REFRACTORY LINING DESIGN

&
ENGINEERING

SMMS Department

00/03/2004
Delivering excellence through people Slide Number- 1 of 8
 APPLICATIONS

NON-FERROUS,
GLASS & OTHERS STEEL

CERAMIC CHEMICAL,PETROCHEM

POWER PLANTS CEMENT INDUSTRY

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 2 of 50
 PURPOSES OF REFRACTORY LINING

- TO PROTECT THE SHELL & STRUCTURE

- TO PREVENT HEAT LOSS & IMPROVE THERMAL EFFICIENCY.

- TO CONTAIN HEAT & CHARGE.

- TO PREVENT LEAKAGE OF THE GASES.

- TO MAINTAIN A CLEAN ENVIRONMENT.

- TO KEEP THE ENTIRE SYSTEM SAFE FROM FIRE HAZARD.

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 3 of 50
 HOT FACE TEMP.: 1150DEG
ْ DEG C

SL. CHARACTERISTICS COLD FACE HEAT LOSS

NO. TEMP. DEG. C W/SQ.M
1. 230MM FIRE BRICK+115MM FIRE 181 2853
BRICK
2. 230MM FIREBRICK + 115MM 132 1641
INSULATING FIRE BRICK (IFB)
3 230MM INSULATING 87 778
FIREBRICK(IFB)+115 IFB
4 178MM IFB+50MM BLOCK (1000) 67 472
+ 75MM BLOCK(800)
5. 275MM CERAMIC FIBRE 67 472
MODULE + 25MM CERAMIC
FIBRE BLANKET

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 4 of 50
 PERFORMANCE OF REFRACTORY LINING DEPENDS ON

- RIGHT DESIGN

- RIGHT MATERIAL

- RIGHT APPLICATION

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 5 of 50
 REFRACTORIES ENGINEERING

• DESIGN OF LINING
• MATERIAL SELECTION AND SPECIFICATION
• MATERIALS PROCUREMENT & INSPECTION
• MATERIALS APPLICATION
• DRY OUT & COMMISSIONING
• MAINTENANCE & REPAIR
• DEVELOPMENT OF MATERIAL COMPOSITION &
MANUFACTURING
• TESTING

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 6 of 50
 OBJECTIVE OF A GOOD LINING DESIGN
• OPERATION & PRODUCTION AT LOWEST
COST & EXPENSES OF REFARCTORIES USED

• TO OBTAIN OPTIMUM TROUBLE FREE

CAMPAIGN LIFE

• TO HAVE RELIABLE & DEPENDABLE LINING

SYSTEM

• EASE OF MATERIAL PROCUREMENT ,

MANUFACTURING ,APPLICATION & MAINTENANCE

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 7 of 50
CRITERIA FOR LINING DESIGN AND SELECTION OF MATERIALS

- OPERATING TEMPERATURE

- MODE OF OPERATION (INTERMITTENT, CONTINUOUS)

- FURNACE ATMOSPHERE (OXIDIZING, REDUCING,)

- FURNACE PRESSURE ( +VE, -VE, NEUTRAL )

- GEOMETRY OF FURNACE

- TYPE OF FURNACE (STATIC, ROTATING, TILTING)

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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CRITERIA FOR LINING DESIGN AND SELECTION OF MATERIALS

- TEMPERATURE GRADIENT ACROSS LINING AND INTERFACE

TEMPERATURE BETWEEN THE LAYERS

- CASING TEMPERATURE AND HEAT LOSS

- REQUIREMENT OF FURNACE EFFICIENCY

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 9 of 50
- PHYSICAL ABUSES SUCH AS ABRASION, EROSION ETC.

- THERMO-CHEMICAL ATTACK

- FUNCTION OF FURNACE SUCH AS HEATING/MELTING OF SOLID,

MOLTEN, GASEOUS MATERIALS

- GAS COMPOSITION WITHIN THE FURNACE (SULFER, SODIUM,

POTASSIUM, CHLORINE, HYDROGEN ,VANADIUM, CO, CO2 ETC.)

- EXPECTED LIFE OF FURNACE

- COST AND ECONOMICS

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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 GENERAL LINING REQUIREMENTS
- EXPECTED SKIN / CASING TEMPERATURE

- EXPECTED INTERFACE TEMPERATURE IN CASE OF MULTI-LAYER LINING

- TYPE OF REFRACTORY STRUCTURE; SELF SUPPORTING OR LOAD

BEARING

- THE THERMAL REQUIREMENTS (GOOD OR BAD HEAT CONDUCTIVITY OR

HEAT STORAGE CAPACITY)

- EXPECTED LIFE OF THE AREA / ELEMENT OF THE FURNACE

- SITUATION AND LOCATION OF THE ELEMENT / AREA TO BE LINED

- AVAILABILITY OF LINING MATERIAL, VIZ. INDIGENOUS OR IMPORTED

- TECHNOECONOMICS OF THE LINING

- WEIGHT OF LINING

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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 HEAT TRANSFER TO DETERMINE LINING DESIGN

- HEAT TRANSFER CO-EFFICIENT

- HEAT TRANSFER UNDER STEADY THERMAL CONDUCTION

- THERMAL CONDUCTION OF LINING IN HYDROGEN MIXED

ATMOSPHERE

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 12 of 50
 FACTORS RESPONSIBLE FOR HEAT LOSS
THROUGH REFRACTORY LININGS

- REFRACTORY MATERIAL DENSITY.

- MINERALOGICAL COMPOSITIONS OF MATERIAL.

- POROSITY, PORE SIZE AND PORE DISTRIBUTION.

- GAPS PRESENT IN LINING (JOINTS, CRACKS, DOORS ETC.)

- EXPOSED AREA OF CASING PLATE.

- MATERIAL AND VITRIFICATION IN COURSE OF OPERATION.

- METALLIC COMPONENTS, ANCHORS, STUDS, SHELL PLATE ETC.

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 13 of 50
 DESIGN OF REFRACTORY LINING

SELECTION OF REFRACTORY MATERIAL :

- INSTALLATION REQUIREMENT

- OPERATIONAL REQUIREMENT

LINING STRUCTURE :

- SINGLE LAYER (FOR LOW OPERATING TEMPERATURE & LESS

SEVERE CONDITIONS)

- DOUBLE LAYER (FOR HIGH OPERATING TEMPERATURE, LOW HEAT

LOSS REQUIREMENT & SEVERE CONDITIONS)

- MULTI LAYER (COMBINATION OF BRICK, BLOCK, CASTABLE,

CERAMIC FIBRE MATERIAL
Engineers India Ltd – Delivering excellence through people FICCI prog.-2008
Slide Number - 14 of 50
 SOME REFRACTORIES MATERIALS
USED FOR PROCESS INDUSTRIES

A. BRICKS AND SHAPES

I. DENSE TYPE :
- MODERATE HEAT DUTY FIRE BRICK (GENERAL / CRITICAL USES,
LOW IRON TYPE)
- HIGH HEAT DUTY FIRE BRICK
- 42-44% A1203 BRICK
- HIGH ALUMINA BRICK (45-99% A1203)

II. INSULATING TYPE :

- MICA BRICK
- INSULATING FIRE BRICK (HOT FACE & BACK-UP)
- LOW B.D. HIGH STRENGTH INSULATING FIRE BRICK

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 15 of 50
B. MONOLITHICS
I. INSULATING TYPE :

- INSULATING CASTABLE (B.D. = .8 TO 1.6)

A. NORMAL STRENGTH
B. HIGH STRENGTH
C. LOW IRON TYPE
D. SPECIAL TYPE (LOW THERMAL CONDUCTIVITY ETC.)

II. DENSE TYPE :

- CONVENTIONAL CASTABLE
- LOW CEMENT CASTABLE
- ULTRA LOW CEMENT CASTABLE
- NO CEMENT CASTABLE
- ABRASION RESISTANT CASTABLE
- RAMMING MASSES

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 16 of 50
C. CERAMIC FIBRE
 BULK FIBRE

 BLANKETS

 MODULES

 VACUUM FORMED BOARDS & SHAPES

 PAPER

 TEXTILES

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 17 of 50
D. INSULATING BOARDS
 -CALCIUM SILICATE BOARDS

 -MILL BOARDS

 -CERAMIC FIBRE BOARDS

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 18 of 50
LINING THICKNESS :
FACTORS DETERMINING THICKNESS :
- STRENGTH OF MATERIAL
- INSTALLATION METHOD
- OPERATING TEMPERATURE
- DESING SHELL TEMPERATURE
- SERVICE / CAMPAIGN LIFE
- CORROSION, EROSION ETC.

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 19 of 50
THERMAL EXPANSION OF LINING :
- EXPANSION JOINTS IN BRICK LINING ARE NECESSARY IN ORDER
TO PROTECT THE LINING AND SHELL AGAINST FORCES DUE TO
THERMAL EXPANSION OF BRICK.

- EXPANSION JOINTS IN MONOLITHIC LINING OFTEN NOT

NECESSARY SINCE ANCHOR FITTED TO THE FURNACE SHELL
ALLOW LIMITED MOVEMENT RESULTING THERMAL EXPANSION.

- EXPANSION JOINTS ARE NECESSARY IN MONOLITHIC LINING

WITHOUT ANCHOR

- SIZE & WIDTH OF EXPANSION JOINT

LOCATION & PORTION OF EXPANSION JOINT

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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SHRINKAGE OF LINING :

- MONOLITHIC REFRACTORY LINING USUALLY SHRINKS DURING

POST INSTALLATION DRYING

- LINING REQUIRES PROTECTION AGAINST CRACKS DUE TO

SHRINKAGE,

HEIGHT OF LINING :
-FOR MONOLITHIC LINING, NO RESTRICTION
IN HEIGHT AS WEIGHT OF
REFRACTORY IS UNIFORMLY DISTRIBUTED
AMONGST THE ANCHORS

FOR BRICK LINING HEGHT DEPENDS ON WEGHT

OF LINING, TEMPERATURE, THICKNESS

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 21 of 50
LINING THICKNESS ON BASIS OF CONSTRUCTION :
MONOLITHICS LINING :
- POURING > 80 MM

- GUNNITING < 150 MM / LAYER

- TROWELLING
- VERTICAL SURFACES < 75 MM
- OVERHEAD SURFACES < 50 MM

- RAMMING > 180 MM

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 22 of 50
 PROPERTIES OF REFRACTORIES CONSIDERED DURING
SELECTION

 CHEMICAL COMPOSIITON
        APPARENT POROSITY
 BULK DENSITY
 CO-EFFICIENT OF THERMAL
EXPANSION
 PERMANENT LINEAR CHANGE
 REFRACTORINESS UNDER LOAD
 PYROMETRIC CONE EQUIVALENT
Engineers India Ltd – Delivering excellence through people FICCI prog.-2008
Slide Number - 23 of 50
 • THERMAL CONDUCTIVITY
• SPALLING RESISTANCE
• PERFORMANCE UNDER VARIOUS GASEOUS
ATMOSPHERE
• PERMEABILITY
• MECHANICAL STRENGTH (ROOM
TEMPERATURE. & HIGH TEMPERATURE)
• ABRASION/EROSION RESISTANCE
• HMOR / CREEP
• RESISTANCE TO CHEMICAL /SLAG ATTACK

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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 DESIGNING OF ANCHOR SYSTEM

- ANCHOR QUALITY

- DIAMETER OF ANCHOR ROD

- ANCHOR CONFIGURATION

- ANCHOR SPACING

- ANCHOR ORIENTATION

- ANCHOR COVER

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 25 of 50
 ANCHORS FOR REFRACTORY LINING

- METALLIC ANCHORS
- CERAMIC ANCHORS

TYPES OF METALLIC ANCHOR :

- L TYPE
- V TYPE
- Y TYPE
- HEXMESH
- CHAIN LINK WIRE MESH
- ANCHOR FOR CERAMIC FIBRE LINING

SELECTION CRITERIA OF ANCHOR SYSTEM :

- LINING THICKNESS
- TYPE OF REFRACTORY MATERIALS
- TYE OF LINING
- FURNACE OPERATING CONDITIONS
- LOCATION OF LINING

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 26 of 50
 ANCHOR MATERIALS

MATERIAL QUALITY OXIDATION TEMPERATURE COMPOSITION

(APPROX.)

CS 450C

SS 304 900C 18 Cr / 8Ni

SS 316 900C 16 Cr / 10Ni

SS 310 1050C 24 Cr / 19Ni

INCONEL 1150C 23 Cr / 60Ni

(601)

RA333 1230C 25 Cr / 45Ni

REFRACTORY ANCHORS ALUMINO SILICATES

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 27 of 50
 WELDING AND FIXING UP ANCHORS

- FACTORS TO BE CONSIDERED FOR CALCULATING SPACING

- HORIZONTAL LINING ( CEILING )

- VERTICAL LINING

- FLOOR LINING

- INCLINED LINING

- CYLINDRICAL

- RELATION BETWEEN LINING THICKNESS AND SUPPORT LENGTH

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 28 of 50
 STEEL FIBRES REINFORCED CASTABLE

TYPE OF STEEL FIBRES & THEIR CHARACTERISTICS :

TYPE OF FIBRE : CUTTINGSTEEL WIRES,SHEARING THIN

STEEL WIRES, MELT EXTRACTION,
SHAVING THICK STEEL PLATES

DIA. OF FIBRE : 0.3 MM TO 0.5 MM

LENGTH : 25 MM TO 30 MM

MATERIAL QUALITY : SS 304, SS 410, SS 310 ETC.

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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ADVANTAGES OF STAINLESS STEEL FIBRE REINFORCEMENT
IN REFRACTORY

- HIGHER TENSILE, FLEXURAL AND COMPRESSIVE STRENGTH

- IMPROVED RESISTANCE TO DAMAGE FROM VIBRATION, IMPACT

AND THERMAL SHOCK

- BETTER RESISTANCE TO CRACKING

- BETTER PERFORMANCE UNDER ABRASIVE CONDITIONS

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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 THERMO-MECHANICAL DESIGN BY FINITE ELEMENT ANALYSIS

THERMAL PROPERTIES :

- SPECIFIC HEAT

- THERMAL CONDUCTIVITY

MECHANICAL PROPERTIES :

- THERMAL EXPANSION

- DENSITY

- STRESS - STRAIN BEHAVIOUR

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 31 of 50
 TESTING OF REFRACTORIES

IMPORTANCE :

- QUALITY CONTROL AT VARIOUS LEVELS OF PRODUCTION TO ENSURE

QUALITY OF THE PRODUCTS.

- TO ENSURE CONFORMITY OF THE PRODUCT SPECIFICATIONS.

- FOR ACCEPTANCE AND REJECTION OF MATERIALS.

- TO ESTABLISH SOME OF THE CAUSES OF FAILURE IN USE AND

OPERATION.

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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 MATERIAL INSPECTION AS PER STANDARD

INSPECTION BY ATTRIBUTES :

- DIMENSIONS, CRACKS, LAMINATIONS, BROKEN CORNER AND EDGES, IRON SPORT, SLAG
HOLE ETC.

INSPECTION BY VARIABLES :

- QUALITY TESTING

- MEASURABLE PROPERTIES

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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 TESTING OF REFRACTORIES

TYPES OF TESTING :

- CHEMICAL TESTING

- PHYSICAL TESTING

STANDARD FOLLOWED FOR TESTING :

- ASTM (AMERICAN SOCIETY FOR TESTING MATERIALS)

- BSI (BRITISH STANDARD INSTITUTION)

- BIS (BUREAU OF INDIAN STANDARDS)

- DIN (DEUTSHE INDUSTRIES NORMEN)

- ISO (INTERNATIONAL STANDARD ORGANISATION)

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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 METHOD OF APPLICATION OF REFRACTORIES

- BRICKS & SHAPES

- MONOLITHICS & UNSHAPED

- CERAMIC FIBRE

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 35 of 50
 PREPARATION FOR LINING

- SHELL PLATE CLEANING

- VERIFICATION OF EQUIPMENT DIMENSIONS

- CHECKING FOR UNDULATIONS AND UNEVENNESS OF SHELL

- MARKING FOR AXIS IN CIRCULAR / CYLINDRICAL PARTS

- MARKING FOR STARTING POINT

- MARKING OF SECTIONS FOR LINING

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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 TOOLS AND EQUIPMENT REQUIRED FOR LINING WORK
- MIXER
- BRICK CUTTING MACHINE
- PNEUMATIC GUNNING MACHINE
- PNEUMATIC VIBRATOR
- TROWEL
- MASSON PATTA
- SPIRIT LEVEL
- ANGLE
- FILLER GAUGE
- PLUMB
- WOODEN MALLET
- HAMMER
- BRICK CUTTING CHISEL (BASULI)
- ELECTRIC DRILL
- WEIGHING BALANCE
- THERMOMETER
- PORTABLE CONVEYOR

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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 REFRACTORY BRICK LINING
COURSES
- STRETCHER
- HEADER
- ROWLOCK (ON EDGE)
- SOLDIER
CRITERIA FOR SELECTION OF BOND
- FURNACE DESIGN
- WALL THICKNESS
- OPERATING CONDITIONS
- GAS TIGHT CONSTRUCTION
- EASE OF MAINTENANCE

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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 BRICK LINING

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 39 of 50
 MONOLITHIC LINING

AREA OF APPLICATION

- WALL (VERTICAL / INCLINED)

- FLOOR, ROOF / ARCH
- DUCT
- STACK ETC.

TYPE OF LINING

- SINGLE LAYER (DENSE / INSULATING)

- MULTI LAYER - COMBINATION OF CASTABLE, BRICK, BOARD,
BLOCK ETC.

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 40 of 50
 CASTABLE LINING

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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 METHOD OF APPLICATION

- GUNNITING
- POURING
- VIBRACASTING
- RAMMING
- RODDING
- TROWELLING

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 42 of 50
 FORM WORK & SHUTTERING

- WOODEN / METALLIC
- FORM SIZE
- FIXING
- INPERMEABLE COATING ON WOODEN FORM
- LUBRICATION OF FORM

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 43 of 50
MOCK UP TRIAL

- FOR SPECIAL APPLICATION

CURING

- TIME, HUMIDITY CONTROL

INSPECTION BEFORE DRYING

- SOUNDNESS OF LINING
- CRACKS
- REPAIR, IF ANY
- NO FINISH/PLASTERING OF SURFACE

DRYING

- DRYING SCHEDULE
- PREPARATION OF CHART FOR TEMPERATURE VERSUS TIME

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 44 of 50
 MIXING OF MONOLITHICS

- SELECTION OF MIXER
- MIXURE CLEANING
- CHECKING OF SHELF LIFE OF MATERIAL
- PHYSICAL CONDITION OF THE MATERIAL
- QUANTITY TO BE MIXED AT A TIME
- DRY MIXING
- QUANTITY OF WATER
- WATER QUALITY AND TEMPERATURE
- MIX TEMPERATURE
- PREDAMPENING
- ADDITION OF REINFORCING FIBRES, IF ANY
- MIXING TIME
- CONSISTENCY CHECKING
- POT LIFE OF MIX

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 45 of 50
 CERAMIC FIBRE LINING

A. AREA OF APPLICATION :

- ROOF / ARCH (HORIZONTAL / SLANTING)

- WALL

B. TYPE OF LINING :

- BLANKET : SINGLE LAYER

: MULTI LAYER

- MODULE

- MODULE AND BLANKET

- VENEERING

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 46 of 50
 CERAMIC FIBRE LINING

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 47 of 50
INSPECTION OF NEW REFRACTORY LINING SYSTEM

WHEN TO INSPECT:

- AT THE TIME OF INSTALLATION

- AFTER COMPPLETION OF LINING

- AFTER DRYING AND HEATING UP OF

LINING

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 48 of 50
INSPECTION OF REFRACTORY LINING SYSTEM

IMPORTANCE OF INSPECTION:

- TO ENSURE PROPER EXECUTION OF LINING WORK

- TO TAKE CARE OF ANY INADEQUACIES IN LINING DURING

EXECUTION OR AFTER DRY OUT

- TO ENSURE LINING HAS BEEN DONE AS PER DESIGN AND

RIGHT MATERIAL

- TO ENSURE FREE FROM CRACKS, VOIDS, DAMAGES ETC.

AFTER DRYING AND HEAT-UP

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 49 of 50
REPAIR & MAINTENANCE INSPECTION OF REFRACTORIES
LINING

ACTIVITIES PRIOR TO INSPECITON:

- BEHAVIOUR OF FURNACES DURING OPERATION

- ANY EMERGENCY FORCED SHUTDOWN
- COOLING RATE DURING SHUTDOWN
- HEATING RATE DURING START-UP
- ANY OBSERVATION OF HOT SPOT/HIGH TEMPERATURE ZONE.

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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 REFRACTORY QUALITY PLAN

VERIFICATION OF REFRACTORY AND

ANCHOR MATERIAL AT SITE

- TEST AND INSPECTION CERTIFICATES

- IN CASE OF WAIVER, MANUFACTURER’S

TEST CERTIFICATES

- PHYSICAL CHECKING OF DIMENSIONS,

SHAPES ETC. OF BRICKS, MODULES ETC.

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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 REFRACTORY QUALITY PLAN

VERIFICATION OF REFRACTORY AND

ANCHOR MATERIAL AT SITE

- BULK DENSITY, COMPRESSIVE

STRENGTH OF MONOLITHIC MATERIALS

- SHELF LIFE OF CASTABLES, MORTARS

- TEST CERTIFICATE OF ANCHORS AND

ACCESSORIES

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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 REFRACTORY QUALITY PLAN

STORAGE OF REFRACTORY MATERIALS

STORING OF:
- INSULATING & DENSE BRICKS

- INSULATING & DENSE CASTABLE

- MORTARS

- CERAMIC FIBRE MATERIALS

- CALCIUM SILICATE BLOCKS

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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 PREPARATION FOR LINING
- STUDY OF LINING DRAWINGS

- IDENTIFICATION OF AREAS TO BE LINED

- SEQUENCE OF LINING

- CHECKING OF CASING PLATE WITH REFERENCE TO:

* PERFORATION & HOLES

* UNEVENNESS & UNDULATIONS
* RIGIDITY & SOUNDNESS
* JOINTS & OPENINGS

- RECTIFICATION OF CASING PLATE, IF ANY

- CLEANING OF CASING PLATE

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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 PREPARATION FOR LINING
- CHECKING OF ANCHOR, REPLACEMENT

- VERIFICATION OF EQUIPMENT DIMENSIONS

- MARKING FOR AXIS IN CIRCULAR/CYLINDRICAL

PARTS

- MARKING FOR STARTING POINT

- MARKING OF SECTIONS FOR LINING

- CORROSION RESISTANT PAINT

- MAINTENANCE OF RECORDS

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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 RE-ASSESSMENT OF COSTS OF REFRACTORIES NON-
PERFORMANCE

 COSTS OF MECH. DAMAGE CAUSED BY

FAILURE
 PRODUCT QUALITY LOSSES
 PROCESS OUTPUT, EFFICIENCY & ENERGY
LOSSES
 ENVIRONMENTAL COSTS DUE TO PROCESS OR
EFFICIENCY PROBLEMS
 DEMOLITION COST OF FAILED REFRACTORY LINING
 REDUCTION IN EXPECTED LIFE OF ADJACENT
REFRACTORY DUE TO LOOSENING DURING DEMOLITION

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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 STRATEGY

 FOR EVERY CRITICAL REFRACTORY STRUCTURE,

INSTITUTE A REFRACTORIES “CONDITION MONITORING”
PROGRAME
 ENSURE ALL REFRACTORY INSTALLATIONS ARE MADE TO
THE SAME QUALITY STANDARD
 ACHIEVE IMPROVEMENTS IN BENCHMARKED
INCREMENTAL STEPS
 MEASURE POLICY EFFECTIVENESS BY REDUCTIONS IN
REVISIT FREQUENCIES AND COSTS
 CONSIDER TRUE COSTS OF FAILURES WHEN TARGETING
EFFORT

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

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 CONCLUSION
1. ALL THE THREE ASPECT i.e, DESIGN,
MATERIAL QUALITY AND APPLICATION ARE EQUALLY
IMPORTANT FOR EFFECTIVE AND DESIRED
PERFORMANCE
2. IN THIS CONNECTION THE MATERIAL &
CONSISTENCY OF PRODUCT IS ESSENTIAL.
3. QUALITY MONITORING OF MATEREIAL PROCURED,
QUALITY MONITORING OF INSTALLTAON, DRY OUT
ARE ESSENTIAL FOR RIGHT PERFORMANCE.

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 58 of 50
 REFRACTORIES DESIGN & ENGINEERING

THANK YOU

Engineers India Ltd – Delivering excellence through people FICCI prog.-2008

Slide Number - 59 of 50