thick mass subject to fairly fast heating the barrier can be burned off with a torch prior to being heated to permit normal air drying. 13. Air Drying Following the curing the castably may be exposed immediately to heat or it can be air dried indefinitely. The longer it air dries before exposure to temperature the more strength it will develop, however, the increase in strength is negligible after several days. As soon as heat is applied further development of strength ceases. 14. Heating In applying heat to a standard castable it is desirable to first subject it to a period of a few hours at temperatures of 250 - 350 F. Following this it can be raised gradually. Generally an effort is made to alternate periods of rising temperature with periods of maintaining a constant temperature. This permits the temperature gradient in the wall to establish itself and avoids undue extremes of temperature between the hot face and the interior. Refinery vessels normally are subjected to slower heating rates. 15. Storage When our refractory castables are stored under dry, well ventilated conditions, the loss of strength over a period of a year is very low, on the order of 10%. If the material is stored where the bags can become wet or exposed to dampness for extended periods, a certain amount of moisture may get into the material and cause a partial setting up with loss of strength. *"Curing Refractory Castables: It isn't the Heat, It's the Humidity, "J. F. Wygant and M. S. Crowley, ACS Bulletin, Vo. 43, No. 1 (1964) 2F59 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORY CASTABLES 4Y(IPGD) 4Y26 21/12-12-S3 *< CONFIDENTIAL APPENDIX B RECOMMENDED CASTABLE AVERAGES B&W Castable Dense Lb/Std. Bag Lbs. Required to Place One Cu. Ft. Recommended Prewet U.S. Qts/Bag Typical Recom'd Rebound % Overases Kaocrete A & A-BF 100 125 1.0 23 1.30 Kaocrete B 100 100 1.0 10-15 1.11-1.18 Kaocrete 28-LI 100 126 -- 13 1.15 Kaocast 100 123 1.0 15-20 1.18-1.20 Kaocrete 32-G 100 135 1.0-2.0 18 1.22 Kao-Tab 93 100 150 1.0 15-20 1.15-1.25 Kao-Tab 95-Gun 100 165 2-3 18 1.22 Kaocrete HS 100 125 1.0 10-15 1.11-1.18 Kaogun BF 100 128 2.0 10-15 1.11-1.IS Kao-Tuff G 100 130 1.0-2.0 12 1.14 Kao-Phos 93 100 170 0 30-40 1.33-1.45 Kaogun pH 100 126 1.25-1.5 10-15 1.11-1.18 Insulating Kaolite 2000-HS Kaolite 2200 Kaolite 2200-HS Kaolite 2300-LI Kaolite 2500-LI Kaolite 2500-HS Kaolite 2800 40 40 50 40 50 75 75 56 4 56 4 82 4 54 4 60 2 85 3 86 2.5 10-15 10-15 15-20 10-15 10-15 5-10 10-15 1.11-1.18 1.11-1.18 1.18-1:25 1.11-1.18 1.11-1.18 1.05-1.11 1.11-1.18 NOTE Gunned onto vertical wall by experienced operator under optimum conditions. Total overage figure should include a 10% contingency factor. 4Y(IPGD) 4Y26 22/12-12-83 BABCOCK & VILCOX industrial power generation division BRICKWORK - REFRACTORY CASTABLES APPENDIX C manufacturers of organic curing compounds CONFIDENTIAL Nox Crete Chemicals 20th and Williams Sts. Omaha, Nebraska, 68108 Telephone (402) 341-2080 Master Builders 23700 Shagrin Blvd. Cleveland, Ohio 44122 Telephone (216) 831-5500 ECO Industries 99 Madison Avenue New York, New York 10016 Telephone (212) 889-0749 ABCO Cure and Seal - horizontal surfaces NATRASTON - verticle surfaces MB-429 - horizontal surfaces Master Cure - horizontal and verticle surfaces Eco-Seal - both horizontal and verticle surfaces 2F63 BABCOCK & VILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORIES CASTABLES 4Y(IPGD) 4Y26 23/12-12-83 APPENDIX D MANUFACTURERS OF CONCRETE VIBRATORS WYCO Tool Company 4601 West Addison Chicago, Illinois Telephone (312) 282-3411 CONFIDENTIAL Cleveland Vibrator Company 2827 Clinton Avenue Cleveland, Ohio 44113 Telephone (216) 241-7157 FMC Corporation Material Handling Equipment Division 3400 Walnut Street Homer City, Pennsylvania 15748 Telephone (412) 479-8011 Flexible Shaft Corporation 217 Eagle Street Brooklyn, New York 11222 Telephone (212) 383-6597 Homelite Division of Textron, Inc. 14401 Carovinds Blvd. Charlotte, North Carolina Telephone (704) 588-3200 28217 4YCIPGD) 4Y26 24/12-12-83 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORIES CASTABLES APPENDIX E BABCOCK & WILCOX, INSULATING PRODUCTS DIVISION SPECIFICATION FOR METAL FIBER ADDITIONS TO CASTABLE Metal fiber additions to castables have demonstrated improvement in various castable properties - those of thermal shock, mechanical shock, and abrasion resistance. . Scope: This specification shall describe: 1. Fiber Type 2. Fiber Quantity 3. Field Mixed Material 4. Pre-Mixed Material CONFIDENTIAL 1. Fiber Type Fiber reinforcement is available from the following sources: The National Standard Co. 1618 Terminal Road Niles, Michigan 49120 (Meltex Fibers) Ribbon Technology 6270 Bowen Road Canal Winchester, Ohio (Ribtec Fibers) 43110 The fiber type required is a function of process temperature and atmospheric conditions. Below is a chart showing which fiber type to use: FIBER RECOMMENDATIONS* Conditions Hydrogen Hydrogen Sulphide Best 446 Under 1000F 310 Over 1000F Next Best 430 304 Carburization 446 310 330 309 302 B Nitrogen 330 309 304 2F66 BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORIES CASTABLES 4Y(IPGD) 4Y26 25/12-12-83 APPENDIX E (CONT'D) CONFIDENTIAL FIBER RECOMMENDATIONS* (CONT'D-) Conditions Coke Oven Gas Sulphur Carbon Compounds Chlorine Oxidation 1600 F 1900F 2100F 2200F Best 446 310 330 430 304 310 446-330 Next Best 309 310 304 446 446-330 '''Taken From Ribbon Technology Published Literature. The Individual fibers are to be 1" x (.016-.020) when, field mixing and 3/4" x (.020 - .025) when pre-mixed by Babcock & Wilcox, IPD. 2. Quantity of Metal Fibers Approximately 1% of volume of fibers (@ 500#/CF) gives optimum rein forcement to refractory castables. The following table correlates the 1 volume % to weight % for castables of various densities. METAL FIBER ADDITION B&W Castables Castable Density Volume % Weight % Dense: Kao-Tab 95 Kaocrete HS 165// 123# 1 -3 1 =4 Insulating: Kaolite 2200 Kaolite 2200 HS 56# 71# 1 *8 1 =6 3. Field Mixed Material Attention must be given to the even distribution of metal fibers throughout the castable to avoid fiber "clumping" or "balling". These fiber clumps if introduced in the mix can lead to voids and weak spots. The following procedure should be followed: a. Using a paddle-tvpe mixer, pour in the dry castable and mix. 4Y(IPGD) 4Y26 26/12-12-83- BABCOCK & WILCOX INDUSTRIAL POWER GENERATION DIVISION BRICKWORK - REFRACTORIES CASTABLES ' APPENDIX E (CONT'D) 3. Field Mixed Material (Coat'd) confidential b. For casting applications, introduce the measured fibers into the operating mixer by means of shaking through a wire basket fashioned from poultry netting or welded wire mesh 1/2" - 1" openings. Half of the necessary water should be added before fiber addition and half after. c. For gunning applications, introduce the measured fibers into the operating mixer by means of shaking through a wire basket fash ioned from poultry netting or welded wire mesh with 1/2" - 1" openings. This should be done immediately after the pre-wetting water has been added to the castable. 4. Premixed Material Babcock & Wilcox can supply castables with metal fiber additions on request. Contact B&W Insulating Products Division for prices and availability. Premixed fiber reinforced castables are used in the same manner as plain castables with regards to mixing and placement. It should be noted, however, that the castable water demand is slightly higher when metal fibers are added. 2F67