RCBM - Batangas Plant SPSI Technical Shutdown Report

2019 Burner Pipe Refractory Lining Installation

SPECIALIZED PRODUCTS AND SERVICES INC.

3rd Flr. Orcel II Bldg., #1611 Quezon Avenue, Quezon City

RCBM - BATANGAS PLANT

BURNER PIPE REFRACTORY LINING INSTALLATION PROCEDURE

A. LINING DESIGN

1. Lining Configuration
a. The burner pipe lining is a combination of Calde Cast Gibram and
Calde Flow LS 60 with ratio of 1:2 at the top and 3:1 at the bottom +
2.5% Stainless Steel Fiber). Calde Cast Gibram is low cement
castable containing more than 80 % alumina and Calde Flow LS 60
is a special material self-flowing low cement dense castable
containing 60% Silicon Carbide.

2. Anchoring System – the anchoring system is based on the burner pipe

manufacturer design and recommendation.
a. Material – Stainless Steel 310 8-10 mm diameter Rod
b. Burner Pipe – V anchor directly welded to the burner pipe shell.
c. Spacing – 60mm Radial x 130mm Longitudinal
d. The anchor is a special “V” type and Y type shaped per attached
drawing.
e. Expansion of the anchorage is allowed for by the two plastic caps
fitted on the ends, which melt on heating up thus creating the
necessary spaces.

3. Expansion Joints
a. The upper portion has an expansion joint spaced at 900 mm. Using
plywood and ceramic fiber blanket with thickness not exceeding
6mm. We can used plywood for vertical expansion and ceramic fiber
blanket for horizontal expansion. The expansion depth is 1/3 of the
lining thickness.
b. At the lower half of the lining, expansion joint spacing is 300 mm
starting from 1 meter after the tip. The closer spacing of expansion
was needed not only to allow for the castable expansion during
exposure to high temperature but also to give room for the
compressive stress under hot load brought about by the deformation
of the steel (bending stress) during operation, taking into
consideration the length of the pipe.

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3rd Flr. Orcel II Bldg.,#1611 Quezon Avenue, Quezon City Telefax # +63 2 352 1432
Manila, Philippines DL +63 2 352 1732
Website: spsi-phil.com Email: spsi@info.com.ph
RCBM - Batangas Plant SPSI Technical Shutdown Report
2019 Burner Pipe Refractory Lining Installation

A. INSTALLATION PROCEDURE

GENERAL INSTALLATION SEQUENCE

1. Installation of scaffolds for burner pipe stand.
2. Setup of equipments for demolition and welding machines for anchoring.
3. Demolition of the damaged lining.
4. Removal of damaged anchor. Ensure that remains of the old anchors are
removed and that the shell is cleaned prior to the installation of new
anchors

5. Installation of new anchors. In installing the anchors, make sure that all
actual conditions are in accordance with the specification, i.e., spacing,
size, anchor orientation and make sure that all plastic caps are in place.
6. Double check the welding integrity by visual inspection and by hammer
testing.
7. After checking all structural supports and anchors, prepare the area for the
installation of formworks.
8. Care in the construction of formworks should be observed, the weight of
the lining is the major consideration in constructing the formworks if
continuous casting will be adopted. If the material is a self flowing, little
vibration is needed. Make sure that the formworks are properly supported
to hold the total weight of the lining.
9. The size of the formworks panels that are joined together must not exceed
900mm x half circumference of the burner and 300mm x half
circumference of the burner to allow insertion of 12.5 mm expansion joint
in between. Dept of expansion joints is 2/3 of the total lining thickness or
up to the groove.
10. Casting should start at the Bottom of the pipe. After casting the first
layer/panel wait for 3 to 4 hrs before casting the next length of the pipe to
prevent disturbance on the setting of castable that may caused cracking or
damage.
11. Make sure that all Standard Procedures for installing low cement castable
are followed during installation.
12. Allot 24 hours of curing for the service lining for it to attain its maximum
strength.
13. Ocular inspection of newly installed lining.

B. CASTING PROCEDURE

BEFORE MIXING
1. Analyze and study specification or technical data sheet of the castable to
be used. Individual instructions on the bag give specific information for the
particular product.
2. Check the ambient temperature.
3. Check the water for mixing, it must be
. between temperature of 15 deg C to 25 deg C.

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3rd Flr. Orcel II Bldg.,#1611 Quezon Avenue, Quezon City Telefax # +63 2 352 1432
Manila, Philippines DL +63 2 352 1732
Website: spsi-phil.com Email: spsi@info.com.ph
RCBM - Batangas Plant SPSI Technical Shutdown Report
2019 Burner Pipe Refractory Lining Installation

. potable
. sufficient for continuous casting.
4. Check the shelf life of the castable. Do not use castable which has
deteriorated in storage. Do not use castable with hard lumps in it.
5. Check anchoring installation – Design, spacing and expansions as
describe above.
6. Check formworks installation – Dimension, water proofing, polyethylene
cover, acrylic lacquer, and bitumen paint or form oil can be used.
Shuttering can be made up of wood or steel.
7. Cover the burner Pipe tip to avoid concrete inside of the burner.
8. Check all equipments needed. Minimum equipment needed as follows:

Item Equipment and Specification Min Qty

Tools
1 Paddle Mixer High Intensity Bottom Ideal is
Discharge
40 to 50 rpm paddle speed. 2 units
200 kg Capacity if available

2 Internal Vibrator High frequency Internal vibrator Ideal is

with 6000 to 9000 2 units
vibration/min.
At 1 ½ (38 mm) poker
diameter.
3 Calibrated Bucket Calibrated bucket for 1 unit, 1
measuring
water, at least 1 liter capacity spare
4 Bucket Container For transferring mix castable 10 pcs
5 Shovel Masonry shovel 2 pcs
6 Plastering Trowel Masonry trowel 3 pcs
7 Mixing Board For Holding mix castable at 3 pcs
mixer discharge

9. All mixing and handling equipment must be cleaned to eliminate

contamination of castable, specially the mixer.
10. Wear safety protection, i.e., dust mask, spectacles and working gloves.

MIXING
1. Mix only needed weight of castable to minimize wastage.
2. Dry mix or premix castable for at least 10/30 seconds prior to water
addition.
3. Avoid contamination of material and water. It may cause castable to set
slowly or not set at all.
4. Use the correct amount of clean potable water.
Calde Cast Gibram – 5.0 % to 6.0 % by weight
Calde Flow LS 60 - 6.5 % to 8.0 % by weight

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3rd Flr. Orcel II Bldg.,#1611 Quezon Avenue, Quezon City Telefax # +63 2 352 1432
Manila, Philippines DL +63 2 352 1732
Website: spsi-phil.com Email: spsi@info.com.ph
RCBM - Batangas Plant SPSI Technical Shutdown Report
2019 Burner Pipe Refractory Lining Installation

5. Mix properly. Using a high intensity paddle mixers, 40 to 50 rpm. Standard

mixing time for low cement is 6 to 8 minutes. Check the workability of the
castable by using the ball in hand technique.

PLACING ( CASTING )
1. The installation time as much as possible should not exceed 30 minutes
from the discharge.
2. The surface of the steel of the Burner Pipe shall be cleaned of all loose mill
scale, rust, oil grease or other foreign materials. There shall be no coating
on the surface of the steel of the pipe.
3. Use high frequency internal vibrator in the lining with frequency between
6000 to 9000 vpm. Vibrator shall be drawn slowly through the castable so it
does not leave voids or channels behind. Vibration time should be between
1.5 to 3 minutes.
4. After finishing the first segment 1 meter high starting from the bottom of the
pipe, wait for 3 to 4 hrs for the castable to set before casting the
succeeding length of the burner. This may prevent castable for any
disturbance on the setting that may cause possible cracking or damage
and may lost the quality and performance of the castable. Provide
expansion joint before casting the next length. Casting should start from
the bottom going up.
5. Don’t smooth surface after casting as this causes an accumulation of the
fines and forms a smooth surface which stops the escaping vapor.
6. Casting must be done continuously until the required full thickness is
attained per panel.
7. Follow same procedure for the remaining blocks/panel.

AFTER CASTING
1. Removed the formworks after 24 hours.
2. Perform hammer testing after 24 hours of curing. Using 1 lb ball pin
hammer, strike the lining about 6” drop, any portion found void shall be
repaired.
3. Records shall be kept for future references for all installed castable, i.e.
weight of castable mix, total amount of water added, etc.

CURING
1. Panels being cured shall be covered by plastic covering to prevent
possible loss of water due to evaporation during this period.
2. Or castable surface can be sprayed intermittently with a fine spray after the
material reached its initial set at an interval of 1 hour.

REPAIR
1. Defective areas found after curing shall be entirely removed down to the
casing. Crack wider than 1.5 mm spaced at 200 mm shall be repaired.
2. To repair damaged lining, remove the affected lining exposing a minimum
of 2 anchors. The newly exposed refractory and the pipe shell should be

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3rd Flr. Orcel II Bldg.,#1611 Quezon Avenue, Quezon City Telefax # +63 2 352 1432
Manila, Philippines DL +63 2 352 1732
Website: spsi-phil.com Email: spsi@info.com.ph
RCBM - Batangas Plant SPSI Technical Shutdown Report
2019 Burner Pipe Refractory Lining Installation

thoroughly cleaned of loose refractory and should be water sprayed prior to

application of the same refractory material as original.
3. Normal curing and drying are again required.

HOUSE KEEPING
1. Clean all equipments and tools used.
2. Disposed all waste to designated areas.

INITIAL HEAT UP
1. Heat up of castable the first time should be in accordance with the
manufacturer schedule. For minimum requirement, we have the following
schedule :

Do not increase the temperature of the hot gas in contact with the castable
at a higher rate than 55 C per hr. At 120 C and 260 C, the temperature
should be held a minimum of ½ hr per inch (25 mm) of castable thickness.
After the final holding period, continue to increase the temperature at a rate
no higher than 55 C per hour to maximum intended temperature.

Heroven Balasabas
Safety Officer

Rhedel Puno
Project Supervisor

Approved By:

Area Champion

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3rd Flr. Orcel II Bldg.,#1611 Quezon Avenue, Quezon City Telefax # +63 2 352 1432
Manila, Philippines DL +63 2 352 1732
Website: spsi-phil.com Email: spsi@info.com.ph