Dgs-mn-003-r1 Materials, Installation and Testing Requirements for Refractory Systems

Abu Dhabi Oil Refining Company

MATERIALS, INSTALLATION AND TESTING REQUIREMENTS FOR REFRACTORY SYSTEMS

DGS-MN-003 Rev-1 March 2009

Takreer DGS-MN-003-Rev-1 March 2009 Printed 14-May-09 10:24:22

Initials Page 1 of 59


Amendment History

1 Mar 2009 AMD-MN-003-BECHTEL Clauses 2, 5,6, 12, 11 & Appendices A1 & A2 HAS/DDC QAM Mar 2009

No Date Amendment Description Proposed Approved Incorporated

DGS History

1 Mar 2009 DGS-MN-003-Rev-1 AMD-MN-003-BECHTEL HAS/DDC QAM / MAY

0 Mar 2006 DGS-MN-003-Rev-0 Previous Project / Lessons Learnt Incorporated

HAS/DDC ETSDM / EPDM

No Date Description Source Reviewed Approved

DGS-MN-003 Rev-1






TABLE OF CONTENTS

1.0 GENERAL ......................................................................................................................... 3 1.1 INTRODUCTION...................................................................................................... 3 1.2 PURPOSE................................................................................................................ 3 1.3 DEFINITIONS .......................................................................................................... 3 1.4 EXCEPTIONS .......................................................................................................... 3

2.0 CODES AND STANDARDS .............................................................................................. 3 3.0 REFERENCE DOCUMENTS ............................................................................................ 3 4.0 DOCUMENT PRECEDENCE............................................................................................ 3 5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL ............................................... 3 6.0 QUALITY ASSURANCE/QUALITY CONTROL ................................................................. 3 7.0 DOCUMENTATION ........................................................................................................... 3 8.0 SUBCONTRACTORS/SUBVENDORS ............................................................................. 3 9.0 HANDLING........................................................................................................................ 3 10.0 GENERAL DESIGN........................................................................................................... 3

10.1 MATERIALS ............................................................................................................. 3 10.2 SURFACE PREPARATION AND MEMBRANE APPLICATION................................ 3 10.3 REFRACTORY MATERIAL ATTRIBUTES ............................................................... 3 10.4 INSPECTION AND TESTING .................................................................................. 3 11.0 MONOLITHIC REFRACTORIES.............................................................................. 3 11.1 DESIGN PARAMETERS.......................................................................................... 3 11.2 SUPPLY OF REFRACTORY MATERIAL ................................................................. 3 11.3 TRANSPORT AND HANDLING OF REFRACTORY LINED EQUIPMENT.............. 3 11.4 INSTALLATION OF ALL TYPES OF MONOLITHIC REFRACTORY MATERIALS .. 3 11.5 INSTALLATION OF PLASTIC REFRACTORY MATERIALS.................................... 3 11.6 INSTALLATION OF CASTABLE REFRACTORY MATERIALS ................................ 3 11.7 INSTALLATION OF GUNNING REFRACTORY MATERIALS.................................. 3

12.0 REFRACTORY BRICKS AND SHAPES............................................................................ 3 12.1 DESIGN ................................................................................................................... 3 12.2 CLASSIFICATIONS OF SHAPED REFRACTORY MATERIALS ............................. 3 12.3 BURNERS................................................................................................................ 3 12.4 REFRACTORY SHIPMENT AND STORAGE .......................................................... 3 12.5 INSTALLATION OF REFRACTORY BRICK CONSTRUCTIONS ............................ 3 12.6 INSPECTION ........................................................................................................... 3

13.0 CERAMIC FIBER LINING SYSTEMS ............................................................................... 3 13.1 MATERIALS FOR CERAMIC FIBER BLANKET AND MODULES........................... 3 13.2 ANCHORING FOR BLANKET AND MODULE INSTALLATION............................... 3 13.3 JOINTS OF CERAMIC FIBER BLANKET................................................................ 3

14.0 SPECIFIC APPLICATIONS ............................................................................................... 3 14.1 FIRED HEATERS..................................................................................................... 3 14.2 STACKS ................................................................................................................... 3 FIGURE 14.1 .................................................................................................................... 3

APPENDIX 1 ............................................................................................................................. 3 APPENDIX 2 ............................................................................................................................. 3

FIGURE A2-1................................................................................................................... 3 FIGURE A2-2 .................................................................................................................... 3 FIGURE A2-3.................................................................................................................... 3






APPENDIX 3 ............................................................................................................................. 3 FIGURE A3-1.................................................................................................................... 3 FIGURE A3-2 .................................................................................................................... 3 FIGURE A3-3.................................................................................................................... 3

APPENDIX 4 ............................................................................................................................. 3 APPENDIX 5 ............................................................................................................................. 3

FIGURE A5-1.................................................................................................................... 3 ADDENDUM SHEET .................................................................................................................. 3

List of Authorized Signatures / Initials

DGS Discipline Committee Member, ADRD: -----------------------

DGS Discipline Committee Member, RRD: -----------------------

DGS Discipline Committee Member Leader, E&PD: Hesham El Ashkar (HAS)

Engineering & Technical Services Manager, E&PD: Quazi Abdul Matin (QAM)

Engineering & Projects Division Manager, E&PD: Mohd Al Yabhouni (MAY)






1.0 GENERAL

1.1 INTRODUCTION

This specification covers the basic design, materials, and application of monolithic refractory linings, refractory bricks and shapes, and ceramic fiber materials to be installed in boilers, gas fired heaters, high temperature piping or exchangers, and waste heat boilers operating in a petroleum refinery environment.

1.2 PURPOSE

The purpose of this specification is to define the requirements for refractory materials, installation, drying, curing, testing, and inspection.

1.3 DEFINITIONS

For the purposes of this specification, the following definitions shall apply:

General Definitions:

CONCESSION REQUEST A deviation requested by the SUBCONTRACTOR or VENDOR, usually after receiving the contract package or purchase order. Often, it refers to an authorization to use, repair, recondition, reclaim, or release materials, components or equipment already in progress or completely manufactured but which does not meet or comply with COMPANY requirements. A CONCESSION REQUEST is subject to COMPANY approval.

SHALL Indicates a mandatory requirement SHOULD Denotes an action or requirement which is not mandatory but which is strongly recommended.

Technical Definitions:

APPLICATOR The party who is responsible for and applies or installs the refractory system including anchors.

BATCH A quantity of material which is made in a manner to insure the same quality. For example, this means an uninterrupted run of material on an automatic weighing system without refilling of any component storage hopper directly in front of the batch weighing. A batch is not that quantity of refractory made during a calendar day.

BRICKS Includes both bricks and special shapes. See Section 12.0 for more detailed description.

CASTABLE REFRACTORY MATERIALS Ready mixed monolithic refractory materials are delivered dry and require mixing with water or other liquids. They are placed by






casting, trowelling, vibrating, rodding, tamping, or pounding, and harden at ambient temperature.

CERAMIC FIBER MODULES Blocks manufactured of continuously folded and compressed ceramic fiber blanket.

GUNNING REFRACTORY MATERIALS Monolithic refractory mixtures which are noncoherent before use, specially prepared for placing by pneumatic or mechanical projection.

METAL FIBER REINFORCED LINING Consists of a light, medium weight or erosion-resistant refractory material reinforced by metal fibers. The lining can be applied by gunning, handpacking, casting, or pouring.

MONOLITHIC REFRACTORY MATERIALS Mixtures of aggregates and binders used either directly in the supplied condition or after the addition of a suitable liquid, and having a Pyrometric Cone Equivalent (P.C.E.) of at least 1500C. These mixtures are either dense or insulating refractories. The true porosity for insulating refractories shall be more than 45%. Even though some insulating refractories have a P.C.E. lower than 1500C, they are still considered as refractory materials.

PLASTIC MOLDABLE REFRACTORY MATERIALS Monolithic refractory materials which are either supplied already moist and ready to use or require moistening into a workable consistency. They are prepared for direct installation as bulk or in cakes.

REFRACTORY Products that include dense, insulating, acid-resistant and/or special composite materials used as a lining within heaters, boilers and other equipment and piping to protect steel from heat, erosion, acids or other service conditions.

REFRACTORY SAMPLE A specified quantity of uncast refractory material, picked at random from a "batch". Sample must be taken from a fully mixed full bag of material.

TEST SPECIMEN A portion of a sample which has been cast (or gunned) and will be subjected to specified physical tests.

1.4 EXCEPTIONS

This specification does not include design and installation for the following:

Erosion resistant refractory linings used for solids-containing services, such as Catalytic Cracker fluidized bed transfer lines

Refractory linings for Sulfur Plants Linings systems for Acid Service Protective shrouds over ceramic fiber blanket (such as ones typically used on

Heat Recovery Steam Generators)






CONTRACTOR shall develop detailed refractory requirements if one or more of the above noted services is a requirement of the project.

2.0 CODES AND STANDARDS

It shall be the VENDOR'S responsibility to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards.

The following codes and standards shall, to the extent specified herein, form a part of this specification. 15 January 2008 is the effective date for codes and standards i.e. the code or standard valid on that date shall be the one to be used.

American Society of Mechanical Engineers (ASME)

Boiler and Pressure Vessel Code

Section I Power Boilers

Section II, Part C Welding Rods, Electrodes, and Filler Metals

Section V Nondestructive Examination

Section IX Welding and Brazing Qualification

American Welding Society (AWS)

AWS D1.1:1995 Structural Welding

American Society for Testing and Materials (ASTM)

ASTM C16 Load Testing Refractory Shapes at High Temperatures

ASTM C20 Apparent Porosity, Water Absorption, Apparent Specific Gravity, and Bulk Density of Burned Refractory Brick and Shapes by Boiling Water

ASTM C24 Pyrometric Cone Equivalent (PCE) of Fireclay and High Alumina Refractory Materials

ASTM C27 Fireclay and High - Alumina Refractory Brick

ASTM C92 Sieve Analysis and Water Content of Refractory Materials

ASTM C113 Reheat Change of Refractory Brick

ASTM C133 Cold Crushing Strength and Modulus of Rupture of Refractories

ASTM C135 True Specific Gravity of Refractory Materials by Water Immersion






ASTM C155 Standard Classification of Insulating Firebrick

ASTM C179 Drying and Firing Linear Change of Refractory Plastic and Ramming Mix Specimens

ASTM C181 Workability Index of Fireclay and High-Alumina Plastic Refractories

ASTM C182 Thermal Conductivity of Insulating Firebrick

ASTM C198 Cold Bonding Strength of Refractory Mortar

ASTM C201 Thermal Conductivity of Refractories

ASTM C202 Thermal Conductivity of Refractory Brick

ASTM C210 Reheat Change of Insulating Firebrick

ASTM C288 Disintegration of Refractories in an Atmosphere of Carbon Monoxide

ASTM C309 Liquid Membrane-Forming Compounds for Curing Concrete

ASTM C357 Bulk Density of Granular Refractory Materials

ASTM C401 Alumina and Alumina-Silicate Castable Refractories

ASTM C417 Thermal Conductivity of Unfired Monolithic Refractories

ASTM C467 Mullite Refractories

ASTM C559 Bulk Density by Physical Measurements of Manufactured Carbon and Graphite Articles

ASTM C560 Chemical Analysis of Graphite

ASTM C577 Permeability of Refractories

ASTM C583 Modulus of Rupture of Refractory Materials at Elevated Temperatures

ASTM C604 True Specific Gravity of Refractory Materials by Gas-Comparison Pyconometer

ASTM C673 Fireclay and High-Alumina Plastic Refractories and Ramming Mixes

ASTM C704 Abrasion Resistance of Refractory Materials at Room Temperature

ASTM C830 Apparent Porosity, Liquid Absorption, Apparent Specific Gravity, and Bulk Density of Refractory Shapes by Vacuum Pressure






ASTM C832 Measuring the Thermal Expansion and Creep of Refractories Under Load

ASTM C860 Determining and Measuring Consistency of Refractory Concretes

ASTM C862 Preparing Refractory Concrete Specimens by Casting

ASTM C865 Firing Refractory Concrete Specimens

ASTM C874 Rotary Slag Testing of Refractory Materials

ASTM C885 Test Method for Youngs Modulus of Refractory Shapes by Sonic Resonance

ASTM C899 Use of Metric Units of Measure for Reporting Properties of Refractory Materials

ASTM C903 Preparing Refractory Concrete Specimens by Cold Gunning

ASTM C914 Bulk Density and Volume of Solid Refractories by Wax Immersion

ASTM C974 Preparing Test Specimens from Basic Refractory Castable Products by Casting

ASTM E177 Use of the Terms Precision and Bias in ASTM Methods

ASTM E228 Linear Thermal Expansion of Solid Materials with a Push Rod Dilatometer

International Organization for Standardization (ISO)

ISO 10080 Refractory products -- Classification of dense, shaped acid-resisting products

ISO 528 Refractory products -- Determination of pyrometric cone equivalent (refractoriness)

ISO 1146 Pyrometric reference cones for laboratory use Specification

ISO 1893 Refractory products -- Determination of refractoriness under load -- Differential method with rising temperature

ISO 3187 Refractory products -- Determination of creep in compression

ISO 2477 Shaped insulating refractory products -- Determination of permanent change in dimensions on heating






ISO 2478 Dense shaped refractory products -- Determination of permanent change in dimensions on heating

ISO 8894-1 Refractory materials -- Determination of thermal conductivity -- Part 1: Hot-wire method (cross-array)

ISO 8894-2 Refractory materials -- Determination of thermal conductivity -- Part 2: Hot-wire method (parallel)

ISO 5018 Refractory materials -- Determination of true density

ISO 8840 Refractory materials -- Determination of bulk density of granular materials (grain density)

ISO 8895 Shaped insulating refractory products -- Determination of cold crushing strength

ISO 10059-1 Dense, shaped refractory products -- Determination of cold compressive strength -- Part 1: Referee test without packing

ISO 10059-2 Dense, shaped refractory products -- Determination of cold compressive strength -- Part 2: Test with packing

ISO 5013 Refractory products -- Determination of modulus of rupture at elevated temperatures

ISO 5014 Dense and insulating shaped refractory products -- Determination of modulus of rupture at ambient temperature

ISO 10058 Magnesites and dolomites -- Chemical analysis

ISO 8841 Dense, shaped refractory products -- Determination of permeability to gases

ISO 8656-1 Refractory products -- Sampling of raw materials and unshaped products -- Part 1: Sampling scheme

ISO 5417 Refractory bricks for use in rotary kilns Dimensions

ISO 9205 Refractory bricks for use in rotary kilns -- Hot-face identification marking.

ISO 13705 Petroleum, petrochemical and natural gas industries -- Fired heaters for general refinery service

ISO 10081 Classification Of Dense Shaped Refractory Products






ISO 1927 Classification of Prepared Unshaped Dense and Insulating Refractory Materials

ISO 2245 Shaped insulating refractory products; Classification

ISO 5016 Shaped Insulating Refractory Products; Determination of Bulk Density and True Porosity

ISO 5017 Dense Shaped Refractory Products; Determination of Bulk Density, Apparent Porosity and True Porosity

ISO 5019 Refractory Bricks; Dimensions

ISO 5022 Shaped Refractory Products; Sampling and Acceptance Testing

ISO 8501-1 Preparation of Steel Substrates Before Application of Paints and Related Products; Visual Assessment of Surface Cleanliness

ISO 8890 Dense Shaped Refractory Products; Determination of Resistance to Sulfuric Acid

ISO 9001 - 2000 Quality Management System Requirements

ISO 9004 - 2000 Quality Management Guidelines for Performance Improvement System

ISO 19011 Guidelines for Quality and/or Environmental System Auditing

3.0 REFERENCE DOCUMENTS

The following reference documents shall, to the extent specified herein, form a part of this specification. When an edition date is not indicated for a document, the latest edition in force at time of vendors proposal submittal shall apply.

Project Specifications

DGS-MN-001 Insulation

DGS-MU-002 Preservation and Export Packing

DGS-MX-001 Painting

Project Drawing

1-STD-MD-00039 Anchoring of Lining for Steel Stacks

4.0 DOCUMENT PRECEDENCE

The VENDOR shall notify the CONTRACTOR of any apparent conflict between this specification, the related data sheets, the Codes and Standards and any other






specifications noted herein. Resolution and/or interpretation precedence shall be obtained from the CONTRACTOR in writing before proceeding with the design of anchoring devices or application of any refractory materials.

In case of conflict, the order of precedence shall be stated in the AGREEMENT or other PROJECT documents as applicable.

5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL

Any technical deviations to the Purchase Order including, but not limited to, the Data Sheets and Narrative Specifications shall be sought by the VENDOR only through the CONCESSION REQUEST format. CONCESSION REQUESTS require CONTRACTOR'S/COMPANY'S review/approval, prior to the proposed technical changes being implemented. Technical changes implemented prior to COMPANY approval are subject to rejection.

6.0 QUALITY ASSURANCE/QUALITY CONTROL

VENDORS proposed quality system shall fully satisfy all the elements of ISO 9001 and ISO 9004. The quality system shall provide for the planned and systematic control of all quality-related activities performed during design, development, production, installation or servicing (as appropriate to the given system). Implementation of the system shall be in accordance with the CONTRACTORS Quality Manual and Project Specific Quality Plan, which shall both together with all related/referenced procedures, be submitted to COMPANY for review, comment and approval as required by purchase/contract documents.

The VENDOR shall identify in purchase documents to its SUBVENDORS all applicable QA/QC requirements imposed by the CONTRACTOR, and shall ensure compliance thereto. On request, VENDOR shall provide objective evidence of its QA/QC surveillance of its SUBVENDORS activities.

The VENDOR shall submit certified reports of production tests as soon as the tests are completed satisfactorily.

The COMPANY/CONTRACTOR reserves the right to inspect materials and workmanship at all stages of installation and to witness any or all tests. The VENDOR/APPLICATOR, within 30 days after award but prior to the inspection shall provide the CONTRACTOR with a copy of its Installation and Inspection Plan for review and inclusion of any mandatory COMPANY/CONTRACTOR witness points.

7.0 DOCUMENTATION

VENDOR shall submit the type and quantity of drawings and documentation for CONTRACTORS authorization or information as listed in the individual Material Requisitions and Purchase Orders.

Mutual agreement on scheduled submittal of drawings and engineering data shall be an integral part of any formal Purchase Order.






Comments made by CONTRACTOR on drawing submittal shall not relieve VENDOR or SUBVENDORS of any responsibility in meeting the requirements of the specifications. Such comments shall not be construed as permission to deviate from requirements of the Purchase Order unless specific and mutual agreement is reached and confirmed in writing.

Each drawing shall be provided with a title block in the bottom right-hand corner incorporating the following information:

Official trade name of the company VENDOR'S drawing number Drawing title giving the description of contents whereby the drawing can be identified A symbol or letter indicating the latest issue or revision Purchase Order number and item tag numbers

Revisions to drawing shall be identified with symbols adjacent to the alterations, a brief description in tabular form of each revision shall be given, and if applicable, the authority and date of the revision shall be listed. The term "Latest Revision" shall not be used.

8.0 SUBCONTRACTORS/SUBVENDORS

The VENDOR shall assume unit responsibility and overall guarantee for the equipment package and associated equipment.

The VENDOR shall transmit all relevant purchase order documents including specifications to his SUBVENDORS.

It is the VENDOR'S responsibility to enforce all Purchase Order and Specification requirements on his SUBVENDORS.

The VENDOR shall submit all relevant SUBVENDOR drawings and engineering data to the CONTRACTOR.

The VENDOR shall obtain and transmit all SUBVENDOR warranties to the CONTRACTOR/COMPANY in addition to the system warranty.

9.0 HANDLING

Preparation for shipment shall be in accordance with the VENDOR'S standards and as noted herein. VENDOR shall be solely responsible for the adequacy of the preparation for shipment provisions with respect to materials and application, and to provide equipment at the destination in ex-works condition when handled by commercial carriers.

Adequate protection shall be provided to prevent mechanical damage and atmospheric corrosion in transit and at the job site.






Preparation for shipment and packing will be subject to inspection and approval by COMPANY'S/CONTRACTOR'S inspectors. All costs occasioned by any rejection shall be to the account of the VENDOR.

10.0 GENERAL DESIGN

10.1 MATERIALS

10.1.1 Details, of the basic refractory material types that are acceptable for use on this project, are given in Sections 11, 12, and 13. If procedures established in this specification are different from those of the refractory MANUFACTURER, the more stringent requirements shall be met. All hot face refractory and insulation materials shall be resistant to temperatures which are at least 167C higher than the maximum process temperature of the equipment.

10.1.2 Recommended anchor materials for the various refractory types and operating conditions are given in Appendix 3.

10.1.3 If national and/or local regulations exist in which some of the requirements may be more stringent than in this specification, the MANUFACTURER shall determine by careful scrutiny which of the requirements are more stringent and which combination of requirements will be acceptable regarding safety, environmental, economic, and legal aspects. Any CONCESSION REQUEST from the requirements of this specification, which is considered to be necessary in order to comply with national and/or local regulations, shall be discussed with CONTRACTOR before initiation of any work.

10.1.4 Besides operating conditions, the design of linings shall also take into consideration construction and maintenance aspects.

10.1.5 The design of refractory linings shall be such that the outer wall temperature of refractory lined equipment shall be maintained between 60C and 80C at the ambient air temperature. The wind velocity shall be assumed to be 2 meters per second. Refractory linings can be single or multilayered, depending on operating temperatures. Maximum allowable surface temperatures of refractories may, for instance, necessitate the use of a hot face layer backed up by an insulating layer (multiple lining). Thicknesses of linings are determined by strength, method of application and insulation properties. Attention shall be paid to proper detailing of joints to compensate for thermal expansion and drying shrinkage.

10.2 SURFACE PREPARATION AND MEMBRANE APPLICATION

10.2.1 Surfaces to be lined with refractory materials shall be clean, free of all oil, grease, rust, loose mill scale, and other foreign matter prior to welding anchors. This work shall be the responsibility of the APPLICATOR.

10.2.2 After anchor attachment, surfaces shall be prepared in accordance with ISO 8501-1, Sa 1, Light Blast Cleaning. Care shall be taken so as not to damage anchors during blast cleaning. The prepared surfaces shall then be coated with a protective membrane applied to a total dry film thickness of 3 mm. The material shall be a urethane asphalt material






such as Pennwalt Tufchem II or Witco Stalastic CP-79 membranes. MANUFACTURERS published application data shall be followed during application of the membrane. This work shall be the responsibility of the APPLICATOR.

10.3 REFRACTORY MATERIAL ATTRIBUTES

10.3.1 Refractory materials shall possess the following characteristics as a minimum:

Resistance to high temperatures and temperature fluctuations. Chemical and mechanical resistance to those substances which come in contact

with the refractory material; (for example: gases, slags, etc.).

Sufficient mechanical strength to be part of the construction of the installation and to withstand loads during maintenance operations; and

Able to withstand conditions encountered with high velocity combustion systems when requirements dictate.

10.3.2 The VENDOR/MANUFACTURER shall supply the CONTRACTOR with the following information on each of the proposed refractory and related materials :

Material type including all data sheets, calculations, and detailed design drawings. Recommended type, spacing, and application method of anchors as required for the

refractory material to be used.

Recommended surface preparation and membrane application requirements. Recommended method for preparing and mixing of all refractory components as

appropriate.

Recommended method for the installation, curing and subsequent drying, initial and subsequent firing of the lining as appropriate.

Statement that the information given on published refractory data sheets is acceptable for testing purposes or that information provided by VENDOR/ MANUFACTURER, in lieu of the data sheets, may be used for testing purposes upon CONTRACTORS approval.

Past installations where the same or similar materials and installation have been used and when.

10.4 INSPECTION AND TESTING

The installation of all refractory materials to refractory lined equipment shall be inspected by an experienced third party inspector who shall be approved by the CONTRACTOR. The inspection shall be done in accordance with Appendices 1 and 2 and will include






reporting of visual observations. Inspection reports shall indicate areas which need repairs. Repairs shall be completed before acceptance of the equipment is made.

After drying of the lining, an inspection shall be made.

The inspection may be combined with the supervision of the final preparations for the firing and start-up operations. At random and as agreed by the CONTRACTOR, areas of the total lining shall be tested by striking with a ball-peen hammer (approximately 500 gm at 300 mm intervals). Any voids or dry filled areas will produce a dull sound. Such areas shall be replaced or core samples tested to established the quality of lining installation.

11.0 MONOLITHIC REFRACTORIES

11.1 DESIGN PARAMETERS

11.1.1 This section covers the design, supply, installation and testing of monolithic insulating, refractory products. If the procedures established in this specification are different from those of the refractory MANUFACTURER, the more stringent requirements shall govern.

11.1.2 The types of refractories that are applied as monolithic linings include castable, gunned, and plastic refractories.

11.1.3 Refractory bricks and shapes are often used in combination with monolithic refractory materials of similar compositions. Those materials are covered in Section 12 of this specification.

11.2 SUPPLY OF REFRACTORY MATERIAL

11.2.1 Manufacture of refractory materials

Refractory materials shall comply with the materials specification in Appendix 1. Sampling and testing shall be in accordance with Appendix 2.

11.2.2 Preparations for shipment

Each shipment shall be clearly identified according to the requirements of Appendix 1. Each pallet or container shall be clearly identified with the batch number, date of manufacture, if not an integral part of the batch number, and shall be waterproof packed.

11.2.3 Refractory shipment and storage

The material MANUFACTURER'S instructions for storage, handling, and shipment of materials shall be met. Shipment of refractory should be scheduled to ensure that it is installed within 6 months from the date of manufacture or within its specified shelf life, whichever is shorter. Material which has been longest in storage shall be used first.

Refractory materials shall be stored with protection from extreme weather conditions and exposure to sun. In winter, plastic moldable refractory materials may freeze and must be thawed before use. This is done by removing only the outside packaging, not the foil, and






storing in a warm place. Thawing may take several days; the material is ready when it can easily be formed by hand.

All hydraulic setting refractory materials shall be protected from moisture absorption during shipment and storage. Air-tight, moisture-tight polyethylene bags shall be used when specified by the CONTRACTOR.

Refractory that shows signs of having set, i.e. hard or unbreakable lumps in the dry mixture prior to installation, shall be rejected and be removed from the job site. Fractional parts from previous jobs as well as damaged bags, shall also be removed from the job site.

Refractory materials, except dated castable refractory materials, shall be protected to withstand ocean transit and extended periods of storage at the jobsite for a minimum period of 18 months. Storage of refractory shall preferably be in an air conditioned room. Materials shall be protected to safeguard against all adverse environments, such as humidity, moisture, rain, dust, dirt, sand, mud, salt air, salt spray, and sea water.

11.3 TRANSPORT AND HANDLING OF REFRACTORY LINED EQUIPMENT

The VENDOR/APPLICATOR shall submit procedures covering the design, manufacture and transportation for approval by the CONTRACTOR. The procedures shall address at least the following:

Maximum weights and the overall dimensions in view of transport facilities, access to the site/plant, and final erection

The shape of the equipment and/or the pieces of equipment. These should be as "compact" as possible since protrusions, small radii, or significant differences between main dimensions may give rise to damage in handling and transport.

Binding and securing methods. Portable sections shall be sufficiently bound or secured so that loading and unloading from barges, railroad cars or trucks will not crack the refractory lining. Rigid box forms are preferred. Lighter bindings consisting of sheets and T-sections should only be used together with an adequate diagonal bracing. Rigging should therefore be such that flexure and distortion do not have an impact on the integrity of the lining. Stiffening rings or structures should be applied where necessary.

Time of moving. To prevent possible cracking, deformation or distortion of the lining, the equipment should be left idle until the lining has been completely cured and air-dried (and hot-dried, if this is done at the prefabrication stage rather than at final installation on site).

Inspection. The installed refractory linings shall be inspected prior to shipment and upon arrival at site.

11.4 INSTALLATION OF ALL TYPES OF MONOLITHIC REFRACTORY MATERIALS






11.4.1 General Requirements

The APPLICATOR shall have successfully passed the APPLICATORS Procedure Qualification (APQ) as specified in Appendix 4, for the installation of the actual lining. An APQ is required for each crew and type of installation.

The APPLICATOR shall verify that the anchorage, applied coating and cleanliness of the surface to be lined is adequate to start refractory installation.

All equipment which will be used for preparation, mixing, transport, and installation of the refractory materials, shall be designed for this use. This equipment shall be clean, free of loose dust, dirt, oil or other foreign matter. Remnants of previously used refractory materials shall not be present as these may impair the quality of the materials to be applied.

11.4.2 Mixing

During "wet" mixing, all devices used, such as bowls, buckets, weighing scales, trowels, beater-arms, and hand tools should be thoroughly cleaned after each batch. Tools used continuously during installation shall be cleaned at least after each shift and each interruption of the work, if materials have set on the tools.

Depending on the abrasive nature of the refractory material, in order to ensure the proper working/mixing of the refractory material components, it is recommended to perform the test procedure in Appendix 4, Section A4-1.4.

Packaged mixed refractory materials shall be installed within 6 months of the date of manufacture, or before shelf-life expiry, whichever is sooner.

Mixing water to be used shall be of potable quality and shall contain less than 50 ppm chloride. If there is no proof that the water is of this standard, it shall be tested and approved by the CONTRACTOR prior to use.

11.4.3 Applying

Prior to the application of insulating refractory materials, all metal surfaces shall be lightly wetted but no puddles shall be present.

Provisions shall be made to maintain the refractory materials and equipment to be lined at a moderate temperature (10C - 25C) until curing is complete. The refractory and steel temperatures shall be continuously monitored and recorded hourly until curing is complete. Thereafter, the lining shall be protected from exposure to water, frost, condensation, or extreme heat until commissioning of the lining.

11.4.4 Joints

In refractory applications, the use of joints shall be minimized; when joints are unavoidable they shall be applied on calculated and practical locations. In general these locations are at corners, edges, changes of material quality, and at locations where a mechanical joint is






designed. Practical locations arise from the application procedures, such as scaffold platforms and changeovers for application equipment.

Distinction shall be made between expansion joints and butt-joints. Butt-joints are used when joining two different materials in the process of application. They are treated as the ordinary surface finish, and may be filled with a 1 mm layer of ceramic fiber paper.

Expansion joints are joints made in the lining to allow for thermal expansion.

It is essential that all expansion joints are constructed so as the specified width and depth still exists after installation has been completed.

Allowance shall be made for the compression of soft expansion joint material during installation of adjacent refractory lining.

All expansion joints shall have square edges and be at right angles to the hot face.

The specified method of construction is to secure the expansion joint material against the completed castable face and to then cast or apply the next section of castable. If fins or overlays of castable bridge over the surface of the expansion joint these shall be cut off neatly.

All joints shall be left with no obstructions against movement and fully packed with the specified expansion joint material.

Proposed expansion joints, fully dimensioned, shall be submitted for approval by CONTRACTOR prior to the start of work.

11.4.5 Internals

All nozzles and other fittings which protrude through or intersect the lining shall be wrapped over the full lining thickness with a layer of ceramic fiber paper having a thickness of 1 to 2 mm. The wrap shall be securely attached to avoid movement during refractory application.

Except for butt-joints, ceramic fiber paper in cast or gunned linings may be treated with a nonabsorbent coating or foil. Anchor tips for refractory materials, (e.g. V-anchors, Double or Y anchors) shall be coated with a mastic or provided with plastic caps before application of refractory.

11.4.6 Preparation for Startup

Refractory lined equipment shall not be operated until the lining has been completely cured, dried, fired and formally accepted by the CONTRACTOR. This shall include inspection in accordance with Section 10.4.

To avoid damage to the lining, the equipment shall be cured and initially heated in accordance with the approved drying and firing procedure. Critical limitation of temperatures during start-up and/or operations shall be submitted to the






CONTRACTOR/COMPANY in order to avoid possible refractory damage in the start-up process. Detailed specifications for curing, drying, and firing are given in Appendix 5.

Refractory lined equipment standing idle should be protected against frost and water ingress, especially for those cases where moisture can accumulate in the lining.

11.5 INSTALLATION OF PLASTIC REFRACTORY MATERIALS

11.5.1 Preparation

Plastic refractory materials are generally supplied ready-to-use, therefore no special preparations are necessary before the start of the work.

11.5.2 Installation

Plastic refractory materials are normally supplied in cartons and packed in foil as cakes, already sliced in 60 to 65 mm thick slices. Otherwise, such slices shall be cut and then broken into small, handsize pieces. The first layer may be applied in slice formation; subsequent small pieces shall be fed continuously and rammed in place. A layer thicker than the slice thickness shall not be rammed at one time.

Compaction shall be executed with pneumatic hammers, having a hammer frequency of 900 to 1200 blows per minute, using as few strokes as possible to avoid the formation of layers. Ramming shall be done by gradually shifting the hammer sideways, providing uniform and thorough compaction and knitting all parts monolithically together, leaving no voids. The rammed refractory surface should not be smooth; it should show hammer impressions (which indicates a good knit with the next material). When ramming refractory in overhead positions, before continuing the next layer, a roughened surface is required to achieve an intimate bond.

To save time and material, rammed refractories should be placed behind molds (e.g. shutter boards, forms, etc.) to prevent loss of compaction force, ensure firmness, minimize cracks, and ensure the specified lining thickness.

In rammed applications, tile anchors shall be placed after premolding with dummy tiles; alternatively, a ceramic tile anchor may be used as a dummy. When fixing the anchor tiles, proper engagement with the anchor jaws and adequate expansion allowance with intersected layers shall be assured.

11.5.3 Trimming

After the refractory has been compacted, the surface shall be trimmed with a scraper before the material hardens. In thick applications (over 100 mm), venting holes with a diameter of 3 to 4 mm and about 2/3 depth, pointing slightly upwards, are required.

Uniformly compacted and installed plastic and moldable refractory materials will often show cracks after drying and firing. Especially in burner walls/throats, score lines 30 to 50 mm deep shall be used to direct crack formation in a desired direction.






When halting application for short periods, to ensure that the refractory material remains moist, the finished area shall be cut at right angles to the shell and the surface re-roughened and covered with vinyl sheets. Longer halts are only permitted if marked-off sections have been finished, adequately secured against collapse or damage, and covered with vinyl sheets. Non-hardening plastics installed in overhead positions must be supported between installation and firing. Support can be provided by secured carbon steel wire mesh or other suitable method.

11.6 INSTALLATION OF CASTABLE REFRACTORY MATERIALS

11.6.1 Preparation

Water used for mixing or preparation of the refractory components, wetting of surfaces to be lined and for water spray during curing shall be potable and shall have a low chloride content (50 ppm maximum).

Castable refractories are normally supplied in moisture proof bags and are mixed with water on site and poured in place. The amount of water to be added depends on the type of the castable and the consistency required during installation. The minimum amount of castable to be mixed shall be one bag and larger mixes shall be made using a whole number of bags. No partial bag should be used.

The materials shall be mixed in a paddle mixer, fed through a 10 mm mesh screen to separate unwanted matter such as paper. The castable material may have compacted somewhat during transport and storage; such lumps may be broken and used. For much larger and continuous mixes, mixers of the rotary bowl or triple paddle type may be employed.

The duration of mixing is usually no more than three to four minutes, even less for light weight castables containing soft granulates such as Vermiculite which can easily be crushed and segregated. Prolonged mixing shall be avoided. The temperature of material and water shall be between 5C and 25C.

During mixing, the consistency shall be checked by the "Ball-in-hand" method in accordance with ASTM C860.

For vibration-cast applications precautions are required to minimize segregation or crushing of aggregate during mixing and transport of extra and lightweight castables.

11.6.2 Installation

Castable refractory materials shall be installed behind molds (e.g. shutter boards, forms, etc.). Pouring molds shall be stable and rigid and shall be constructed from wood or metal. They shall be treated to avoid water absorption. Mold height shall not exceed ten times the lining thickness, with a maximum of 1000 mm. Molds and forms should be sealed when jointed to prevent loss of water or material.






The castable shall be allowed to fill-in all the edges and corners, and air bubbles shall be expelled by tapping the mold with a hammer, thrusting a rod into the mix, or using a vibrator.

Each batch of the mixer shall be cast over the full thickness and evenly distributed. Once application has started it shall proceed without intervals until the entire scheduled lining has been completed. If an unavoidable interruption occurs, the wet ending of the lining shall be cut back at an angle to the surface to provide a slight keyed effect when the final material is cast. All material ahead of the cut shall be discarded.

Special attention shall be paid to dense, high quality and low-cement castables. They normally require small amounts of mixing water, are sensitive to temperature conditions and shall be treated as specified by the MANUFACTURER. Rodding shall be applied during placement.

If the castable material within the form must flow around numerous anchors or other torturous paths, easy flow refractory products should be used where practical unless otherwise approved by CONTRACTOR/COMPANY.

When using vibra cast products, proper substantial forms (inner and outer) must be provided with a means to attach external vibration devices. MANUFACTURERS recommendation for proper placement of these products shall be followed.

11.6.3 Trimming

When casting horizontal areas without molds, the finished surface shall be leveled off with a scraper or screed only; slurry shall not appear after finishing the surface. Horizontal linings shall be cast continuously without layer forming. Partitioning into suitable parts may be necessary; if so, the layout is subject to approval of the CONTRACTOR.

11.7 INSTALLATION OF GUNNING REFRACTORY MATERIALS

11.7.1 Preparation

Gunning refractory materials are normally supplied as ready-mix, packed in moisture proof bags. The contents of one or more bags shall be dry-mixed in a paddle mixer in order to negate possible segregation during transport. Should there have been some compaction during transport and storage, the materials should be fed through a 10 mm mesh screen to separate unwanted matter such as hard lumps, which may be broken and used unless they have set, and paper.

Materials found to have set (unbreakable hard lumps in the dry mixture), bags which are damaged, or fractional parts from previous installations shall be rejected and removed from the jobsite.

Predampening should be used to reduce dust formation during gunning and to improve the overall gunning performance. This shall be done by adding 4 to 6% by weight of the required water during mixing to the paddle mixer. This should be done to a point where a






handful of the mix can be squeezed into a ball which, when lightly pressed, breaks down again into fine material. Inspection should be performed at regular intervals.

All equipment should be as close to the area to be lined as practicable, including intermediate storage of materials to facilitate an easily controlled, continuous operation.

11.7.2 Installation

The appearance of the gunned refractory surface is the best indicator of a correct water/mix ratio. The amount of water shall be controlled such that the gunned surface has a wet, silky sheen and is such that coarse aggregates make craters on the gunned surface upon impact. A sandy or gritty surface means that too little water has been used. Slumping, ripples or a washboard effect indicates that too much water has been used.

The gunning operation shall be started on a surface other than the production surface. When the proper flow is achieved, the nozzleman shall then direct the stream towards the base of the production surface and proceed to build upwards. The nozzle should be kept about one meter away, and perpendicular to, the surface of the work.

Material shall be deposited as the nozzle is moved rhythmically in a series of oval loops, approximately. 150 to 250 mm high and 450 to 600 mm wide. These loops shall gradually cover an L-shaped surface of approximately 1000 mm x 1500 mm leg length. The total height of a band should be 1500 mm to 1900 mm, depending on the platform height of the installed scaffold.

Care shall be taken to ensure that rebounds fall or bounce clear of the target and are not entrapped. Entrapment of rebounds by the fresh stream from the nozzle can lead to laminations or spots of low density in the application.

Build-up of the lining shall be continuous and regularly measured. In order to minimize the numbers of stops (which then require jointing) the application routing shall be planned and executed such that assistants can continuously measure the applied thickness and clean the anchoring and platform.

11.7.3 Trimming

When finishing gunned refractory materials, the surface shall be scraped with a tool such as a curry comb, and not trowelled. Excess trowelling works the binder into the surface, seals the surface and restricts the escape of moisture during drying and firing. It may also create a thin crust of pure binder which will flake off when subjected to heating and cooling.

The surface should be left rough, but excessively built-up lining, mud-like spots, tears, and dry spots shall be removed. If anchors are exposed, the complete anchor shall be cleaned and the section of material repaired.

Finishing of the surface and checking of the nominal thickness should be done directly after a part is ready but before 'setting' starts. The thickness shall be checked either with a ruler or a marked awl. The frequency of required measurements depends on the skill of






the nozzleman. The specified minimum thickness shall be applied; material in excess of 15 mm over the specified minimum thickness shall be removed.

Although the major part of the rebound material consists of coarse granulate, continuous removal of the rebound material is essential because it hardens relatively quickly.

12.0 REFRACTORY BRICKS AND SHAPES

12.1 DESIGN

Walls, arches, hearths, and other equipment parts shall be designed and constructed to ensure structural stability at both ambient and at high temperature operation. Proven material properties and anchorage systems shall be used in the design and determination of lining thickness and stresses.

All shaped (insulating, dense, special composite or acid-resistant) refractory materials are classified in terms of the chemical and mineralogical nature of the main constituents according to ISO 1109, as follows:

High alumina products (Group HA) Fireclay and low fireclay products (Group FC and LF)

12.2 CLASSIFICATIONS OF SHAPED REFRACTORY MATERIALS

Refractory bricks are divided into four subgroups:

12.2.1 Shaped Insulating Refractory Materials

Insulating refractory materials are manufactured from base refractory materials, fired and with a total porosity of at least 45% determined in accordance with ISO 5016.

NOTE: This definition stems from the fact that thermal insulating products all have a low thermal conductivity and a small thermal capacity, properties which are related to the total porosity of the product. The bulk density, which for a given product is directly linked with porosity, can therefore be chosen as a criterion for classification.

12.2.2 Dense Shaped Refractory Materials

Dense refractory materials are manufactured from base refractory materials with a total porosity of less than 45% and with a Pyrometric Cone Equivalent (P.C.E.) of at least 1500C. The main constituents are alumina silicates.

In the manufacturing process, the method of bonding and the process of shaping the materials define to a great extent the ultimate properties of rectory bricks and shapes. A distinction may therefore be drawn between plastic, semi-dry and dry formed products.

12.2.3 Special Compositions






Special compositions are mainly manufactured from refractory base materials other than the alumina silicate group, i.e., basic compositions (magnesia), silicon carbide and zirconium silicate used for special applications.

12.2.4 Acid-Resistant Refractory Materials

Acid-resistant materials are outside the scope of this specification.

12.3 BURNERS

Refractory systems for burners shall be designed, fabricated, prefired and installed as an integral part of the burner assembly by the VENDOR. The refractory shall be resistant for a minimum service temperature of 16500C, to the gas velocity, and to the environment created by the combustion products.

12.4 REFRACTORY SHIPMENT AND STORAGE

All bricks shall be carefully unloaded and stacked by hand on the job site. Any items that are damaged, broken, chipped, or cracked during handling, or no longer conform to the specification, shall be removed from the job and replaced.

12.5 INSTALLATION OF REFRACTORY BRICK CONSTRUCTIONS

12.5.1 General

Only APPLICATORS experienced in refractory work shall be employed for the installation of refractory linings.

Before installation, the steel surface shall be prepared and coated and a thorough inspection shall be carried out of the condition and cleanliness of the surface to be lined. See section 10.2. The bricks shall also be clean. Sufficient ventilation shall be provided during the application of chemical containing materials, i.e. mortars.

Proper scaffolding shall be provided and overhead work shall only be executed with appropriate equipment and prior approval from the CONTRACTOR.

12.5.2 Temperature Control During Installation

To avoid temperature and humidity changes during installation, bricks should be stored near the job under the temperature conditions given below for approximately 48 hours before using.

The temperature of equipment that will be bricked-lined should be maintained between 5C and 25C. Lower and higher temperatures will influence the correct curing of the mortar.

At temperatures below 5C the equipment should be heated, preferably with electrically heated air. This heating should avoid uncontrolled moisture development and create an unoppressive environment for the labor force.






If the equipment to be lined is at a temperature above 25C, the mortar shall be mixed in small quantities in some other location and kept between 15C and 20C before use. Temperatures which are too high shorten the 'pot-life' of the mortar.

12.5.3 Bricked Constructions

All brickwork shall be set out and built to the required dimensions as shown on the drawings.

Generally, an appropriate mortar is used to level courses and to provide smooth bedding of the bricks. The thickness shall be consistent, as thin as possible, and be specified 1 to 4 mm thick. The mortar thickness selected depends strongly on the brick quality, the dimensional tolerances due to manufacturing, the type of mortar used, the desired resistance against gas permeability and slag penetration, and the thermomechanical stress applied under operating conditions.

Mortar shall be applied in full and consistent thin layers. All walls shall be built up regularly, not leaving any part more than 1 meter lower than another, unless because of special circumstances this is impracticable. Any walls left at different levels shall be stepped and sufficiently supported to avoid sagging in any direction. The courses shall be properly leveled, and plumbed as the job proceeds.

Standard bricks and shapes can be laid in four different ways in order to obtain a proper, strong and stable construction; combinations of all four ways (known as 'bonds') are used during installation.

Notwithstanding the shape of the standard bricks, whether or not they are rectangular tapered or radially shaped, the same bonds should be used for construction of walls, hearths, arches, and other flat, cylindrical or curved constructions.

In this manner a minimum number of shapes has to be ordered and stocked for maintenance, while reducing the need for special shaped nonstandard brick sizes.

12.5.4 Anchors

Anchor systems shall be used to assure sufficient stability of bricked constructions.

In general these systems shall consist of dedicated and specially designed refractory anchor blocks, attached to the shell or other support constructions by means of steel anchors. The metallurgy of these anchors shall meet the requirements in Appendix 3.

The properties of ceramic anchor blocks shall be at least equal to the highest properties of the refractory materials they support at the hot face.

Anchor systems shall be placed in square or staggered arrangements, with dimensions as summarized in the table below. The APPLICATOR/VENDOR shall state the exact dimensions in the design drawings, supported by calculations.






Table 12.1: Anchor Spacing

Construction Anchor Spacing

Roof < 450 mm

Vertical Wall: < 500 mm

Floor Only in special cases

12.6 INSPECTION

12.6.1 The installation of refractory materials shall be inspected by experienced third party inspection personnel who shall be approved by the CONTRACTOR before inspection begins. Equipment to be assembled from parts shall be checked for correct assembly before installation of the refractory lining. Brick-lined equipment shall be inspected at regular intervals. The inspection during new construction, as a minimum, shall include visual observations with consideration of the following:

General condition of the brick lining Color of the bricks Regular shape of the brick lining: disbonding of bed joints could cause irregularities Expansion joints; cleanliness and presence of loose particles Cracks; deformation of equipment due to lack of improper pretreatment can cause

irregularity

Level and condition of cement in the joints Lining in and around nozzles and manholes

12.6.2 If visual inspection or hammer testing reveals defects, e.g. disbonding, cracks (other than normally expected, e.g. due to shrinkage) or open joints, a further thorough examination is necessary. This may require locally opening up the brick lining, dependent on the severity of the defect.

13.0 CERAMIC FIBER LINING SYSTEMS

This section covers the design, supply, and installation of insulating ceramic fiber blanket or modules, and is intended to be primarily applicable to side walls and roofs of heaters.

A lining installation procedure shall be submitted for review and acceptance by the contractor prior to installation.






A properly designed and installed ceramic fiber module lined heater can withstand temperatures of 1400C. Ceramic fiber blankets are limited to velocities of 16 meters/second. Ceramic fiber modules can be used up to velocities of 23 meters/second. Modular designs shall be installed using a soldier courses pattern with batten strips for a tight installation. Initial shrinkage is removed during manufacture thus eliminating the need to repack joints after short periods of operation.

The module is approximately 450 mm x 300 mm as installed. Its thickness varies in order to suit individual heater wall and roof requirements. Modules shall be installed per MANUFACTURERS recommendations.

13.1 MATERIALS FOR CERAMIC FIBER BLANKET AND MODULES

Ceramic fiber materials shall have a composition within 46 to 49% Alumina and 51 to 54% Silica. Minimum blanket density shall be 128 kg/m3 . Materials having constituent parts outside of these ranges shall be submitted to CONTRACTOR for approval before initiation of any work.

Location of fibrous materials on the hot face are to be kept out of turbulent areas, around burners, kept from high velocity zones, and are not to be installed in locations where significant vibration would cause tearing or sagging of the fiber material. For those locations, materials from Section 11.0 or 12.0 of this specification are required.

The steel wall behind ceramic fiber refractories shall be coated with a 3 mm dry film thickness of impermeable mastic prior to installation. See section 10.2 for requirements.

Either layered blanket material or modularized units may be considered for use on equipment vertical walls. Details for this must be submitted for review and acceptance by the CONTRACTOR prior to initiation of any work.

It is important that the joints on successive layers be staggered a minimum of 100 mm so that hot gases cannot be channeled back to the steel shell.

Ceramic fiber in conformance with this section may be used for expansion joint material with plastic, brick, or insulating refractory materials as shown on drawings.

13.2 ANCHORING FOR BLANKET AND MODULE INSTALLATION

Anchor types and installation shall conform to the ceramic fiber materials manufacturers guidelines, with suggestions and recommendations understood to be requirements. Metallurgy of the anchors shall meet the requirements given in Appendix 3. After installation of ceramic fiber blanket, hold down clips shall be covered with LDS moldable to protect the metal from oxidation.

Anchors and studs shall be installed in accordance with AWS D1.1, 1995, Section 7, Stud Welding. Qualification of all equipment and personnel shall be conducted prior to use for anchor attachment. The number of tests to be conducted on qualified welders shall be 20% minimum, in addition to the 100% visual examination required by paragraph 7.8.1 of AWS D1.1. Testing shall also be conducted in accordance with paragraph 7.7.1.3 and






7.7.1.4 of AWS D1.1 for the first two studs welded each day or shift. The verification inspector for this work shall be certified by the American Welding Society or by the MANUFACTURER with special training as a qualified inspector.

Anchoring and joining of ceramic fiber modules shall be in accordance with the MANUFACTURERS instructions.

13.3 JOINTS OF CERAMIC FIBER BLANKET

The two basic methods for joining ceramic blankets are butt and overlapping.

13.3.1 Butt Joints

Butt joints are used to join backup layers of fiber material in a ceramic fiber blanket system. When installing, the joint should be compressed by overlapping the ends 15 mm and compressing them together to form a butt joint. Butt joints shall be staggered in successive layers of blanket.

13.3.2 Overlapped Joints

All hot face ceramic fiber blanket material shall have overlapping joints. When installing blanket using the overlapped joint, overlap the ends 50 mm on both layers of the hot face material to give a total 100 mm lap.

13.3.3 After installation of ceramic fiber materials and during shipment, they shall be covered and protected from collecting water or being completely wetted. Materials that have loosened, sagged, or been soaked shall be replaced. If installation is in the field, all ceramic fiber materials shall be kept clean and dry through installation.

14.0 SPECIFIC APPLICATIONS

14.1 FIRED HEATERS

Reference shall be made to Table 14.1 below, for specific refractory materials to be installed in each particular location of a fired heater.

Table 14.1: Refractories for Fired Heaters

Gas Fired Heaters Oil Fired Heaters

Radiant

Walls:

Ceramic fiber modules or blankets with vacuum formed ceramic fiber special shapes used at peep doors, arch areas, etc.

Same as for gas fired.

Roofs:

(Arch)

Same as for walls except that castable may be used in some instances

Same as for gas fired, but Group FC30 refractory bricks around uptakes






Table 14.1: Refractories for Fired Heaters

Gas Fired Heaters Oil Fired Heaters

Convection Section

Insulating Castable Same as for gas fired

Floors: FC30 refractory bricks protection layer (hot face) over either Group 125 insulating castable or Group 130 insulating firebricks

Same as for gas fired.

Hot ducts: Ceramic fiber modules or blanket, or castable. (Ceramic fiber materials have velocity limits which shall not be exceeded).

Same as for gas fired, but FC30 refractory bricks around uptakes and areas susceptible to erosion.

Stacks: Monolithic, Gunning Same as for gas fired.

*See Figure 14.1 for details.

14.2 STACKS

The refractory system to be applied for lining of steel stacks shall be in accordance with drawing STD-MD-00039, Anchoring of Lining for Steel Stacks.






FIGURE 14.1

REFRACTORIES FOR FIRED HEATERS

The abbreviations used on this drawing and Table 14.1 are:

CFVF ceramic fiber vacuum formed IC insulating castable CFM ceramic fiber modular (system) IFB insulating fire brick FC fireclay brick CFB ceramic fiber blanket BI block insulation






APPENDIX 1

SPECIFICATION FOR MONOLITHIC REFRACTORY MATERIALS

A1-1.0 Scope

This appendix specifies the properties required for monolithic insulating and dense refractory materials which are used in heaters, ducts, stacks, vessels, or piping.

The materials specified are plastic or moldables, castables or gunned mixes, depending on their method of application.

A1-1.1 Specification of Monolithic Refractory Materials

Designation of materials shall be in accordance with ISO 1927.

A1-1.2 Temperature

Classification of insulating and/or dense refractory castables, moldables and plastic ramming mixes are made on the basis of the maximum temperature of use and permanent linear change in dimensions.

For moldables and plastic ramming materials, the sum of the linear drying and firing shrinkage after testing for a soaking period of five (5) hours, at this temperature, shall not exceed the specified value given in Appendix 2, Table A2-3.

For insulating and dense refractory castables, the permanent linear change (PLC) after testing for a soaking period of five (5) hours at this temperature shall not exceed the specified value as given in Appendix 2, Table A2-3.

A1-1.3 Application

Installation or repair of refractory linings shall be executed with the specified refractory materials.

A1-1.4 Applicable Standards

Testing shall be performed in accordance with the standards shown in Appendix 2, Table A2-1.

The test results shall be reported on forms having the minimum content of those shown in Appendix 2, Figure A2-3.

The VENDOR/APPLICATOR shall submit to the CONTRACTOR, the MANUFACTURERS certificates for all refractory materials supplied.

Certificates shall attest that the materials comply with the MANUFACTURERS data sheets and shall include the following information:






Name of manufacturer* Material name* Dates of manufacture/preshipment tests*, combined with batch identification

numbers*

Order number Shelf life and storage precautions* Recommended water/liquid quantity Preshipment test results of the batches and specifications to which these test

results comply

*This data shall also be marked on the packaging

A1-1.5 Material Limitations

A1-1.5.1 Exposure to Sulfur and Vanadium Components

When the fuels fired in equipment contain >0.5% (weight) sulfur or >400 ppm (mg/kg) vanadium, the monolithic refractory materials shall be submitted to the following limitations:

Fuels containing >0.5% (weight) Sulfur:

the 'facing' material shall be 1250 kg/m3 or denser; the binder shall be calcium aluminate cement with >50% (weight) aluminate facing material shall belong to the 'Low-Iron' class of materials

Fuels containing >400 ppm (weight) Vanadium:

the 'facing' material shall be 1250 kg/m3 or denser the aluminate content shall be not less than 40% (weight)

A1-1.5.2 Other Limitations

When fired equipment is designed for water washing of tubes, 'facing' materials shall be 1250 kg/m3 or denser. In these cases the design should be a multi-layer system consisting of a layer of dense refractory bricks, backed up by an insulating layer of not lighter than ISO LW 110-L.






APPENDIX 2

SAMPLING AND TESTING MONOLITHIC REFRACTORY MATERIALS

A2-1.0 Introduction

This Appendix specifies the testing and acceptance criteria for monolithic insulating and dense refractory materials.

Testing shall be performed in accordance with the standards shown in Table A2-1. The tests shall be performed by a laboratory, subject to approval by the CONTRACTOR, which is experienced and qualified to test refractory materials.

Additional specific properties may be controlled depending on the field of application or the operating factors on the basis of which the refractory material is chosen.

The following are the various tests that may be used for evaluation of refractories during manufacturing:

Table A2-1

Properties of Refractory Materials Available Test Methods According To: ISO ASTM Classification 10081

1927 2245 10080

C27, C155, C401, C467, C673

Refractoriness (PCE) 528 1146

C24

Refractoriness under load 1893 C16 Creep 3187 C832 Permanent Linear Change (PLC) 2477

2478 C179, C113, C210

Thermal Expansion C832 E228

Thermal Conductivity 8894-1/2 C182, C201

C202, C417 Density (Bulk, True)

5016 5017 5018 8840

C20, C135, C357, , C559 C604, C830 C914

Cold Crushing Strength 8895 10059

C133






Table A2-1

Properties of Refractory Materials Available Test Methods According To: ISO ASTM Modulus of Rupture 5013

5014 C133 C198, C583

Abrasion Resistance C704 Porosity (Apparent, True)

5016 5017

C20, C830

Young's Modulus C885 Sieve Analysis C92 Chemical Analysis

10058 C560

Workability, Moisture content (Ball-in-hand)

C92, C181 C860

Gas Permeability 8841 C577 Resistance to Slags, Gases, Vapors 8890 C288,

C874 Sampling and Preparation 5022

8656 C862, C865 C903, C974

Installation C903 Dimensions 5019

5417 9205

C899

A2-1.1 Sampling for Testing of Supplied Refractory Materials

Sampling shall be executed on all supplies of refractory materials according to Table A2-2. In case of urgent supplies and/or limited quantity to be delivered, reduced sampling and testing may be performed if approved by the CONTRACTOR. A sample shall contain the appropriate amount of refractory material to produce the required specimen to execute testing according to the relevant standards.

Table A2-2 Number of Samples for Testing

Bulk Density kg/m3

Material Group

Number of Samples

1250 Extra light weight Light weight

Minimum 2, plus 1 for every 12.5 tons (or part thereof)

1250-1750 MW Minimum 2, plus 1 for every 25 tons (or part thereof)

> 1750 Over MW including plastic, moldables

Minimum 2, plus 1 for every 10 tons (or part thereof) above 20 tons






Each sample of refractory material shall be clearly stamped with a day code and a code for the sequence of production. The coding shall be unique, and identifiable to the applicable MANUFACTURER'S test report.

Prior to shipment of the refractory materials, the MANUFACTURER shall regularly and at random check the quality on consistency and granulometry during the production of the batches, according to Table A2-2.

The MANUFACTURER shall take one sample per day's production or batch for testing in the test laboratory and the remainder of the samples shall be stored for subsequent (if necessary) retesting in air tight plastic bags. The MANUFACTURER is responsible to ensure that the samples are regularly delivered for testing to the test laboratory.

A2-1.2 Testing of Material Properties During Manufacture

The refractory materials shall meet the requirements of the MANUFACTURER'S data sheet with a tolerance (for sieve analysis) and a range of tolerances for other characteristics as stated in Table A2-3. The MANUFACTURER'S requirement as well as 95% of tested results shall fall within the range of tolerance and be presented on a form similar to that of Figure A2-2, Preshipment Test Report.

Table A2-3 Acceptance Criteria Tolerance (+/-) Property Tolerance

Sieve analysis, per retainment

20% of the specified percentage

True Density: (kg/m3) less than 1250 50 kg/m3 1250-1750 35 kg/m3 over 1750 20 kg/m3 Bulk Density (BD): (kg/m3) less than 1250 125 kg/m3 1250-1750 150 kg/m3 over 1750 175 kg/m3 Individual Total Cold Crushing Strength: for BD less than 800 kg/m3 2 MN/m2 1 MN/m2 800-1249 kg/m3 6 MN/m2 3 MN/m2 1250-1750 kg/m3 12 MN/m2 8 MN/m2 over 1750 kg/m3 20 MN/m2 15 MN/m2 Permanent Linear Change (PLC): for BD less than 1250 kg/m3 150% 75% 1250-1750 kg/m3 200% 100% over 1750 kg/m3 200% 100%

Additional testing to be performed for plastic and moldable materials shall be:






Moisture Content Workability

A day's production or batch of refractory of which the test results do not meet the tolerances specified above shall be retested, using the stored reference samples. Retesting shall additionally be performed for:

Cold crushing strength, dried at 110C Permanent linear change, fired at the appropriate temperature

Any failure in this testing shall mean rejection of the day's production or batch.

A2-1.3 Sampling and Testing During Installation

a. Prior to Installation

Prior to the installation of a lining, the APPLICATOR shall perform procedure tests to demonstrate, to the third party inspector, that his working methods, equipment and operators can produce refractory linings in accordance with the design requirements. A successful test qualifies the procedure and the operators for the installation of the actual lining. Refer to Appendix 4 for details of the APPLICATORS Procedure Qualification (APQ).

b. During Installation

At randomly selected times during each shift, at the direction of the third party inspector, the APPLICATOR shall prepare a number of samples (panels) using the same refractory materials being installed. The minimum number of samples is shown in Table A2-2. Preparation of the samples shall be witnessed by the CONTRACTOR. Depending on the type of refractory material, samples shall be either (Figure A2-1):

standard shape: 230 x 114 x 64 mm (see Note below) box: 280 x 280 x 75 mm, for ramming and poured castables; panels: 500 x 500 x 114 mm, for gunned refractory materials.

NOTE: Filling shall be done with the dimension of 114 mm upright.

Each sample shall be clearly marked with the APPLICATORS code numbers for that day/shift/crew and for sequence of production. Each code shall be unique, and traceable to the locations where refractory has been applied by that crew during that shift.

The APPLICATOR is responsible to ensure that the samples are regularly delivered for testing to the test laboratory. Test specimens shall be cut from the samples at the laboratory, after being prepared, cured and air-dried at the work site.






A2-1.4 Testing of Refractory Samples Taken During Application

For each sample, the following properties shall be tested:

Bulk Density Apparent Porosity Water Content (1 per shift)*; Cold Crushing Strength; Permanent Linear Change.

*for information purposes only, not subject to acceptance criteria.

The acceptance criteria for these tests shall be as stated in Table A2-3.

If the test values do not meet the specification, new samples from the same panel or, if necessary, from the related lining section, shall be retested for:

Bulk Density Cold Crushing Strength Permanent Linear Change

If the retest results do not meet the specification, the lining section related to the tested samples shall be rejected.

Results shall be presented on a form similar to that of Figure A2-3.






FIGURE A2-1

TEST PANELS






FIGURE A2-2

PRE-SHIPMENT TEST REPORT

PRESHIPMENT

Manufacturer: Product Name: Date

TEST REPORT Order Number: Identification Number: Serial Number:

Remarks: Mixing water % (wt) Chemical Analysis % (mass)

SiO2 Al2O3 TiO2 Fe2O3 CaO MaO K2O Na2O

Mean

SIEVE ANALYSIS

Numb

er

Date

True Density, t

(kg/m3)

< 0.063 mm

0.063 - 0.125 mm

0.125 - 0.25 mm

0.25 - 0.5 mm

0.5 - 1 mm

1 - 2 mm

2 - 4 mm

4 - 8 mm

8 - 16 mm

MEAN

STANDARD DEVIATION,




Takreer DGS-

Dgs-mn-003-r1 Materials, Installation and Testing Requirements for Refractory Systems

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