REFRACTORY STRUCTURES

THE PROBLEM TODAY

To date, companies have had little choice when it comes to refractory repairs. In most cases the choice has been an offer from an installation contractor to supply and install refractory to some "take what you get" quality as companies do not have the in-house expertise to know what is on offer.

Too often we see refractory structures regarded as a nonessential component of the plant, with maintenance delegated to material suppliers and installation contractors. A material supplier's business focus is selling refractory products while the installation contractor's business focus is selling repair labour with neither motivated to drive the owner's maintenance efficiency.

There is no doubt that refractory structures are complex and behave in unexpected ways, but they cannot be thought of as a "black box" and repairs cannot be considered as a "black art".

The approach often used by other companies to repair refractory linings or structures and to carry out design changes is based on repeating historic practice or observation. This method is frequently prone to failure, what we call "fatal gene" transfer.

There is another alternative...

HOW WE SOLVE IT

At Palmer we focus on the key elements needed to deliver a reliable solution

1. Firstly, the correct material is selected for the job (with the right properties for the service conditions) – this is what material supply companies focus on delivering to our specifications.
2. Secondly, assist installer's to focus on their expertise - the coordination and scheduling of resources, equipment and materials to complete the specified tasks within the allotted time. Installers achieve this by employing people of various skills. Their weakness is lack of process and engineering knowledge, or understanding of the reasons why refractory needs to be installed to particular design requirements.
3. Quality – Palmer focuses on the installed refractory quality, based upon our professional engineering expertise. We analyse a problem, recommend a repair method and employ our expertise to ensure refractory is installed to the required design and procedures.

WHY WE CAN SOLVE IT

• We understand failure mechanisms and the engineering science behind refractory design.
• We combine our know-how with the use of advanced engineering software.
• Because we are independent from the installer it allows us to maintain an objective focus on quality outcomes and avoid any potential conflict of interests that may occur.
• We focus on the engineering and QA/QC that is needed during a shutdown when time is critical. As independent engineers we can quickly solve the engineering issues.
• We have a wealth of engineering experience and many satisfied customers. Check out our testimonials.

LEGAL REQUIREMENTS

Because refractory structures are complex and the design of refractory structures is not covered by any National or International Standards the design requires advanced engineering analysis.

This means there are legal responsibilities on companies and professional engineers. In Australia, the Queensland Professional Engineers Act (2003) defines a professional engineering service, "an engineering service that requires, or is based on, the application of engineering principles and data to a design, or to a construction or production activity, relating to engineering….."

In delivering a "professional engineering service" then the service should preferably be signed off by the RPEQ (on documents / plans etc)

Also any contractor, manufacturer or the like who varies from the design / detailing / intended construction provided as a "professional engineering service" must appropriately notify the RPEQ designer of such variations and seek their approval to proceed.

Examples of professional engineering service include,

• the correctness of constructing must remain consistent with the approved plans (including the design intent – based on the designer's information & method / sequence of construction/ manufacture) & specifications;
• validating any changes to design calculations / plans / specifications that may have arisen during the construction / fabrication or manufacture;