GCD KA-Weld® Preformed Modular Pipe Insulation

Description

KA-Weld® Preformed Shapes

Ka-Weld® has been supplied to the steel industry by the Sterling Industries PLC companies (Bloom Engineering, Urquhart, PCCS and GCD International) since 1949.

Ka-Weld® preformed shapes are a precast modular refractory system reinforced with three dimensional heat resisting steel mesh.

In addition to strengthening each refractory module, the three dimensional heat resisting steel mesh assists in connecting the modules to each other and to the water cooled steel pipe support structure itself.

The steel mesh reinforcement substantially increases the life expectancy of each Ka-Weld® preformed shape.

In the case of composite Ka-Weld® preformed shapes, where ceramic fibre is used to improve the insulation ability (ie. reduce the heat loss through to the water in the water-cooled pipes below), the three dimensional heat resisting steel mesh protects and secures the ceramic fibre in place next to the water cooled pipes

Continuous Improvement

The Sterling Industries PLC Group continues to develop better and more cost effective Ka-Weld® preformed modules through research and development programs within the group.

A range of Ka-Weld® preformed shapes, either cast or pressed, or ceramic fibre modules are available within the group to satisfy the water cooled pipe support structures of most modern re-heat furnaces.

Emphasis on product development has always been placed on product life, reliability, and ease of installation.

• Ease of Installation:  Many of the designs now simply hook on or bolt on to the water cooled pipe support structure.  Being modular and sized for easy handling within the furnace, installation is cleaner, simpler and faster.  There is no need for forms and moulds or support scaffolding

• Long life:    BHP in Australia has installed cast Ka-Weld® preformed modules in almost all of their re-heat furnaces.  Some of the cast Ka-Weld has been in place for over 11 years

Types of Insulation Systems for Water Cooled Pipe Structures

There are basically two ways to insulate the water cooled pipe support structures in re-heat furnaces:

• Using preformed refractory shapes such as Ka-Weld®.
• Using cast in place refractory materials

A survey of the water cooled skid pipe systems in all the under fired re-heat furnaces in the USA and Canada in March

• 70% of the surface area of water cooled support pipe was insulated with preformed refractory shapes.
• 27% of the surface area of water cooled support pipe was insulated with cast in place, and
• 3% of the surface area of water cooled support pipe was insulated by other methods

It is interesting to note that the 27% mentioned for water cooled support pipe insulated with cast in place represents almost all new first time insulated, walking beam re-heat furnaces in USA and Canada.  Since then almost all of the 27% have chosen to repair the cast in place with preformed shapes.
 

Preformed Shapes

Some of the advantages of preformed shapes include::

• Consistent high quality because they are manufactured under controlled shop environment

• Quick and easy to install

• Allow burner operators to maintain a high level of coverage

• Require no added downtime to dry out.  They are pre-cured during manufacture.

• Long lasting service life

• Eliminate welding in most applications

• Protect water cooled support structure

• Improve furnace temperature uniformity

• Can be designed for virtually all pipe sizes and configurations

• Does not require the welding of large numbers of  anchors to the pipe. As noted below, anchors  increase heat loss to the bare pipe when exposed

A survey of the water cooled skid pipe systems in all the under fired re-heat furnaces in the USA and Canada in March 1995 revealed:
 

• 70% of the surface area of water cooled support pipe was insulated with preformed refractory shapes.
• 27% of the surface area of water cooled support pipe was insulated with cast in place, and
• 3% of the surface area of water cooled support pipe was insulated by other methods

It is interesting to note that the 27% mentioned for water cooled support pipe insulated with cast in place represents almost all new first time insulated, walking beam re-heat furnaces in USA and Canada.  Since then almost all of the 27% have chosen to repair the cast in place with preformed shapes.
 

 

 

 

 

 

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