Wearpipe. Induction Hardened Chromium Carbide Overlay Ceramic Lined

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1 Wearpipe Induction Hardened Chromium Carbide Overlay Ceramic Lined

2 WEAR PIPE OPTIONS St. Lawrence Steel is a provider of wear resistant solutions serving heavy industry since We are a leader in supplying abrasion resistant pipe options including pipes, elbows, reducer pipes and components for use in pneumatic and hydraulic conveying systems. We offer a variety of technologies including Induction Hardened, Chromium Carbide Overlay, and Engineered Ceramic Lined products that have been instrumental in reducing downtime within mission-critical processes in industrial markets. Our products have reduced downtime in the mining, power generation, aggregate, cullet, and glass industries. With our portfolio of products we can tailor the best solution for abrasion and impact situations in the transportation of materials such as; aggregates, ash, cullet, gravel, limestone, magnetite, mill scale, mine tailings, ores, pyrites, raw kiln feed, slurries with solids, sludge, slag, and sand. Advantages A wide variety of Wear Pipes for most applications Outlasts other steels by an average of 4 to 15 times in many applications Reduces life cycle maintenance cost, and unplanned outages Maximum resistance to abrasion Superior resistance to chipping, flaking, peeling or separation under severe conditions Wide selection of sizes 4 to 40 diameter Available in multiple layers and structural shapes. Abrasion resistant properties are unaffected by sustained operating temperatures of up to 1,200 C. (2195 F). Induction Hardened Pipe Induction hardening utilizes magnetic fields to induce a current in the steel pipe wall. This current causes the heating of the pipe. By utilizing a proprietary steel chemistry and by quenching the inside surface of the pipe, an extremely hard inner surface, with a tapering hardness profile through the pipe wall thickness is obtained. Overlay Pipe It is possible to produce piping products having all the advantages, but without the disadvantages of the double wall pipes. These bimetallic pipe walls are produced through the use of weld overlay. The weld overlay can be optimally selected for the particular slurry being conveyed, independent of the base plate material. The base material is selected for pressure capacity, weldability, and field durability. Engineered Ceramic Lined Pipe A layer of engineered ceramic material is applied to the inside wear surfaces of the pipe. Industrial engineered ceramic materials can be spun cast or trowelled in place, while retaining hardness between 8 & 9 on the Moh s scale. Mohs Hardness is applied to non-metallic elements and minerals. This product is designed for high temperature abrasive environments. Services With our portfolio of technologies and our experience in the conveyance of abrasive media St. Lawrence offers expertise in addressing wear issues. Our services include on-site wear assessments, pipe component layout according to application specific requirements, design and construction of various piping components. From our technologies our product range includes; pipes, elbows, reducers, branch pipes, long-radius bend elbows, wear back elbows, and custom components according to customer requirements. The St. Lawrence North American Fabrication Facility has the advanced fabrication equipment, products, people, and expertise to provide technological solutions for the most challenging wear problems.

3 Field Fabrication/Modification of Pipe This section covers the field welding and cutting of our wearpipe products. It is intended solely as a guide. All St. Lawrence Steel s pipe products must be supported on both sides of the cut area to prevent damage to the pipe and or cutting equipment. Normal safety and workmanlike practices are recommended. Joint Preparation Inspect surfaces to be welded avoid welding areas that have tears, cracks and other discontinuities. Clean joint area at least 1/2 from welding joint; remove all loose scale, rust, moisture, grease, etc. Bring parts into as close contact as practical; root opening should not exceed 3/16. For separations greater than 1/16, increase leg of fillet weld by the amount of the opening. Electrodes or Wire Any low carbon electrode is acceptable. (AWS 5.1 E7018 or 7016 type), 1/8 or smaller should be used. See below concerning welding Ultra-Met Chromium Carbide Overlay Pipe Preheat and Interpass Temperatures If ambient temperature of parts is below 70 F, preheat the weld zone and 6 of the adjacent material to 100 F. SLS600 Induction Hardened Wearpipe Care must be taken to cool the inner surface. The hardness of the inner surface will begin to decrease as temperatures approach 500 F (260 C). WARNING: The Induction hardening process imparts internal stresses in the pipe wall. Pipe must never be cut lengthwise. Cutting Cutting SLS600 products can be accomplished with plasma cutting equipment, or an abrasive cut-off wheel (water-cooled). The use of Oxy-fuel cutting equipment is not recommended. The heat imparted to the SLS600 material should be kept to minimum. Welding - Water Cooling Required Place welds on exterior of pipe. Aim a gentle stream of water (4 to 6 GPM) at the weld area inside the pipe. No water should come in contact with the exterior of pipe. Maintain a maximum of ¼ weld fillet per pass. Do not exceed 450 F interpass temperature. Rotate the pipe during the welding process to eliminate excessive starting and stopping of weld. Allow pipe to cool before applying additional beads. Ultra-Met Chromium Carbide Overlay Pipe WARNING: All structural welding must be confined to the base plate and not overlap into the overlay, to prevent carbon embrittlement and failure of the weld Cutting Ultra-Met can be cut with water jet, plasma burning equipment, air arc or abrasive saws. When using and an abrasive saw use of an abrasive silicon carbide wheel is recommended. Welding Pipe Interior St. Lawrence PN 200-W-ACF hard surface wire is recommended. Additional cracks may be noticeable on the inside surface of the pipe, but these will not affect the abrasion resistance. Welding Working from the exterior of the pipe, join the pipes using a low hydrogen electrode. After the structural welds are complete, fill the joint on the pipe interior with the approved St. Lawrence overlay welding wire. Grind surface smooth. Ceramite Ceramic Lined Pipe WARNING: Ceramite lined pipe must be support on both sides of the cut area to prevent damage to the pipe and or cutting equipment. Cutting Ceramite lined pipe can be cut with an abrasive saw using an abrasive silicon carbide wheel. Working in 6 to 8 section of the outside diameter, cut the steel layer of the pipe shell only, avoid penetrating into the ceramite liner section of the pipe. After completion of cutting the steel layer, cut the ceramite layer. Repeat this procedure around the OD of the pipe. Welding Working from the exterior of the pipe join the pipes using a low carbon electrode. Allow the pipe to cool before proceeding. Liner Touch up All chipped areas should be filled with Ceramite T from St. Lawrence. Trowel on Ceramite T into all chips of the liner. Allow proper curing.

4 SLS600 Induction Hardened Wearpipe The hardness of the structure of the inner surface is typically 600 BHN. Max Temperature = 230C (450 F) In the hardening process the raw pipe, medium carbon-low alloy steel, is heated to a fully austenitic temperature of approximately 1550º F. The inside diameter is then rapidly quenched with a treated coolant thus producing different microstructures and BHN hardness throughout the wall thickness. Induction hardening leaves a hard abrasion resistant inner surface so as to withstand flow deterioration and a ductile outer surface to accommodate handling and welding. Ultra-Met Chromium Carbide Overlay Pipe Ultra-Met pipe is recommended for severe sliding abrasion applications. The result is a surface possessing an excellent combination of high resistance to erosion, severe abrasion and moderate impact strength. The hardness of the structure of the inner surface is typically 1740HV. Max Temperature = 676 C (1250 F) Ultra-Met overlay can be formed into pipe sections, pipe bends, and fabricated fittings. The result is a pipe surface possessing an excellent combination of high resistance to erosion, severe abrasion and moderate impact strength. Ultra-Met pipe has exhibited wear resistance; up to 10 times the life of mild steel. Overlayed bends and fittings can be used in conjunction with induction hardened pipe within the total system to afford the additional abrasion resistance needed in areas of extreme turbulence and wear. SUGGESTED APPLICATIONS BY INDUSTRY CEMENT Chalk handling Lime slurry lines Raw kiln feed POWER GENERATION Ash handling Bottom ash Drain lines FGD Piping Limestone handling Mist eliminator piping Scrubber sludge transport Slurry transfer lines COAL PREP Effluent handling Raw coal slurry pipes Waste pond lines GLASS Cullet handling IRON & STEEL Furnace scrubber slurry handling Mill scale pipes Slag transport lines MINING Backfill / feedback systems Crushed and ground ore lines Magnetite transport Slurry transfer lines Tailings handling Waste products PHOSPHATE Phosphate ore transport Tailings handling STONE, SAND & GRAVEL PLANTS AND QUARRIES Crushed and ground rock transport Gravel handling Sand piping SEWAGE TREATMENT Sludge transport Sludge ash systems Ceramite Ceramic Lined Pipe Ceramite lined pipes are cast resulting in monolithic seamless interiors, with no material buildup or weak points. Ceramite specializes in configurations that others can t produce due to the incredible versatility of Ceramite mortars. The use Ceramite to line pipes yields results in Bohme Abrasion Test of 0.5 (mm) 3 The structure of the inner surface is typically > 8 Moh. Max Temperature = 1200C (2195 F)

5 Wearpipe Comparison Chart based on mild steel SLS 600 Induction Mild Steel Hardened Pipe Ultra-Met Pipe Ceramite Cast Pipe Hardness BHN 600 BHN > 600 BHN > 8 Mohs Max Temperature 230 C (450 F) 676 C (1250 F) 1200 C (2195 F) Abrasion Resistant Poor Good Very Good Excellent Impact Resistant Good Average Marginal Poor Strength Good Excellent Good Excellent Std Sizes (OD) Unlimited 3 to to 40 4 to 24 Handling & Installation Excellent Very Good Very Good Heavier, Slightly Brittle Fabrication Unlimited Some Limitations Some Limitations Some Limitations Emergency Repair Easily Patched Easily Patched Easily Patched Easily Patched Initial Cost 3-8 Times Above 6-10 Times Above 4-8 Times Above Mild Steel Mild Steel Mild Steel Life Expectancy Up to 6 Times Up to 8 Times Up to 15 Times Mild Steel Mild Steel Mild Steel Advantages Low cost A Good Combination Very Good Wear High Wear Resistance Readily available of Abrasion Resistant. Highly & Compressive & Impact Resistance Adaptable in Strength, Jointless Design with Good Lining & Highly Ductility. Moderate Temperature Resistant, Temperature Good Thermal Resistance. Shock Resistance. Disadvantages Poor abrasion No corrosion Limited length Heavier, may Require resistance; resistance; & diameter Additional Supports. Costly change-out Low ductility Smaller ID for a Given OD than other Types Pipe Product Range/Size GRADE Max Length Standard Diameters Schedule SLS600 Induction Hardened Pipe 20 3 to to to 26 Special Order Ultra-Met Chromium Carbide Overlay Pipe 6 10 to 40 N/A Std Wall Thickness Options: 1/2 or 3/4 Ceramite Ceramic Lined Pipe 21 4 to with ½ or 1 Ceramite Lining 21 4 to with ½ or 1 Ceramite Lining 21 4 to with ½ or 1 Ceramite Lining

6 Wearpipe 2500 Crane Centre Drive P.O. Box 2490 Streetsboro, Ohio or Fax