contents why superon superon in thermal power stanvac in thermal power
TRANSCRIPT
Stanvac – Superon
Services to Thermal Power Industry
Contents
Why Superon Superon in Thermal PowerStanvac In Thermal Power
Why Superon
…Enhancing Components Life …Cost reduction of 10-15 %
ILL effects of Welding
Heat input, while welding leads to Creation of HAZ besides the Welded Zone
HAZ is the vulnerable area- for the welded joints
to fail
HAZ is hard and brittle – hence Cracks
Sudden/ Dynamic loads make the welded area
crack from the HAZ
Superon’s Technology basis for component life enhancement
- Lowest in class HAZ
How Superon Achieves lowest in Class HAZ
• Lowest in class input amperes
• Lowest in class arc gap
We can Demonstrate our technologies via comparitive
Demonstrations
• Lowest Input Amps
• Lowest Arc Gap
• Bead Finish
Superon’s Applications in Process Industries
• Cement
• Power
• Sugar
• Steel
• Paper
• Forging…
Features Applications Demo Free trials Outcome- FADFO
• Total application – Payment after successful completion of the trial
period– Pro-Rata payments for longer trial periods.– Full job on FOC basis to prove the superiority
One of the above depending on the application and your requirements
Thermal Power Industry
Ring Granulator Hubs
• Application Requirements– Abrasion Resistance– Impact Resistance– Slight Erosion Resistance
• Base Material– 14% Manganese Steel
• Superon Recommendation– Base Layer with Super Stanhard MN
73 ( to be used for building up worn out ones)
– Hardfacing with Super Stanhard AC 76 ( only this for new Hubs)
• Product USP’s– MN 73 is work hardening nickel fortified –
Hence better impact and bond strength – Does not chunk out – 50 HRc ( WH)
– AC 76 – High hardness best suited for Abrasion resistance- High wear Factor – 63-67 HRc
• Very Fine stress relief checks• Single Layer Hardness• No chunking• Good erosion resistance
Roller Crushers
• Application Requirements– Abrasion Resistance– Impact Resistance
• Base Material– 14% Manganese Steel/ Cast Steel
• Superon Recommendation– Base Layer with Super Stanhard MN
73/ FC 72 ( to be used for building up worn out ones)
– Hardfacing with Super Stanhard CC 78 ( only this for New Rollers)
• Product USP’s– MN 73 is work hardening nickel fortified –
Hence better impact and bond strength – Does not chunk out – 50 HRc ( WH). To use FC 72 in case of Cast Steel
– CC 78 – High hardness best suited for Abrasion resistance- High wear Factor – 63-67 HRc
• Very Fine stress relief checks• Single Layer Hardness• No chunking• Good erosion resistance
Ring Granulators
• Application Requirements– Abrasion Resistance– Impact Resistance
• Base Material– 14% Manganese Steel/ Cast Steel
• Superon Recommendation– Base Layer with Super Stanhard MN 73 (
to be used for building up worn out ones)
– Hardfacing with Super Stanhard AC 76
• Product USP’s– MN 73 is work hardening nickel fortified
– Hence better impact and bond strength – Does not chunk out – 50 HRc ( WH).
– AC 76 – High hardness best suited for Abrasion resistance- High wear Factor – 63-67 HRc
• Very Fine stress relief checks• Single Layer Hardness• No chunking• Good erosion resistance
Crusher Sieves
• Application Requirements– Impact Resistance
• Base Material– 14% Manganese Steel
• Superon Recommendation– Crack Joining with Super Stanalloy
EM 35– Hardfacing on the sieve corners with
Super stan hard AC 76
• Product USP’s– EM 35- Best alloy with excellent
elongation & High TS for joining Mn Steel.
– AC 76 – High hardness best suited for Abrasion resistance- High wear Factor – 63-67 HRc
• Very Fine stress relief checks• Single Layer Hardness• No chunking• Good erosion resistance
Mill Discharge Valves
• Application Requirements– Erosion Resistance
• Base Material– Cast Steel
• Superon Recommendation– Hardfacing with Super Stan Hard AC 76.– Can give single layer hardness
without affecting the flow parameters
• Product USP’s– AC 76 – High hardness best suited for
Abrasion resistance- High wear Factor – 63-67 HRc
• Very Fine stress relief checks• Single Layer Hardness• No chunking• Good erosion resistance
Multi Port Outlet
• Application Requirements– Erosion Resistance
• Base Material– Cast Steel
• Superon Recommendation– Hardfacing with Super Stan Hard AC 76.– Can give single layer hardness
without affecting the flow parameters
• Product USP’s– AC 76 – High hardness best suited for
Abrasion resistance- High wear Factor – 63-67 HRc
• Very Fine stress relief checks• Single Layer Hardness• No chunking• Good erosion resistance
Mill Table RJ Shaft
• Application Requirements– Frictional Wear Resistance– Low Temperature welding
• Base Material– Forged Alloy Steel
• Superon Recommendation:– Super Stanalloy DS 34
• Product USP’s– DS 34 – can be used at lowest
possible currents in its class– Deposits exhibit a very low coeff of
friction.– Can be used on highly contaminated
surfaces directly– Can be used for all dissimilar steel
and high alloys steels– Highly crack resistance- Longer life of
important components
Sinter Cast Table Liners – Roller Segments
• Application Requirements– Good Bonding on CI– Impact Resistance– High Abrasion Resistance
• Base Material– Special Cast iron with Sinter’s Embedded
• Superon Recommendation:– Super Stan Hard UL 81
• Product USP’s– UL 81 – Exhibits high penetrations
with CI– High Hardness of 68-70 HRc– Minimal or no Stress relief checks– Boron rich carbides showcasing high
abrasion resistance– High Impact resistance on this
application – best suited for this kind of application
Nozzle Ring Segments
• Application Requirements– High Erosion Resistance– Medium Abrasion Resistance– Single Layer Hardness
• Base Material– Wear Resistant Cast Steel
• Superon Recommendation:– Super Stan hard CC 78
• Product USP’s– CC 78 Gives a complex carbide kind of
deposit hence a high wear factor– Very minimal and fine stress relief
checks – hence good erosion resistance
– Deposits are slag free – high metal recovery and higher deposition efficiency
– Deposits Exhibits 63-67 HRC– Good resistance to Erosion/ Abrasion
Coal Mill Body - Liners
• Application Requirements– High Erosion Resistance– Medium Abrasion Resistance– High Wear Factor
• Base Material– Structural Steel
• Superon Recommendation:– Super Stan Plate 55
• Product USP’s– High Hardness of 58-61 HRc– Minimal Relief checks – hence
increased erosion resistance– Better bead wash and Over lap leading
to Better life– Automatic welding leading to uniform
hardness all across.– Due to better orientation of Carbides,
this gives the best erosion resistance for this application
Coal Mill – Reject Cones
• Application Requirements– High Erosion Resistance– Medium Abrasion Resistance– High Wear Factor
• Base Material– Structural Steel
• Superon Recommendation:– Super Stan Plate 56
• Product USP’s– High Hardness of 59-61 HRc– Minimal Relief checks – hence
increased erosion resistance– Better bead wash and Over lap leading
to Better life– Automatic welding leading to uniform
hardness all across.– Due to better orientation of Carbides,
this gives the best erosion resistance for this application
Coal Burner Tips
• Application Requirements– High Erosion Resistance– Temperature– Minimal Turbulence on the weld deposit
• Base Material– SS 310
• Superon Recommendation:– Super Stan Hard (T ) 93
• Product USP’s– High Hardness of 63- 67 HRc– Minimal Dilution inspite of SS 310 BM
and hence low hardness reduction– Comparitively smooth beads – leading
to low turbulence and hence better efficiency
– Can resist high temperatures.– Nil slag design– Low- find stress relief checks hence
better erosion resistance
Coal Burner Nozzles
• Application Requirements– High Erosion Resistance– Minimal Turbulence on the weld deposit
• Base Material– Cast iron
• Superon Recommendation:– Super Stan Hard (T ) 91
• Product USP’s– High Hardness of 61- 63 HRc– Bonds well on Cast Irons– Comparitively smooth beads – leading
to low turbulence and hence better efficiency
– High hardness on the first layer– Nil slag design– Low- find stress relief checks hence
better erosion resistance
Sinter Crushers - AHP
• Application Requirements– High Abrasion Resistance– Temperature resistance– Impact Resistance
• Base Material– Cast Steel/ Manganese Steel
• Superon Recommendation:– Build up with Super Stan Hard FC 72 – Cast
steel / MN 73 for Mn steel– Top layers with Super Stan Hard CC ( T ) 91
• Product USP’s– High Hardness of 61- 63 HRc– Bonds well on Cast steels– Comparitively smooth beads – leading
to low turbulence and hence better efficiency
– High hardness on the first layer– Nil slag design– Low- find stress relief checks hence
better erosion resistance
Screw Conveyors - AHP
• Application Requirements– High Abrasion Resistance– Erosion Resistance– Corrosion Resistance
• Base Material– Structural Steel
• Superon Recommendation:– Super Stan hard CR 77
• Product USP’s– Exhibits High hardness of 57-60 HRc.– High Wear factor due to Complex and
primary Hexagonal Chromium Carbide deposit
– Deposits are bald – exhibiting high erosion resistance
– Can take temperatures also– Good corrosion resistance also
Pumps- AHP
• Application Requirements– High Erosion Resistance– Corrosion Resistance– Moderate Impact
• Base Material– Alloyed Cast Iron
• Superon Recommendation:– Super Stanalloy FN 65 for base– Hardface with CR 77
• Product USP’s– Best suited for Alloyed Cast iron– Excellent bonding to these types– Ease of machining– High Crack resistance– CR 77 has good resistance
• Abrasion• Erosion• Corrosion• Impact &• Heat
ID Fans
• Application Requirements– High Erosion Resistance– Moderate Heat
• Base Material– Structural Steel
• Superon Recommendation:– Super Stan alloy HT 79
• Product USP’s– Best suited for High erosive
atmospheres– Can withstand high heat– Minimal and fine stress relief check
making it the best suited for highly erosive applications
– Nil slag design – Hence high recovery and deposition efficiency
Coating Applications
Power Industry
Machine Stacker Reclaimer
ComponentAlkyde Enamel Structures
Base MetalFabricated structure
Stanvac Solution
Polyhyb 2050 (1040+725)
Customer Benefits• Low Application Time• Self Priming• Higher Corrosion Resistance• Double the Life of Alkyede Enamel
Power Applications
Power Applications
Machine Stacker Reclaimer
Component Conveyor Belts
Base MetalRubber with Cotton/ Nylon Ply
Stanvac Solution
717 Polyurethane Kote- Black
Customer Benefits
• Lower Cost of Reclamation• Better than Hot/ Cold Vulcanising• Fast curing- Lower down time• Can be used on all areas like edges, Centre portion or
any
Power Applications
Machine Bowl Mill
Component Pipe Bends
Base Metal Struc Steel
Stanvac Solution
731Stangard ER
Customer Benefits
• Zirconium Carbide based- High abrasion/ erosion resistant.
• Lower down time.• Insitu application.• Enhanced life > 4 times MS
Power Applications
Machine Coal Lines
Component Orifices
Base MetalStruc Steel+ Ceramics
Stanvac Solution
731Stangard ER
Customer Benefits
• Zirconium Carbide based- High abrasion/ erosion resistant.
• Lower down time.• Insitu application.• Enhanced life
Power Applications
MachineElectrical panel Areas
ComponentDie Electric Flooring
Base MetalConcrete/ Tiles/ marbles
Stanvac Solution
1311 Insulkote A / B
Customer Benefits
• Meets requirement of 15652.• BDV of more than 34/ 45 KV in air medium• Abrasion resistant & No tracking due to non
accumulation of dust.• Non Inflammable• Repairable
Power Applications
Machine Pumps- utilities
ComponentCasing & Impellors
Base Metal Grey Cast Iron
Stanvac Solution
1170/1180 or731/1180
Customer Benefits• Improves the efficiency- hene lower energy consumption• Higher Abrasion/ Erosion resistance- Higher life
Power Applications
Machine Work Shop
ComponentShafts/Emergency Leak Reapairs
Base MetalForged Steel / bar stock
Stanvac Solution
815 StangardSteel Putty
Customer Benefits
• Ultra High Compressive strength• Fast curing• Repeated no of applications• Machinability. Good Shore hardness• Temperature range -100C to +2000C
Power Applications
Machine Chimney
Component Chimney
Base Metal Concrete
Stanvac Solution
754( Inner)754+ 725 ( Outer)
Customer Benefits
• Stops carbonation of the concrete• Improved Aesthetics- Prevents lichen, moss and fungus
growth• Protects moisture and Vapour Migration- Rebar
Protection
Power Applications
Machine Cooling Towers
Component Cooling Tower
Base Metal Concrete
Stanvac Solution
1311 MVT System
Customer Benefits
• Stops carbonation of the concrete• Improved Aesthetics• Enhances Life.• High Tolerance to Salt & Chloride• Wet Tolerance capability – best suited for Cooling towers
Power Applications
Machine DM Plant
Component DM Tank
Base Metal Concrete
Stanvac Solution
1311MVT System
Customer Benefits
• Stops carbonation of the concrete• Improved Aesthetics• Enhances Life.• High Tolerance to Salt & Chloride• Wet Tolerance capability – best suited for Cooling towers• Minimum Downtime – On damp surface• Negative Pressure applications
Power Applications
Machine DM Plant
Component DM Flooring
Base Metal Concrete
Stanvac Solution
754/756*+ 727 System
Customer Benefits
• Stops carbonation of the concrete• Improved Aesthetics• Stops Water Ingress• Increased Flooring life
Power Applications
Machine Bowl Mill
ComponentReject Cone - Outer
Base Metal Strutural Steel
Stanvac Solution
Stangard 731 ER/1190
Customer Benefits
• Abrasion Resistant• Erosion Resistant
Power Applications
Machine Bowl Mill
Component MDV
Base MetalSt Steel+ Ceramic Tiles
Stanvac Solution
731Stangard ER
Customer Benefits• Abrasion Resistant• Erosion Resistant• No need to replace the total MDV.• Low downtime
Power Applications
Machine Bowl
Component Multi Port Outlet
Base MetalSt Steel+ Ceramic Tiling
Stanvac Solution
731Stangard ER
Customer Benefits• Abrasion Resistant• Erosion Resistant• No need to replace the total MPO.• Low downtime
Power Applications
Machine Boiler
Component Coal Nozzle
Base Metal Cast Steel
Stanvac Solution
731Stangard ER
Customer Benefits• Abrasion Resistant• Erosion Resistant• Low downtime• Higher Life
Power Applications
Machine Bowl Mill
Component Nozzle Ring
Base Metal Fabricated/ Cast
Stanvac Solution
731Stangard ER
Customer Benefits
• Abrasion Resistant• Erosion Resistant• Insitu applications- No down
time
Power Applications
Machine Battery room
Component Flooring
Base Metal COncrete
Stanvac Solution
4029 System
Customer Benefits• 98% H2SO4 33% HCL resistance• 100 % Volume Solids• High Build
Power Applications
Machine GCT
Component Scrubbers
Base Metal Steel
Stanvac Solution
1040+ 718EGF-NV+ 727*
Customer Benefits• 98% H2SO4 33% HCL resistance• 100 % Volume Solids• High Build
Power Applications
Machine Flue Gas Ducts
Component Flue Gas Ducts
Base MetalSt Steel With Insulation
Stanvac Solution
Aluclad 710/ 706 Stangard
Customer Benefits• Heat Resistance- upto1600C• Stops Corrosion due to sweating• No reduction of shell thickness• 710- Stop Moisture Entry into the Ducts
Power Applications
Machine Condensors
Component End Shields
Base Metal Cast Steel
Stanvac Solution
1180
Customer Benefits• Heat Resistance• Stops Corrosion• No reduction of Plate thickness.• Stops leakage
Power Applications
MachineAlkali & Acid Metering Tanks
Component Tanks
Base Metal Structural Steel
Stanvac Solution
Stangard706+1040Stangard+715 Stangard EGF( NV)
Customer Benefits• Resistance to Alkali’s & Acids• Good adhesion to Structural• Good Flexural Strength• Resistance to 33 % HCl, 98% H2So4
Applications for 1040+ 725/727*• Bowl Mills Outer• Stacker Reclaimer• Boiler Structures• Ash Handling plant Structures• Ash Handling Pumps.• Coal Handling plants
• Cleaning by Water• Coating before drying – Wet Surface Tolerance• Long durable life than standard Epoxies• No Blistering – Hence higher life.• PUTC gives anti sticking properties apart from UV resistance
Power Applications
Thank You