Refractory Fibre & Anchor Systems. Our answer to fixing & fastening.

Transcription

1 Refractory Fibre & nchor Systems D Our answer to fixing & fastening.

2 Introduction Refractory Fibre & nchor Systems manufactures and installs anchor systems for all types of monolithic, ceramic fibre and brick refractory linings, ensuring that the correct grade of material, dimensions, spacing patterns and welding methods are selected for an anchorage system, which is essential for retaining the refractory material and enhancing the lining peformance. 1. G.W.H.W. - Gull Wing Hand Weld G.W.S.W. - Gull Wing Stud Weld H.H.W. - ull Horn Hand Weld 3 G.W.H.W. - diameter, length G.W.H.W. 50 x 5,5Ø; ,50 or 75 mm long. 5,5 mm diameter lloy: Mild Steel (EN3) G.W.S.W. - diameter, length G.W.S.W. 35 x 5,5Ø; ,50 or 75 mm long. 5,5 mm diameter. 11 or 12 mm wide lloy: EN3.H.H.W. - diameter, length.h.h.w.100 long x 8Ø; 310 Dimensions.90;100;110;125;140;150; ,5 or 8 mm diameter lloy: Mild Steel (EN3) Various Monothic nchors Many specifications call for refractory anchors to be % to 75% of the lining depth. In general practice however, the anchor should not extend closer than 25 mm to the lining surface. nchor spacing depends on the type of material used, the operating conditions and the physical characteristics of the unit being lined. Generally the more severe the operating conditions the closer the anchors should be spaced and spacing should also alter according to the material density. 5. V.X.H.W. - Vee Wriggle Hand Weld 5. V.X.S.W. - Vee Wriggle Stud Weld 7..O.X.V. - olt on Wriggle Vee 7 8. H.W.V. - Hand Weld Vee 8 V.X.H.W. - diameter, length V.X.H.W.75 x 5,5Ø; 310. On request (90-370). 5,5 or 8 mm diameter lloy: V.X.S.W. - diameter, length V.X.S.W. 90long x 8Ø; 304. On request (90-200). 5,5 or 8 mm diameter lloy: O.X.V. - diameter, length.o.x.v. 150 long x 8Ø; 310. On request ( ). 5,5 or 8 mm diameter lloy: H.W.V. - diameter, length & alloy H.W.V. 50 long x Ø; or 75. 5,5 mm diameter lloy: H.S.W. - ull Horn Stud Weld 4.H.S.W. - diameter, length.h.s.w.100 long x 5,5Ø; 304 Dimensions. 90,100,110,125,140,155,175. 5,5 or 8 mm diameter lloy: V.S.W. - Vee Stud Weld nchor 9 V.S.W. - diameter, length & alloy V.S.W.-50 long x Ø; 310 Dimensions ,5 mm diameter lloy:. EN

3 10. S.. - Suspension nchor D RP - nchor S.. total length, leg length, diameter hole and material diameter S. 170 long; 80 long; 50 diameter hole & 8 mm diameter material..& on request D. 5,5 or 8 mm diameter lloy: V.X.. - orrugated nchor castable Insulation board 30 Sq washer or tack weld 20 Shell Fluxball 14 V.X.. - diameter, length & alloy V.X..150 long x Ø; 304. On application. or 8 mm diameter lloy: Studweld Handweld 11. RP - nchor 11 ase 12. V.X.S.. - Vee Wriggle Screwed 12 RP. x length x material diameter RP x 50mm long; Mildsteel. On request. 1,5 mm lloy: Mildsteel V.X.S.. - diameter, length, alloy and type of anchor V.X.S..x10Ø x40 long; 310 & nchor length. On request. 5,5 or 8 mm and 12mm diameter lloy:. EN eramic Fibre Fixings 1. ock Washer (to fit fibrelock pin) 2. Fibrelock pin 5,5 1.8 x 0.7 deep hole for 2 fluxball T Fibrelock pin - lock washer lloy: dia./ 0 dia. T. 1,5 mm thickness Fibrelock pin 45 Fibrelock pin x103; ,103,123,133,153,203 lloy:. 304 oinin. 310 punch 13. V.X.D.. - Vee Wriggle Drilled ase V.X.D.. - diameter, length, alloy and type of anchor V.X.D..150 x 8Ø x33 long ase. 1Ø. 33, 88 mm. 10Ø lloy: EN Spring lip Washer Spring clip washer lloy: Plated mild steel Stainless Steel 13 8 M.S or Shell M.S. base Shell Tack weld 10 hole 10 hole hole x 1.9 deep lternative shell fastenings M.S. base for stud welding (EN3)

4 Refractory Fibre & nchor Systems Element Support System Electrically heated furnace users can now benefit, with complete confidence, from a low thermal mass lining and the resultant, very considerable, energy saving. The problems created by unstable furnace linings in the past can now be eliminated using the Refractory Fibre and nchor Systems element support, which is both locally developed and manufactured. The unique ceramic washer and pin firmly retain the high temperature fibre lining and at the same time provide a fully insulated support. consider just a few of the benefits: Fits standard fibrelock pins with no modification. It is extremely fast and simple to install or replace. Ideal for both side wall and roof element support. Eliminates stress in the blanket from the roof element. Operates at temperatures up to Washes are supplied in both full circular configuration and in a trimmed type for intermittent or continuous installation. The element will remain totally insulated even if the holder fails ocal manufacture gives a very competitive price, full technical back-up and spares availability Maintenance is exceptionally fast and economical. Full insulation ensures minimal heat transfer and thus optimum furnace performance. Figure 1 eramic pin 48,0 mm Trimmed washer 8,0 mm 45 mm (When used as cup lock) Washer Figure 2 Figure 3 ocking pin 80,0 mm Figure 4 Figure1: section showing the pin and washer fitted to the standard fibre lock system. Figure 2 & 3: The basic components of the system showing the trimmed washer (Fig 2) and the full circular washer (Fig 3). Figure 4: diagram showing how the system can be used for continuous or intermittent installation, depending on the requirements of the application. Fibrelock pin length; 310, eramic pin - Part no 2992, ircular washer - Part no 2993, Trimmed washer - Part no eramic rick Retainers Scissor lips Element Full circular washer lip (rick lip) Mounting pin D Z Furnace shell M.S. ngles by others 92 3 Sections: 5,5mm and 8mm diameter Material Types: 301, 304 and arbon Steel Flat bar: Width - 75mm Thickness - 3mm Note: Various fixings to the shell can be designed and manufactured to customer requirements

5 nchor Patterns Typical anchor Patterns ll three stud anchor patterns illustrated have been widely and successfully used. The most important fact is that an irregular pattern is achieved by opposing individual anchors. This increases the overall holding power of the anchor pattern. It also helps prevent cracks from extending dangerously far in any one direction or from linking together in regular networks to cause weakened areas. For best results, especially if studs are rectangular in base cross-section, the long dimension should be welded at an angle to the vertical position as indicated. Diamond Square Staggered nchor alloys Research indicates that the tip of an anchor buried approximately 25mm behind the lining hot face will be approximately 150 lower in temperature than the hot face. ased on the suggested use temperatures by alloy manufactures, the tip temperature difference and experience, the hot face temperatures shown in the table (right) are suggested for the various anchor alloys. The temperatures given are continuous use limits. Slightly higher temperature reached is cyclic in nature and below the suggested limits for most of the duration of the operation. nchor alloy Mild steel Stainless steel 304 or 305 Stainless steel 309 or 310 Hot face temperature Numbers of nchors The number of anchors that are required varies according to the particular application and the centreto-centre anchor measurement. the table gives the number of anchors required per square metre for various anchor spacings: entre to centre anchor measurements in millimetres nchors required per square metre General omments olted Refractory nchors 1 It has generally been found that metal stud welded anchors used with gunned linings, coarse aggregate materials or relatively thick linings do not require a coating of wax, grease, tar or mastic to combat anchor expansion. 2 In two-component linings, the anchor portion extending into the hot face component should develop full V configuration for maximum benefit. 3 Various adaptations of the anchors illustrated in this brochure are available on special orders for anchoring into existing brick linings or into concrete shell units. Data and technical advice on these and other applications are always available from your Refractory Fibre & nchor Systems representative. n RF&S welded stud makes a quick, inexpensive substitute for manually welding a common Y type anchor with a bent-up shank. Hand welding right around the loop or bent-up portion requires considerable time. Instead, an M10-diameter threaded stud can be welded to the shell. The stud accommodates a hex nut that firmly secures the anchor. If it is desirable to make the anchor stand off from the shell, a longer threaded stud and double nuts may be used. Either way, positive holding power is provided, since the anchor cannot slip off over the nut. In addition, careful tightening of the nut will incorporate sufficient movement into the system so that the anchor will accommodate stresses by floating.

6 Stud Welding of Refractory nchors There are a variety of options available for securing refractory anchors, but we recommend stud welding where possible for the following reasons: PROEM:- Drilling and tapping: These processes are slow. The system also requires thicker parent material and longer studs. Inserts: These can work loose. Holes must be punched and deburred, weakening parent material and taking time. The reverse side is not always clean and flat. ack welding: The process is slow. Holes need to be punched and deburred in parent material, which weakens it.the excess weld has to be ground off to achieve a clean flat finish. Through bolting: Requires two-handed assembly with access from both sides. Holes need to be punched and deburred taking time and weakening the parent material. the assembly is not leakproof. SOUTION:- Stud welding: The process is fast (up to 30 studs a minute) as the entire arc welding cycle normally takes less than a second. No reverse marking is required. There is minimal heat and penetration depth, preventing distortion and ensuring good attachment to thick and thin materials (from 0,7 to over 2,0 mm). The weld is stronger than the parent material or the stud. ccess is required from only one side. Pre-coated or painted materials can be welded. No holes are needed eliminating the possibility of leaks or weakening of the sheet. The stud welding equipment is portable and easily jigged. Welds are clean and require no finishing. There are a variety of stud welding processes suitable for securing studs ranging in diameter from 1,0 to 30 mm. Taylor Stud Welding Systems is a specialist in the design, manufacture and supply of stud welding equipment and studs. Within the extensive range of ritish built equipment we have a system to suit you whatever your requirements. Refractory Fibre & nchor Systems (Pty) td PO ox 3, Vereeniging 1930, South frica Tel: +27(0) Fax: +27(0) dickinson@dickinsongrp.co.za Web: Supplier and S gent for Taylor Stud Welding Systems, compliant with International ISO 9002.