Repair of boiler lining

For any homeowner, keeping their house warm and comfortable throughout the winter is of utmost importance. The boiler is an essential part of your home heating system; it produces the heat that keeps your space comfortable. But over time, regular use can cause the lining in your boiler to deteriorate, which can result in inefficiencies and even safety risks. This post will examine the significance of keeping a boiler lining in good working order as well as the key components of boiler repair.

It is essential to comprehend the function of the boiler lining in order to appreciate the need for repair. A boiler’s lining acts as a shield between the exterior of the boiler and the intense heat generated during combustion. Heat can seep into the boiler’s structure if the lining isn’t working properly, damaging the boiler and lowering its efficiency. Furthermore, a failing lining can raise the possibility of leaks or even possible risks like carbon monoxide emissions.

There are a few warning indicators to look out for when determining whether the lining in your boiler needs to be repaired. These could be obvious fractures or fissures in the lining, uneven heating patterns, higher energy costs as a result of lower efficiency, or odd noises coming from the boiler when it’s working. For your heating system to last as long as possible, prompt repairs are crucial because ignoring these warning indicators could eventually result in more serious issues.

Fortunately, knowledgeable professionals can repair a boiler lining to restore the functionality and safety of your boiler. Assessing the extent of the damage, removing the old lining material, and applying a new lining using specialized methods and materials made to withstand high temperatures and thermal stress are the usual steps in the repair process. In addition to improving your boiler’s efficiency, well-executed repairs guarantee the security of your house and its occupants.

To sum up, keeping your boiler lining functional and well-maintained is essential to the effective operation and security of your home heating system. Your home can stay warm and cozy even on the coldest days if you can identify the warning signs of lining deterioration and take prompt action to fix them with expert repairs.

Materials Needed

Procedure

Insulating material (e.g., ceramic fiber blanket)

1. Turn off the boiler and let it cool completely. 2. Remove the outer casing of the boiler. 3. Clean the surface of the boiler lining to remove any debris or old insulation. 4. Cut the insulating material to fit the dimensions of the boiler lining. 5. Apply adhesive to the back of the insulating material. 6. Carefully place the insulating material onto the boiler lining, ensuring full coverage. 7. Allow the adhesive to dry completely before reassembling the boiler.

DKVR boilers

The systems in this series are intended to supply both heat and heated water. They are frequently utilized in ventilation systems and enable the production of saturated steam. Two drums and tubes positioned vertically are two of the design’s standout elements. This brand’s boilers have a lot of advantages.

• wide power range;
• the use of any type of energy carrier, including fuel oil and gas;
• automated operation of the system;
• The construction can be assembled in the boiler room without dismantling the walls;
• lining of "DKVR" boilers is made of any materials suitable for the intended mode of operation;
• The reliability of the aerodynamic and hydraulic system ensures a high level of efficiency.

Features of protective constructions

Cladding of DKVR boilers and other series can be:- Heavy. It is made of brick (the main wall is made of red brick, in the zone of high temperatures – of fireclay brick) and rests on the foundation slabs of the boiler room. It is used to enclose units with a small capacity and a maximum temperature of up to seven hundred degrees Celsius. The thickness of the fence can be up to 640 millimeters, the load – up to 1200 kg per square meter. In order to exclude the destruction of the wall under the influence of high temperatures in the masonry perform thermal seams filled with asbos cord.- Framed. Characterized by a small mass (up to 400 kg per square meter). Consists of several layers: fireclay brick, red brick, insulation (diatomite, vermiculite) or two layers of heat-resistant concrete, mineral wool. Used in medium and large capacity boilers.- Tubular. Represents successive layers of chromite mass, heat-resistant concrete and thermal insulation boards.

Cladding of hot water boiler description

All used parts need to be free of dirt, corrosion, and mortar droplets before work is done. The connection points for reinforcement should be welded together using electric welding or tied together with wire that has a diameter of approximately 2 mm. Using copper and aluminum wire is not desirable.

To strengthen the concrete, bitumen is evenly applied to the fixing components and reinforcement.

For the formwork, coniferous wood is used, with the exception of larch. The sides that face the concrete mortar are meticulously polished and filed. Gaps in the formwork can be filled with highly malleable clay or paper. When cladding a vertical surface or at an angle of at least 40 degrees, double formwork is appropriate. To prevent the wooden surface from sticking to the concrete, it is advised to apply a lubricant to it. As a lubricant, a mixture of mineral oil and water can be utilized.

Boilers and furnaces are still necessary equipment in industry today, so these buildings frequently require maintenance and modernization. The boiler should also be clad, and any failed components should be replaced if needed.

Cladding of DKVR boiler

Depending on the initial parameters, such as whether to install new protective shields or restore existing ones, the sequence in which these steps are completed may change. The creation of a continuous protective contour of the heavy type is the fundamental technical requirement for boiler lining.

Work is completed in accordance with the following plan:

• Erection of walls. Their thickness should be at least 2 bricks, and for the back wall – 1.5 bricks.
• Only fireclay brick is used.
• Binding materials must withstand the maximum exposure temperature without changing their initial shape.
• Installation of basalt wool is not mandatory, but recommended.

The boiler DE 16 13’s lining is completed in accordance with the same plan. Every case is evaluated on an individual basis for material consumption.

Features of DKVR series boilers

The DKVR brand of heating equipment is utilized in ventilation systems, hot water preparation, and heat supply organization. This brand of boiler is intended to produce saturated steam. They have a system of vertical tubes and two functional drums, which sets them apart from the standard design.

Benefits of DKVR boiler series use:

• Efficiency index up to 91%. This is achieved by reliable operation of hydraulic and aerodynamic schemes.
• Prefabricated construction. It can be assembled in the limited space of the heating unit without dismantling the walls.
• Boiler conversion to different types of energy carrier – gas, fuel oil, solid fuel.
• Variability of power setting – from 40% to 150%. In the latter case, the wear period of components increases.
• Presence of automation system.

Conventional boiler lining materials can also be used. The design mode of operation influences their decision.

What you need to know

Thermal insulation slabs are formed from basalt fiber, which has a high resistance to temperature changes.

There are situations where brickming the boiler partially makes more sense. Treating the structure’s doors can help prevent heat loss and guarantee the security of the operating staff.

Throughout the cooling process, the temperature distribution needs to be monitored.

Disassembling the strapping is the first step in boiler lining repair; it is best to keep the structure’s foundation intact for future use. You can apply a layer of thermal insulator to the screens and pipes if there are any uneven areas. The application of aluminum coloring compounds as a finishing coat can extend the structure’s service life.

Boiler lining technology

Masonry lining scheme.

Only after the boilers’ hydraulic testing is fully completed can cladding be installed. Nevertheless, occasionally the initial rows are planted before the thorough examination is finished. Time is saved by doing this.

There are two phases to boiler cladding: internal lining and external lining. Only refractory mortar and refractory bricks are used to create the lining. The refractory materials used in boiler lining technology must fulfill the following specifications:

1. The sand and cement should be free of any unnecessary debris and hard lumps.
2. The red clay must also be free of any foreign impurities.
3. Refractory clay, quartz sand and fireclay powder must be sifted through a fine sieve before use.

The items listed below are needed for the task:

• refractory mortar;
• equal in thickness brick with even edges;
• construction level;
• wooden hammer.

Upon finishing every row of masonry, use a level to ensure that all convexities and depressions have been laid correctly. The temperature joints are checked using a template, and the accuracy of the corner placement is checked using a metal angle.

We can therefore draw the conclusion that doing the work alone is exceedingly risky and that careful supervision is needed at every turn. It is best to leave cladding to a professional who has been doing it for a number of years because it is a sophisticated and complicated process. Even minor imperfections down the road could cause big problems.

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How to protect boilers by means of cladding

• 14 Feb/
• admin /
• popecham

A series of unique constructions known as boiler cladding are used to create a unique protective shell around the boiler.

Diagram showing the cast iron boilers’ smoke exhaust.

Only boilers without all-welded screens can use cladding. Such a shell offers extra insulation and is essential for allowing all combustion products to exit the boiler correctly. Laundries have the simplest boiler lining because they are designed with brick walls specifically for this use. It should be made clear that cladding can be extremely complex, so it is best left to the professionals. Cast iron boilers do not require additional insulation; only steel boilers do.

Boiler cladding types:

1. Heavy (brick). It is used for small capacity boilers with wall heights not exceeding 12 m.
2. Lightweight (refractory material is used).
3. Light (concrete). It has a small mass.

Repair of lining from piece refractory and heat-insulating products

Tab. 9.17 lists refractory mortar classifications for fireclay bricklaying based on consistency. Section 10.5.2 provides more information on the compositions of air-hardening fireclay mortars and refractory mortars that harden under heat, along with preparation techniques.

Classification of Refractory Solutions (Solution Consistency) Table 9.17

Solution	Fineness of the grinding of the mertel	Cone settlement limits, cm	Joint thickness, mm, not more
Liquid Semi-dense Thick	Thin Coarse Coarse Coarse	6-9 5-6 3-5	1-2 3 5

When disassembling a damaged or disassembled portion of the masonry lining for repair, care should be taken to preserve as many of the items as possible for potential secondary uses, subject to laboratory testing (fireclay items). Sections of disassembled masonry are moistened to minimize dusting. Every exposed masonry fastening component is cleared of mortar residue and made the appropriate repairs.

The process of joining newly constructed masonry with the section that hasn’t been disassembled calls for dressing the strobe "with a runaway." The brick-laying technique and masonry thickness must match those specified in the factory design. Beginning at the corners and moving toward the center is the process of refractory bricklaying. The top row of refractory bricks is placed across the slag movement on the rib when laying boiler floors with liquid slag removal.

To create a level surface for the refractory brickwork, any irregularities or curvatures (within tolerance bounds) in the metal structures, hearth lining, and screen pipes—all of which support the masonry—should be leveled with a layer of thermal insulation.

It is required to prefit shaped or wedge bricks before laying burner embricks. The joint’s thickness shouldn’t be more than 1 mm. It is not advised to use technological openings such as manholes, hatches, etc. ought to be constructed using refractory bricks for the whole lining’s thickness. It is important to use extra caution when installing masonry where pipes pass through the cladding, as well as where movable supports and screen pipe fasteners are located, to prevent these components from becoming pinched in the cladding. Before pouring concrete, cuffs at pipe penetrations through cladding must be firmly secured to the pipes.

The collars’ length ought to be 40 mm greater than the concrete layer’s thickness. The masonry interface between the ceiling and the vertical wall lining needs to have a 20 mm temperature gap.

Lime-silica or perlite-cement thermal insulation boards should be laid dry, with a maximum 3-millimeter space between each board and a minimum 50-millimeter joint overlap. There should be no gaps in the layer of thermal insulation. Pieces of thermal insulation board may be used to fill in the gaps.

The design data must match the space between the metal boiler shell and the outer surface of the thermal insulation layer. When repairing the metal cladding, the gap is measured using a check rail.

The edges of the mineral wool mats must be stitched together with soft carbon wire to create the thermal insulation layer when using metal mesh lining. Mineral wool is to be used to fill the spaces at the mat joints. The insulation layer’s surface needs to be level.

When installing the cladding, permissible deviations from the design dimensions cannot be greater than the information listed in tab. 9.18. Table 9.18. Allowable alterations to the design dimensions for lining

The separation between the screen pipe and cladding axes

The separation measured between the axes of the outermost coils of the superheater, economizer, and lining

The temperature joint’s width

Prominent bricks, bulges, and depressions on the lining surface measuring one meter in length

The exterior surface at a length of one meter is the same.

Diagrams of DKVR units

The unique features of the boiler’s design provide all of its benefits. The coolant circulates more freely and the furnace chamber’s heat is distributed as much as possible thanks to the two tanks and pipe system. However, this complexity has an impact on how much labor-intensive equipment maintenance is.

Examining the DKVR boiler’s circuit components

• Two drums – the upper long and the lower short one. They are located along the axis of the equipment. Separation devices for steam generation are located in the upper one. The lower one is necessary to create water circulation.
• Convective tube bundle. They connect the containers of the drums with each other.
• Shield tube system. They are used to create a circulation system. They are connected only to the upper drum, the return flow is provided by manifolds.

To shield the bottom tank from direct flame exposure, screens are included. When gas or fuel oil is used as fuel, they are required.

When it comes to keeping your home warm and energy-efficient, the condition of your boiler lining plays a crucial role. A well-maintained boiler lining ensures that heat is distributed evenly throughout your home, preventing energy wastage and reducing heating bills. However, over time, boiler linings can deteriorate due to wear and tear, leading to decreased efficiency and potential safety hazards. In this article, we"ll explore the importance of repairing your boiler lining promptly. We"ll discuss common signs of lining damage, such as leaks and uneven heating, and explain how timely repairs can not only improve efficiency but also extend the lifespan of your boiler. Additionally, we"ll provide practical tips on finding qualified professionals for the job and outline the repair process to help you make informed decisions about maintaining your home"s heating system.

Technology of boiler equipment cladding

The technology indicates that boiler lining should not be started until all hydraulic tests have been finished. Rarely, the completion of the boiler equipment strength tests and the first row of the structure are done at the same time. This makes it possible to shorten the time needed for the facility’s final commissioning and work execution.

The inner lining of the furnace is also included in the lining for large boilers. It is constructed using refractory materials (bricks and mortar), just like the exterior. The three main tools required to create the cladding are level bricks, a hammer (ideally made of wood), and a level. Additionally, a dry refractory mixture that has been appropriately diluted is used during the work. The primary phases involved in acquiring the structure are referred to as:

1. Mixing the mortar in a concrete mixer;
2. Checking the correct positioning of the metalwork around the boiler to be protected;
3. laying bricks, the thickness of which must be perfectly matched. In order to maintain the same thickness of the layer, a wooden hammer (mallet) is used to avoid damaging the material;
4. continuation of laying the next rows, which should be located strictly one after another. In this case, be sure to control the filling of the joints with mortar. Leaving unfilled joints can lead to the leakage of flue gases during combustion.

No matter how much you would like it, there are situations when it is just not possible to refuse heating in an apartment building.

There are numerous approaches. Take the burning of potato peelings, for instance.

Make sure to verify that the next row is laid correctly and evenly after finishing each one. A metal angle gauge is used to regulate the laying angles, and a special template is used to check all temperature joints.

Conclusions

It should be mentioned that lining boiler equipment can be highly challenging for an inexperienced worker to complete. Professionals with specialized training and experience are invited to design these kinds of structures. This will decrease labor hours, enhance boiler maintenance safety, and produce better results. When the boiler’s structure is compromised or specific boiler and pipe components need to be replaced, the same experts are called in to repair the boiler lining.

Installation and repair of DKVR boiler cladding

Heavy protective structures made of bricks or blocks are used for this type of unit. In general, the procedure is the construction of a continuous protective lining, three walls of which are 510 mm thick and the rear wall is 380 mm thick (t. е. in two and one and a half bricks). It is also recommended to finish the circuit with basalt wool.An important condition for ensuring the integrity of the lining is its drying, the purpose of which is to remove excess moisture (otherwise, uneven heating of the insulation may occur, which can lead to its cracking). Drying is performed by burning wood on the grate. In this case, the boiler is partially filled with water. The temperature of the masonry must be kept constant to achieve the specified strength and uniformity values.

Experts from "Control Technologies" Ltd. are prepared to handle boiler lining DKVR installation and repairs. The business is authorized to conduct these kinds of operations by all relevant permits. Correcting the fuel combustion modes is necessary after the boiler lining has been installed.

Types and features of boiler lining

There are three distinct lining variations based on the construction density:

• heavy (or brick), which is suitable for boilers with low output and a room wall height of 10-12 meters;
• lightweight, involving the use of fireproof material. A special mesh is used to fix this cladding;
• light, intended for protection of boilers and steam generators of high power.

Understanding what cladding is and which variant will be used for a specific boiler are important considerations. It first affects the insulating layer’s quality, which needs to be sufficiently dense and made without cracks. You should pick your materials carefully and stay away from using broken bricks in order to meet this requirement. Additionally, the resulting masonry’s joints need to be completely airtight and level.

Not only should the brickwork receive special attention, but also the mortar that holds it all together. It needs to be thoroughly mixed in addition to being appropriately prepared.

Refractory clay and fireclay powder are used to make the mortar for fireclay bricks; the quantity used depends on the fat content of the base material. More fireclay will be required the greasier it is. Such clay occasionally has table salt and regular sand added to it.

For a conventional masonry, the thickness of the mortar layer laid should not be greater than 0.3 cm; for a complex variant, it should be even thinner, at about 0.2 cm. As a result, the mixture is mixed as thoroughly as possible to increase its fluidity.

Use a medium density mortar for average quality masonry. And for even simpler options, which are selected for small-capacity boilers, you can make masonry with a mortar that has a consistency like sour cream. It is not desirable to prepare the cladding mixture with unclean liquid. The presence of impurities in the water can lower the quality of the finished cladding project.

Preparation and laying of packing masses on the surfaces of the screens

For the purpose of covering the surfaces of the boiler screens, the packing masses chromite, chromite-magnesite, carborundum, and corundum are utilized.

Liquid glass, refractory clay slurry, sodium tripolyphosphate, and aluminophosphate binder based on orthophosphoric acid were used as binder in carborundum masses.

Phosphate binder carborundum mass has the best performance characteristics.

Tab. 9.15 lists the properties and compositions of packing masses.

Table 9.15 lists the characteristics and compositions of printed masses.

Name of mass	Mass composition	Maximum application temperature, oC	Density, kg/m3	Coefficient of linear expansion (at temperature 20 – 800oC)	Thermal conductivity coefficient (at temperature 300 – 700oC), W/m×oC
1	2	3	4	5	6
Chromite	Chromite mixture СХ-1 or СХ-2, liquid glass with density 1.4 – 1.5 g/cm3, 7% to chromite mixture	1350	2500 – 3200	(7,0 – 8,0)×10- 6	1,1 – 1,3
Carborundum	Black silicon carbide # 160-63 – 40%, # 50-12 – 30%, silicon carbide slurry – 30%, binder over 100%: liquid glass with density of 1.3 g/cm3 – 6%, aqueous suspension of refractory clay with density of 1.13 g/cm3 – 5%	1500	2100 – 2300	5,5×10- 6	4,0 – 4,5
Carborundum on phosphate binder	Black silicon carbide № 160-63 – 40%, № 50-12 – 30%, silicon carbide slurry – 30%, binder over 100%: aluminophosphate binder – 18%, refractory clay – 6%	1700	2100 – 2300	8,9×10- 6	2,0 – 3,0
Carborundum on phosphate binder	Black silicon carbide No. 160-63 – 40%, No. 50-12 – 30%, silicon carbide slurry – 30%, binder over 100%: refractory clay – 5%, tripolyphosphate – 3%	1600	2300 – 2500	5.5×10- 6	5.5 – 7.2
Phosphate-bonded carborundum	Black silicon carbide No. 160-63 – 40%, No. 50-12 – 30%, silicon carbide sludge – 30%, binder over 100%: orthophosphoric acid – 15%, electrocorundum – 10%, refractory clay – 6%	1500	2100 – 2300	4,1×10- 6	4.0 – 6.0
Corundum on aluminophosphate binder	Corundum № 400-100 -25%, refractory clay – 25 – 35%; binder over 100%: orthophosphoric acid 75-percent – 15%	1650	2100 – 2400	7,6×10- 6	0.8 – 1.2
Chromomagnesite	Chromomagnesite grain composition: grain from 7 to 3 mm – 40%,

Between 1 and 0.09 mm – 30%, less than 0.09 mm – 30%; binder over 100%: refractory clay – 6%, sodium silicofluoride – 1%, liquid glass density of 1.4 – 1.5 g/cm3 – 10%

Section 10 contains the compositions and characteristics of heat-resistant concrete.

Prior to the need to prepare the padding masses:

• – Dilute liquid glass with water and bring it to the specified density;
• – refractory clay should be dried, ground and sieved through a sieve with holes not exceeding 1 mm;
• – dissolve refractory clay in water;
• – density of clay suspension should be 1.13-1.15 g/cm3.

Grind larger grains in ball mills with steel grinding bodies to prepare fine grain carborundum.

Paddle mixers are used to prepare the masses. After adding the dry ingredients to the mixer and mixing for three minutes, add the liquid ingredients in any order without pausing the machine. The mass is agitated for ten minutes after all the ingredients have been added to the mixer.

Within 1.5 hours of preparation, prepared packing masses—particularly chromite and carborundum—are utilized in business. The mass should be kept in closed containers to prevent drying out and solidifying. The healed mass cannot be reapplied.

Sandblasting the treaded and smooth screen pipes, chambers, and other steel surfaces is necessary prior to laying the packing masses. The mass on the ignition belts is packed so that there is a 3-5 mm layer of compacted mass over the studs. The mass is piled on the studded pipes with a sufficiently large area at once. It should be remembered that stratification results from packing the mass into multiple layers spaced at different intervals.

Using pneumatic hammers, the mass is compressed through a 200×200 mm steel plate with a thickness of 12–15 mm. There are no spaces between the spikes and pipes; the mass is firmly packed. Applying pressure to the hand with a force of 10–15 kg on the thumb will reveal the degree of sealing. At the same time, the mass’s surface ought to be devoid of any discernible traces.

While placing the bulk beneath boilers that have had liquid slag removed, burner embrasures, etc. ο. It is advised to arrange the masses in layers no thicker than 100 mm. Pneumatic tampers or manual wooden tampers are used to compact the material. Should the second layer need to be applied, the surface of the first layer is divided into 80 x 80 mm squares, with a depth of 7-8 mm. It is preferable to lay the masses continuously, particularly when the layer thickness is high. It makes sense to use hot water that is 60 °¡ to quickly dry the mass after it has been laid through the screens.

Purpose of boiler lining

Boiler lining’s primary function is to shield the environment from flue gases. It is possible to attribute additional goals for the same design to:

• reducing heat loss from the unit (and thus increasing its efficiency and reducing fuel costs);
• preventing the intake of outside air into the gas ducts, in which the pressure is reduced;
• ingress of flue gases from gas ducts at pressure rise.

The boiler’s surface temperature is one of the requirements that the lining must meet. In areas where personnel can touch it, the temperature should not be higher than 45 degrees; in other areas, it should be as high as 55 degrees. In this instance, the specific heat losses fall within the 350 W/m range.

Cavitation heat generators are too noisy to be used for home heating under domestic conditions.

Properly installing foam on the facade will drastically cut down on the amount of heat that escapes the room.

Boiler equipment cladding comprises structural elements such as insulation, brickwork, metal fastening, and sealing cladding (refer to the table below). The temperature inside the boiler and the degree to which the fuel slag affects the furnace are taken into consideration when choosing the density and thickness. The lining should be thicker and stronger the higher these values are.

Cladding of DKVR boilers

Steam boilers series DKVR are double-drum vertical-water-tube units with gas-oil furnaces, used in heating and hot water supply systems, ventilation, as well as in the technological chains of industrial enterprises. The units are characterized by high efficiency (over 90%), the possibility of using several types of fuel, compatibility with different types of control and measuring equipment and burners, regulation of working power within the range of 40-150% of the nominal one. In the process of equipment operation there is a low level of maintenance costs.DKRV series boilers are not equipped with all-welded protective shields, so to reduce heat losses, maintain the required temperature over the entire surface of the unit, to eliminate the risk of burns to the operating personnel is performed cladding unit. Characteristics of the protective structure depend primarily on the capacity of the equipment, temperature on its inner surface, the nature of the impact of slag and ash on it.

Making sure your boiler is adequately insulated is essential to preserving its lifespan and energy efficiency. Your boiler’s lining serves as a barrier to keep out corrosion and extremely high temperatures. The integrity of this lining may be compromised over time by wear and tear, which could result in malfunctions and inefficiencies.

Boiler lining repair is an investment in your home’s long-term safety and comfort, not just a way to solve a problem. You can stop future damage and save money on expensive repairs by taking care of problems as soon as they arise. In addition to running more smoothly, a well-maintained boiler lowers your carbon footprint and promotes environmental sustainability.

Consulting with qualified professionals is crucial when considering boiler lining repair. DIY attempts at such repairs run the risk of causing more harm or even danger to one’s safety. Putting your trust in skilled technicians guarantees that the work is done correctly, providing you confidence in your heating system and peace of mind.

Early detection of any possible problems with the lining in your boiler is dependent on routine maintenance and inspections. Regular check-ups allow you to identify issues before they become more serious, ultimately saving you time, money, and trouble. When it comes to maintaining the heating system in your home, keep in mind that prevention is always preferable to treatment.

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