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Cremator, When to Consider a Repair |
1. Cremation Chamber Ceilings There are a variety of types of Cremation Chamber Ceilings, in accordance to the brand name and model of your Cremator. IE&E and Crawford Cremators have Castable Cremation Chamber Ceilings. Castable Cremation Chamber Ceilings can also be found in the later model B&L Cremators. This ceiling is made of a refractory material that is poured like concrete, and hardens to a consistency of concrete. To replace this type of ceiling, the top of the Cremator must be removed, along with the burners, mechanical, and electrical components on top of the Cremator. Jones Incinerators, ALL, American, and some models of the B&L Cremator have Insulating Firebrick Ceilings. These are composed of either arch shaped or wedge shaped Firebricks, which are installed in such a manner as to produce an arch shaped ceiling. This type of ceiling can be removed and replaced from within the Cremator; eliminating the need to remove components from the top of the cremator. This saves time when replacing the ceiling. Earlier models of B&L N-20AA and B&L Phoenix Cremators have Ceramic Fiber Module Ceilings. These ceilings consist of modules of ceramic fibre. Each module contains hardware which is utilized to secure the module to to the ceiling. A special stud gun is utilized to secure the module and weld it's associated hardware to a metal sheet on the ceiling. This type of Cremation Chamber Ceiling can be completely removed and replaced from within the Cremator, eliminating the need to remove components from the top of the Cremator. this saves time when replacing the ceiling. Individual modules can be replaced as they wear out, eliminating , in some cases, the need to replace the entire ceiling. A time will inevitably come when the entire Ceramic Module Ceiling will need to be replaced. This usually occurs after some years of use, by way of normal wear and deterioration of the product. Ceramic fibre modules in ceilings in earlier model B&L Systems Cremators tend to shrink over time. If you find modules that have gaps betweem each other in which you can slip your finger, the gaps should be packed with strips of ceramic blanket. Hi-Temp Refractory can provide you with the necessary materials to perform this task, as well as instruct you on how to properly carry out this operation. Or, we can send a qualified technician to install the material for you. Contact us for more information. CLICK HERE TO LEARN ABOUT POTENTIAL CREMATION CHAMBER CEILING PROBLEMS 2. Cremation Chamber Hearth Floor The Cremation Hearth Floor in a Cremator is made of a refractory material that is poured like concrete, and hardens to a consistency of concrete. Its average temperature rating is 3000 Degrees F. The Cremation Hearth Floor in the ALL cremator consists of castable tiles. When we replace this type of floor, we pour a solid, smooth castable floor. This type of floor makes sweeping out the cremains a much easier task. There are basically two types of Cremation Hearth Floors; the hot floor design and the warm floor design. The warm floor design is found in the All, American, early IE&E Power Paks, and early Crawford Cremators. The early IE&E and early Crawford Cremation Chamber Floors have a steel plate under the floor. The ALL and American Cremators have a metal pan, containing insulating firebricks, under the floor. The hot floor design is found in B&L, later model IE&E, and later model Crawford Cremators. This type of Cremation Chamber Floor is suspended between two side walls. It is supported only by the two side walls, a front wall, a center wall, and a lentil in the back. B&L models also have lentils supporting the floor in the center of the Cremator, also. The hot floor design allows the Cremator to operate more efficiently, by allowing heat in the lower afterchamber to conduct through the bottom of the floor into the Cremation Chamber. After the retort is initially heated up, this heat conductivity from under the floor allows the additional cremations to start burning sooner. Jones Cremators have a Cremation Hearth Floor, which sit directly on top of a hard Firebrick arch. This has a similar effect as a hot floor design. In Animal and Pet Cremators and Incinerators, calcium buildup can occur on the surface of the Cremation Chamber Hearth Floor. This substance can be cleaned off the floor surface occasionally. If this buildup is allowed to go unchecked, the accumalation of calcium can become so severe that it becomes higher than the floor level, causing grease to run out the front door of the Cremator. |
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On Cremation Chamber Floors where the height of the floor is not critical, and no hole is completely through the floor; a floor cap, consisting of a one and one half to three inch layer of refractory castable; can be installed over the existing floor. This can be achieved at a fraction of the cost of a complete floor replacement. |
3. Cremation Chamber Side Walls The Cremation Chamber Side Walls in every make and model of Cremator consists of Firebricks. Some brands of Cremators; such as B&L and Jones; install hard Firebricks in the entire Cremation Chamber Side Wall. While other brands; such as IE&E, ALL, Crawford, and American; install hard Firebricks in the lower portion of the wall, and Insulating Firebricks in the upper portion of the wall. Refractory insulating materials are installed behind the Cremation Chamber Side Walls in every brand of Cremation retort. This helps to keep an excessive amount of heat form radiating to the exterior of the Cremator. CLICK HERE TO LEARN MORE ABOUT POTENTIAL CREMATION CHAMBER SIDE WALL PROBLEMS 4. Afterburner Chamber Walls The Afterburner Chamber Walls are located in the rear of the B&L, ALL, American, later model IE&E, and later model Crawford Cremators. The Afterburner Chamber Walls are located on the back section of the Cremation Chamber Side Wall on earlier versions of IE&E and Crawford Cremators. They can be identified by the fact that they always have an opening; known as the gas pass window; in this Area. Jones Cremators have a series of gas pass openings, along the bottom of the left and right Cremation Chamber Side Walls. Gases from the Main Cremation Chamber go through the gas pass, where an afterburner incinerates the pollutants, in order to produce clean emissions out of the stack. CLICK HERE TO LEARN MORE ABOUT POTENTIAL AFTER BURNER CHAMBER WALL PROBLEMS 5. Lower After Chamber Walls The Lower After Chamber Walls are located below the Cremation Hearth Floor and under the after burner chamber in the B&L, IE&E, Crawford, And Jones Cremators. In older models of IE&E and Crawford Cremators, the Lower After Chamber Walls are located beneath a Lower Chamber Ceiling. This ceiling is made of a Refractory castable, and is located beneath a steel plate, on which the Cremation Chamber Hearth floor sits. All Lower After Chamber Walls in all makes and models of Cremators are made of high duty Firebricks. In the ALL and American Brands of retorts, there are no lower after chamber walls. The gases simply go into the gas pass window, under a lentil, then directly out the stack. In Jones Cremators, the lower after chamber walls are directly beneath the Cremation Chamber Hearth Floor. The lower after chamber needs to be cleaned out now and again. Access panels are located at the rear of the B&L, IE&E and Crawford Cremators. The panel is removed, followed by some layers of insulation, followed by Firebrick which is stacked in the access opening. After you remove these items, you can clean out the lower chambers. At this time, you can also inspect the lower after chambers, in order to get some idea of what condition it is in. These Firebricks tend to deteriorate over time, especially in the area nearest the after burner. So it is always a good idea to inspect them while performing a clean out underneath. When looking into the clean out door opening on a B&L, IE&E, or Crawford Cremator, keep in mind that the wall on the inside area of the opening is the center wall. The center wall helps support the Cremation Hearth Floor. It also blocks the smoke by providing an extended path for the gases to follow, on their way to the stack. This allows more time for the pollutants to burn off the gases. A failure of this wall can cause the Cremator to extract excessive smoke from the stack, as well as possibly causing a collapse of the Cremation Hearth Floor. Earlier models of IE&E and Crawford Cremators have a lower after chamber ceiling made of castable. This ceiling is below the Cremation Chamber Hearth Floor, seperated from the Cremation Chamber Hearth Floor by an airspace of 3 to 4. The Cremation Chamber Hearth Floors in these particular Cremators are supported by a metal plate, which rests on top of metal I beams. Inspect this ceiling carefully, making certain there are no holes in it. A breach in this ceiling, in conjunction with continued operation of the Cremator, could cause extensive damage to the metal infrastructure beneath the Cremation Chamber Hearth Floor. In early models of IE&E and Crawford Cremators, check to see if the baffolds on the after burner side are still intact. If not, then they should be replaced, in that they play a major role in slowing down the gases, so the pollutants can be burned off the gases more thoroughly and efficiently. After the clean out and inspection is completed, the bricks, insulation and access panel must be put back in the access door opening. Sometimes, the bricks that you remove from the access door opening may be too worn and brittle to reinstall. Because of this fact, you should always have some replacement Firebrick on hand. Hi-Temp Refractory can supply you with the replacement Firebricks you need. Contact us for more information. CLICK HERE TO LEARN MORE ABOUT POTENTIAL LOWER AFTER CHAMBER WALL PROBLEMS 6. Stack Linings The Stack Linings in B&L and Crawford Cremators consist of Insulating Castable. Thus far, we have never seen a B&L or Crawford Stack Lining in need of repair or replacement. The ALL and American Cremator Stack Lining consists of 4 1/2 thick Insulating Firebrick. IE&E Stacks are made of stainless steel, and have no Refractory Lining. THe IE&E Stack has a 2 layer of insulation wrapped around its exterior. CLICK HERE TO LEARN MORE ABOUT POTENTIAL STACK LINING PROBLEMS 7. Venturis IE&E, ALL, Crawford, and later model B&L Cremators have venturis attached to the base of the stack, between the stack and the cremator. The venturis are designed to help increase the draft to the Cremator stack. The IE&E version tends to rust after prolonged use, and it is recomended the venturi be replaced when the rusting begins to cause the IE&E venturi to start deteriorating. We have as yet to see a B&L or Crawford venturi in need of replacement. CLICK HERE TO LEARN MORE ABOUT POTENTIAL VENTURI PROBLEMS 8. Cremation Chamber Doors The ALL, IE&E, Jones, and American Cremation Chamber Doors have a 4 1/2 thick Insulating Firebrick Lining. The B&L Cremation Chamber Door has a 6 thick Ceramic Fibre Module lining. The Crawford Cremation Chamber Door is lined with 4 1/2 of castable Refractory. ALL, IE&E, Jones, American, and B&L Cremation Chamber door linings can usually be replaced from within the Cremator; while the Crawford Cremation Chamber Door lining would have to be replaced by removing the door. CLICK HERE TO LEARN MORE ABOUT POTENTIAL CREMATION CHAMBER DOOR PROBLEMS 9. Side Cleanout Door On B&L Cremator B&L Cremators have an exclusive side cleanout door. This door is lined with Insulating Firebrick. It also has a gasket which is utilized to seal the door when it is closed. This gasket tends to recieve a substantial amount of wear after prolonged use. When the gasket becomes frayed and tattered, it is recommended that it be replaced. CLICK HERE TO LEARN MORE ABOUT POTENTIAL SIDE CLEANOUT DOOR PROBLEMS 10. Characteristics Unique To Jones Cremators The Cremation Chamber Hearth Floor in a Jones Cremator, sits on top of a hard Firebrick arch. Directly below this arch, there is another arch consisting of hard Firebrick. It is a checkerboard arch. This arch resembles a checkerboard, due to the fact htat it has holes all along it in a checkerboard pattern. Gases pass through these holes on the way to the stack. This checkerboard arch acts as a baffold, slowing down the gases movement, so that the pollutants can be more thoroughly burned off the gases. If a Jones Cremator produces excessive smoke out of the stack, it could indicate that this arch has either fallen out, or is severely damaged, and is in need of replacement. This arch can be reached via a cleanout door at the front of the retort. There are Firebrick tiles along the sides of a Jones Cremator Cremation Chamber Hearth Floor. The purpose of these tile is to prevent cremains from going into the gas pass holes along the sides of the Cremation Chamber Hearth Floor. It is imperative that these be repaired when they start deteriorating. CLICK HERE TO LEARN MORE ABOUT POTENTIAL PROBLEMS UNIQUE TO JONES CREMATORS 11. Hot Spots Visible hot spots on the exterior metal of any cremator is a definite indication of a Refractory problem. Periodically inspect the entire exterior of the Cremator while it is operating. Check for any areas on the metal surface which is either darkened, glowing red, or is excessively hot to the touch, in combination with being either darkened, discolored, or glowing red. It is reccomended that if such a situation is present, that the situation be addressed immediately, without hesitation. The purpose of Refractory Linings in a Cremator is to retain the heat and flames within the confines of the Cremator, and to protect the steel infrastructure of the cremator from heat damage. A hot spot is a sure sign that the Refractory Linings purpose is being severely and excessively breached. 12. Cleanout Of Lower Afterchamber Periodically, the lower afterchamber should be cleared of obstructions which can accumalate over time, obstructing the flow of gases through the cremator. An access panel is located at the rear of the Cremator under the stack on B&L, Crawford, and early model IE&E Cremators. On later model IE&E Cremators, there are two access panels on the rear of the Cremator, one on the stack side, and one on the afterburner side. On Jones Cremators, accessiblity to the afterchambers is available via the lower front area of the retort. To perform the cleanout procedure, remove the access panel, the layers of insulation, and the Firebricks that fill the opening. Clean all accumalated soot and obstructions from the chambers, perform a general inspection of the condition of the Refractory, then replace the Firebricks, layers of insulation, and Access panel. Sometimes, the Firebricks and insulation may be deteriorated to the point that they may have to be replaced with new materials. It is a good idea to always keep replacement Firebricks and insulation on hand in case replacement becomes necessary. Contact us at Hi-Temp Refractory, so that we can provide you with the materials you need for this purpose. 13. Afterburner Chamber Ceiling Afterburner chamber ceilings in earlier model B&L Cremators consist of Ceramic Fibre Modules. Over time, these Modules may deteriorate and fall out. When this occurs, the fallen Module must be immediately replaced. The afterburner chamber ceiling in IE&E, Crawford, and later model B&L Cremators consist of Refractory castable, which has the consistency of hard concrete. Over time this type ceiling can have pieces of castable fall out, or develop extreme cracks. When this starts occuring, the problem should be addressed before further damage is inflicted on the cremator. CLICK HERE TO LEARN ABOUT POTENTIAL AFTERBURNER CHAMBER CEILING PROBLEMS |
The floor cap consists of the same kind of Refractory Castable that
is installed in the original Cremation Hearth Floor. Capping the floor can greatly further the life of the floor. Once a floor is capped, it is as smooth as a brand new floor. Hi-Temp Refractory can supply you with the material necessary if you would like to install the floor cap yourself, or we can provide a qualified technician to perform the installation for you. Contact us for more information. CLICK HERE TO LEARN ABOUT POTENTIAL CREMATION CHAMBER HEARTH FLOOR PROBLEMS |
Potential Problems |
A. Potential Problems With Cremation Chamber Ceilings Click here to go back 1. Ceramic fibre Modules dropping out of early model B&L Cremator Ceilings. 2. Pieces of castable falling out of IE&E, Crawford, & later model B&L Cremator ceilngs. 3. Severe melting of castable in IE&E, Crawford, & later model B&L Cremator ceilings. 4. Pieces of Firebrick falling out of ALL, American, Jones, and certain models B&L Cremators. 5. Severe meltdown of Firebricks in ALL, American, Jones, and certain models of B&L Cremators. 6. Pieces of ceiling falling out at door opening exposing steel . Smoke coming out of the top area of the door when it is closed could be an indicator of this problem. 7. Ceramic Fibre modules falling out at door opening exposing steel on B&L Cremators. 8. Hot spot on top of Cremator over ceiling. B. Potential Problems with Cremation Chamber Hearth Floor Click here to go back 1. In Animal and Pet Cremators and Incinerators, watch for severe calcium deposit buildup on hearth floor surface. Clean this buildup off occasionally to prevent grease from flowing out the front door of the Cremator. 2. Watch for excessive wear and pitting of the surface of the Cremation Chamber Hearth floor surface. If there are no holes in the floor, and the maximum allowable floor height is not restrictive, a cap can be installed on top of existing floor. This will make the floor surface as smooth as a new floor. Contact us at Hi-Temp Refractory for further information. 3. Watch for holes in the hearth floor. This will indicate that the cremation hearth floor is in need of replacement . 4. Cremation Chamber Hearth Floors tend to begin wearing out and developing pits directly under the main cremation chamber burner. When this begins to create problems with the sweeping out of cremains, some may advise you to simply patch the affected area. We recommend capping the entire surface of the floor when this occurs, due to the fact that a small patch will not last very long. The constant sweeping of cremains over a small patch will ultimately knock the patch lose, and you will have the same problem as before, all over again. Where as capping the entire floor surface will make the surface smooth, just like a new floor, and it will last for a good while. C. Potential Problems With Cremation Chamber Side Walls Click here to go back 1. Pieces of Firebrick falling out of wall. 2. Pieces of Firebrick breaking off the wall at the door frame, exposing the steel. Steel exposure at the door frame can cause the steel to warp. This creates problems opening and closing the door, as well as sealing problems. 3. Severe meltdown of Firebricks in the walls. 4. Holes in the walls. 5. Hot Spots developing on the sides of the exterior of the Cremator. D. Potential Problems With Afterburner Chamber Walls Click here to go back 1. Severe meltdown of Firebricks. 2. Bricks falling out of gas pass knee wall. This could indicate a failure of the support beam under the knee wall, especially if the bricks are falling form the bottom portion of the knee wall. 3. Severe deterioration of the Firebrick within the gas pass throat area where the afterburner is. This area recieves a significant amount of direct heat and the firebricks here tend to deteriorate more rapidly. The rear wall of the gas pass throat area has been known to melt away toward the bottom of the wall. This area should be inspected extra carefully. 4. Hot spots on the rear sides and back of the exterior of the cremator. E. Potential Problems With The Lower After Chamber Walls Click here to go back 1. Note: you must remove access panel, insulation, and Firebrick in opening before you can inspect the lower after chamber walls. 2. Pieces of bricks falling out of walls. 3. Make certain the center wall is intact. 4. Make sure there is no extreme meltdown of bricks. The after burner side walls are especially susceptible to this, so be sure to check that area very carefully. 5. Pieces falling out or severe meltdown of ceiling above the lower after chamber walls. In B&L, later model Crawford & later model IE&E Cremators, this could be an indication of deterioration of Cremation chamber Hearth floor on its bottom side. In earlier model Crawford & IE&E Cremators, this could be an indication of deterioration of lower after chamber ceiling. This ceiling protects the steel infrastructure beneath the Cremation hearth floor from direct heat and flame exposure. 6. Hot spots along lower side, lower rear, and lower front portions of exterior of Cremator. F. Potential Problems With Stack Lining Of ALL Cremator Click here to go back 1. Remove thermocouple from stack, look inside hole and make certain there is at least 3of Firebrick thickness remaining. If there is less than 3 thickness remaining, replacement of Insulating Firebricks in stack should be considered. 2. Hot spots on exterior of stack. G. Potential Problems With Cremation Chamber Doors Click here to go back 1. Always keep watch of the exterior metal of the door, making certain no hot spots are developing. A hot spot is a burnt area of the metal, where the protection from the heat has failed, resulting in the heat slowly burning a hole in the metal from the inside out. the hot spot will be glowing red when cremator is operating, and you will not be able to touch it. A hot spot on the Cremation chamber door is a direct indication that the Refractory lining has failed. It is recommended that this problem be addressed immediately. H. Potential Problems With B&L Side Cleanout Door Click here to go back 1. If smoke comes out of door when it is completely closed, the seal is failing and the gasket on the door should be replaced. Hi-Temp Refractory can supply you with the items you need to replace the gasket. Contact us for more information. 2. Pieces of castable falling out of side door jamb on the Cremator. 3. Bricks deteriorating or falling out of the side door. I. Potential Problems Unique To Jones Cremators Click here to go back 1. Inspect checkerboard arch in after chamber, making certain the Firebricks in this arch are not falling out or deteriorating. this arch is accessible via a front access plate at lower front of the Cremator. To access this, you must remove access plate, insulation, and Firebricks enclosing the opening. these items must be replaced when done with inspection. 2. Deterioration of tiles along the sides of the Cremation Chamber Hearth Floor. These tile keep cremains from getting into the after chamber, so it is imperative they be repaired or replaced when they begin deteriorating. J. Potential Problem With Afterburner Chamber Ceiling Click here to go back 1. In earlier model B&L Cremators, make certain Ceramic Fibre Modules are in place, and have not dropped down. If a module has dropped out, it is very important that the problem be taken care of immediately. 2. In earlier model B&L Cremators, the ceramic fibre modules will tend to shrink over time. If you detect excessive shrinkage, for example, if you can slip your finger in crack between modules, then the gap should be filled with strips of ceramic fibre blanket. Hi-Temp Refractory can provide you with this blanket, as well as instruct you on its proper installation. Or, we can send a qualified technician to install this for you. Contact us for more information. 3. Pieces of castable falling out of IE&E, Crawford, & later models of B&L Cremators. 4. Severe meltdown of castable in IE&E, Crawford, and later model B&L Cremators. 5. Hot spots on top of Cremator in afterburner area, as well as upper side and back of Cremator in this same vicinity. K. Potential Problem With Venturis Click here to go back 1. Check for severe rusting and holes in the metal, especially on IE&E venturis, being that IE&E venturis are constructed entirely of metal, and have no Refractory lining. 2. Check for hot spots on exterior of venturi. |