Transcript Base Material - Stanvac Superon Group

Contents
Why Superon
Superon in Thermal Power
Stanvac In Thermal Power
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
Ring Granulator Hubs
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Application Requirements
– Abrasion Resistance
– Impact Resistance
– Slight Erosion Resistance
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Base Material
– 14% Manganese Steel
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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)
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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
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Very Fine stress relief checks
Single Layer Hardness
No chunking
Good erosion resistance
Roller Crushers
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Application Requirements
– Abrasion Resistance
– Impact Resistance
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Base Material
– 14% Manganese Steel/ Cast Steel
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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)
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Product USP’s
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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
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Very Fine stress relief checks
Single Layer Hardness
No chunking
Good erosion resistance
Ring Granulators
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Application Requirements
– Abrasion Resistance
– Impact Resistance
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Base Material
– 14% Manganese Steel/ Cast Steel
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Superon Recommendation
– Base Layer with Super Stanhard MN 73 (
to be used for building up worn out
ones)
– Hardfacing with Super Stanhard AC 76
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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
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Very Fine stress relief checks
Single Layer Hardness
No chunking
Good erosion resistance
Crusher Sieves
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Application Requirements
– Impact Resistance
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Base Material
– 14% Manganese Steel
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Superon Recommendation
– Crack Joining with Super Stanalloy
EM 35
– Hardfacing on the sieve corners with
Super stan hard AC 76
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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
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Very Fine stress relief checks
Single Layer Hardness
No chunking
Good erosion resistance
Mill Discharge Valves
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Application Requirements
– Erosion Resistance
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Base Material
– Cast Steel
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Superon Recommendation
– Hardfacing with Super Stan Hard AC 76.
– Can give single layer hardness
without affecting the flow
parameters
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Product USP’s
– AC 76 – High hardness best suited for
Abrasion resistance- High wear Factor
– 63-67 HRc
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Very Fine stress relief checks
Single Layer Hardness
No chunking
Good erosion resistance
Multi Port Outlet
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Application Requirements
– Erosion Resistance
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Base Material
– Cast Steel
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Superon Recommendation
– Hardfacing with Super Stan Hard AC 76.
– Can give single layer hardness
without affecting the flow
parameters
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Product USP’s
– AC 76 – High hardness best suited for
Abrasion resistance- High wear Factor
– 63-67 HRc
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Very Fine stress relief checks
Single Layer Hardness
No chunking
Good erosion resistance
Mill Table RJ Shaft
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Application Requirements
– Frictional Wear Resistance
– Low Temperature welding
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Base Material
– Forged Alloy Steel
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Superon Recommendation:
– Super Stanalloy DS 34
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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
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Sinter Cast Table Liners – Roller
Segments
Application Requirements
– Good Bonding on CI
– Impact Resistance
– High Abrasion Resistance
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Base Material
– Special Cast iron with Sinter’s
Embedded
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Superon Recommendation:
– Super Stan Hard UL 81
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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
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Application Requirements
– High Erosion Resistance
– Medium Abrasion Resistance
– Single Layer Hardness
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Base Material
– Wear Resistant Cast Steel
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Superon Recommendation:
– Super Stan hard CC 78
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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
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Application Requirements
– High Erosion Resistance
– Medium Abrasion Resistance
– High Wear Factor
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Base Material
– Structural Steel
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Superon Recommendation:
– Super Stan Plate 55
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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
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Application Requirements
– High Erosion Resistance
– Medium Abrasion Resistance
– High Wear Factor
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Base Material
– Structural Steel
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Superon Recommendation:
– Super Stan Plate 56
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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
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Application Requirements
– High Erosion Resistance
– Temperature
– Minimal Turbulence on the weld deposit
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Base Material
– SS 310
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Superon Recommendation:
– Super Stan Hard (T ) 93
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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
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Application Requirements
– High Erosion Resistance
– Minimal Turbulence on the weld deposit
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Base Material
– Cast iron
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Superon Recommendation:
– Super Stan Hard (T ) 91
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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
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Application Requirements
– High Abrasion Resistance
– Temperature resistance
– Impact Resistance
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Base Material
– Cast Steel/ Manganese Steel
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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
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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
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Application Requirements
– High Abrasion Resistance
– Erosion Resistance
– Corrosion Resistance
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Base Material
– Structural Steel
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Superon Recommendation:
– Super Stan hard CR 77
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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
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Application Requirements
– High Erosion Resistance
– Corrosion Resistance
– Moderate Impact
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Base Material
– Alloyed Cast Iron
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Superon Recommendation:
– Super Stanalloy FN 65 for base
– Hardface with CR 77
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Product USP’s
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Best suited for Alloyed Cast iron
Excellent bonding to these types
Ease of machining
High Crack resistance
CR 77 has good resistance
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Abrasion
Erosion
Corrosion
Impact &
Heat
ID Fans
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Application Requirements
– High Erosion Resistance
– Moderate Heat
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Base Material
– Structural Steel
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Superon Recommendation:
– Super Stan alloy HT 79
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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
Component
Alkyde Enamel
Structures
Base Metal
Fabricated
structure
Stanvac
Solution
Polyhyb 2050
(1040+725)
Customer Benefits
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Low Application Time
Self Priming
Higher Corrosion Resistance
Double the Life of Alkyede Enamel
Machine
Stacker Reclaimer
Component
Conveyor Belts
Base Metal
Rubber with
Cotton/ Nylon Ply
Stanvac
Solution
717 Polyurethane
Kote- Black
Customer Benefits
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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
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
Machine
Coal Lines
Component
Orifices
Base Metal
Struc Steel+
Ceramics
Stanvac
Solution
731Stangard ER
Customer Benefits
• Zirconium Carbide based- High abrasion/ erosion
resistant.
• Lower down time.
• Insitu application.
• Enhanced life
Machine
Electrical panel
Areas
Component
Die Electric
Flooring
Base Metal
Concrete/ 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
Machine
Pumps- utilities
Component
Casing &
Impellors
Base Metal
Grey Cast Iron
Stanvac
Solution
1170/1180 or
731/1180
Customer Benefits
• Improves the efficiency- hene lower energy
consumption
• Higher Abrasion/ Erosion resistance- Higher life
Machine
Work Shop
Component
Shafts/Emergency
Leak Reapairs
Base Metal
Forged Steel / bar
stock
Stanvac
Solution
815 Stangard
Steel Putty
Customer Benefits
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Ultra High Compressive strength
Fast curing
Repeated no of applications
Machinability. Good Shore hardness
Temperature range -100C to +2000C
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
Machine
Cooling Towers
Component
Cooling Tower
Base Metal
Concrete
Stanvac
Solution
1311 MVT System
Customer Benefits
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Stops carbonation of the concrete
Improved Aesthetics
Enhances Life.
High Tolerance to Salt & Chloride
Wet Tolerance capability – best suited for Cooling towers
Machine
DM Plant
Component
DM Tank
Base Metal
Concrete
Stanvac
Solution
1311MVT System
Customer Benefits
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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
Machine
DM Plant
Component
DM Flooring
Base Metal
Concrete
Stanvac
Solution
754/756*+ 727
System
Customer Benefits
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Stops carbonation of the concrete
Improved Aesthetics
Stops Water Ingress
Increased Flooring life
Machine
Bowl Mill
Component
Reject Cone Outer
Base Metal
Strutural Steel
Stanvac
Solution
Stangard 731
ER/1190
Customer
Benefits
• Abrasion Resistant
• Erosion Resistant
Machine
Bowl Mill
Component
MDV
Base Metal
St Steel+ Ceramic
Tiles
Stanvac
Solution
731Stangard ER
Customer Benefits
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Abrasion Resistant
Erosion Resistant
No need to replace the total MDV.
Low downtime
Machine
Bowl
Component
Multi Port Outlet
Base Metal
St Steel+ Ceramic
Tiling
Stanvac
Solution
731Stangard ER
Customer Benefits
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Abrasion Resistant
Erosion Resistant
No need to replace the total MPO.
Low downtime
Machine
Boiler
Component
Coal Nozzle
Base Metal
Cast Steel
Stanvac
Solution
731Stangard ER
Customer Benefits
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Abrasion Resistant
Erosion Resistant
Low downtime
Higher Life
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
Machine
Battery room
Component
Flooring
Base Metal
COncrete
Stanvac
Solution
4029 System
Customer Benefits
• 98% H2SO4 33% HCL resistance
• 100 % Volume Solids
• High Build
Machine
GCT
Component
Scrubbers
Base Metal
Steel
Stanvac
Solution
1040+ 718EGFNV+ 727*
Customer Benefits
• 98% H2SO4 33% HCL resistance
• 100 % Volume Solids
• High Build
Machine
Flue Gas Ducts
Component
Flue Gas Ducts
Base Metal
St Steel With
Insulation
Stanvac
Solution
Aluclad 710/ 706
Stangard
Customer Benefits
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Heat Resistance- upto1600C
Stops Corrosion due to sweating
No reduction of shell thickness
710- Stop Moisture Entry into the Ducts
Machine
Condensors
Component
End Shields
Base Metal
Cast Steel
Stanvac
Solution
1180
Customer Benefits
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Heat Resistance
Stops Corrosion
No reduction of Plate thickness.
Stops leakage
Machine
Alkali & Acid
Metering Tanks
Component
Tanks
Base Metal
Structural Steel
Stanvac
Solution
Stangard706+1040
Stangard+715
Stangard EGF(
NV)
Customer Benefits
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Resistance to Alkali’s & Acids
Good adhesion to Structural
Good Flexural Strength
Resistance to 33 % HCl, 98% H2So4
Applications for 1040+ 725/727*
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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
Thank You