IRM-SU-4789-E: Installation of Fired Heater...

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IRM-SU-4789-E

INSTALLATION OF FIRED HEATER REFRACTORIES

APPLICATION: ONSHORE

Installation of Fired Heater Refractories IRM-SU-4789-E


CONTENTS

Part A: Scope, References, and General Requirements ....................................................41.0 Scope ...........................................................................................................................42.0 References ..................................................................................................................4

2.1 ......Purchaser Documents ......................................................................................42.2 ......Industry Standards ...........................................................................................4

3.0 Governing Documents ...............................................................................................5Part B: Materials Other Than Refractory Ceramic Fiber for Fired Heaters .......................61.0 Scope ..........................................................................................................................62.0 Materials ......................................................................................................................6

2.1 ......Castable Refractory Material ............................................................................62.2 ......Insulating Firebrick (IFB) ..................................................................................62.3 ......Brick and Shapes (other than IFB) ...................................................................62.4 ......Mortar ...............................................................................................................62.5 ......Metallic Components ........................................................................................72.6 ......Block Insulation ................................................................................................8

3.0 Storage and Handling of Refractory Material ..........................................................83.1 ......Moisture Protection ..........................................................................................83.2 ......Water Contaminated Materials .........................................................................83.3 ......Shelf Life ..........................................................................................................93.4 ......Handling Requirements ....................................................................................9

4.0 Installation of Anchors and Other Metallic Components .......................................94.1 ......Welder Qualification .........................................................................................94.2 ......Surface Preparation .........................................................................................94.3 ......Vee Anchors for Castable Linings ....................................................................94.4 ......Installation Requirements - Metal Fiber Reinforcement ...................................94.5 ......Installation Requirements - Anchorage System for IFB Lining .........................94.6 ......Anchor Welding Hold Point ............................................................................10

5.0 Installation of Castable Linings in Fired Heaters ..................................................105.1 ......General Requirements ...................................................................................105.2 ......Weather Protection .........................................................................................105.3 ......Surface Preparation .......................................................................................115.4 ......Thickness Tolerances ....................................................................................125.5 ......Cast Installation of Hydraulically Bonded Castable Linings ...........................125.6 ......Gunned Installation of Hydraulically Bonded Castable Linings ......................12

6.0 Installation of Insulating Firebrick and Fireclay Brick ..........................................136.1 ......Insulating Firebrick .........................................................................................136.2 ......Installation of Fireclay Brick ............................................................................13



7.0 Ambient Temperature Curing and High Temperature Dryout of Castable Linings ......................................................................................................147.1 ......Ambient Temperature Curing .........................................................................147.2 ......Controlled High Temperature Dryout .............................................................15

8.0 Crew Prequalification ..............................................................................................158.1 ......General Requirements ...................................................................................158.2 ......Castable Refractory Installation Crew ............................................................15

9.0 Production Sampling ...............................................................................................169.1 ......General ...........................................................................................................169.2 ......Field Curing of Production Samples ...............................................................17

10.0 Inspection and Testing ............................................................................................1710.1 ....Hold Points .....................................................................................................1710.2 ....Crew Prequalification Inspection ....................................................................1710.3 ....Anchor Inspection ...........................................................................................1710.4 ....Inspection of Installed Castable Linings .........................................................1810.5 ....Testing ............................................................................................................1810.6 ....Inspection of Firebrick and Special Shape Lining Installations ......................19

Part C: Refractory Ceramic Fiber Linings for Fired Heaters ............................................211.0 Scope ........................................................................................................................212.0 General Requirements .............................................................................................213.0 Materials ....................................................................................................................21

3.1 ......Anchors ..........................................................................................................213.2 ......Vapor Barrier Coating .....................................................................................223.3 ......RCF Products .................................................................................................22

4.0 Storage and Handling of RCF Lining Materials .....................................................225.0 Anchor Installation ...................................................................................................23

5.1 ......Welder Qualification Testing ..........................................................................235.2 ......Production Weld Testing ................................................................................23

6.0 Vapor Barrier Installation ........................................................................................237.0 RCF Installation ........................................................................................................23



PART A :SCOPE, REFERENCES, AND GENERAL REQUIREMENTS

1.0 SCOPEThis specification covers the installation requirements for refractory material in fired heaters and boilers. These materials include:1. Castable, hydraulic setting refractory2. Insulating Firebrick (IFB)3. Firebrick and special shapes4. Refractory Ceramic Fiber (RCF)

2.0 REFERENCES1. The following documents are referenced herein and are to be considered part of this specifica-

tion.2. Use the edition of each referenced document in effect on the date of the publication of this

specification.

2.1 Purchaser DocumentsSpecificationsIRM-SU-4785 Purchasing Specification–Monolithic RefractoriesIRM-PU-4786 Installation of Monolithic Refractory Linings in Vessels and Lines

Standard Drawings and FormsGD-N1262 Details for Installation of Module Lining and Veneering for Refractory

Ceramic Fiber Linings in Fired HeatersGD-N1263 Details for Installation of Layered Blanket and Blanket/Board for Refrac-

tory Ceramic Fiber Linings in Fired HeatersGC-N1268 Monolithic Refractory Material Requirements (Sheet 1)

Monolithic Refractories Recommended Brands (Sheet 2)GD-N1269 Installation Details for Monolithic Refractory Linings Thicker than 1 InchGD-N1271 Sample Boxes for Refractory Materials Qualification, Crew Prequalifica-

tion, and Production Sampling

2.2 Industry StandardsAmerican Petroleum Institute (API)RP 936 Refractory Installation Quality Control Guidelines - Inspection and Testing

Monolithic Refractory Linings and Materials

American Society of Mechanical Engineers (ASME)VIII Paragraph UW-32 "Surface Preparation for Welding"IX Paragraph QW-181.2 and QW-462.4(b) "Welder Qualification"

American Society for Testing and Materials (ASTM)A 743/ A 743M Standard Specification for Castings, Iron-Chromium, Iron-Chromium -

Nickel, Corrosion Resistant, for General Application



C-155-70 Classification of Insulating FirebrickC-909-81 Dimensions of a Modular Series of Refractory Brick and ShapesC-133 Concrete Aggregates

Society of Protective Coatings (SSPC)SP-3 Power Tool CleaningSP-7 Brush Blasting (NACE #4)

3.0 GOVERNING DOCUMENTS1. Refractory lining materials, testing, installation and inspection shall comply with the

requirements of API 936 except where modified by either Owner’s Standard Specifications or Owner’s Project Specifications and Drawings.

2. The refractory manufacturer's installation instructions are part of this specification. 3. Any conflict between this specification and other instructions shall be submitted to the

Purchaser representative for resolution prior to the start of any work where the particular material or procedure in conflict will be used.

4. Prior to the start of any work, the installation Supplier shall prepare and submit written installation procedures for approval. a. The approved procedures are part of this specification. b. The procedures as a minimum shall include:

1) Materials Safety Data Sheets (MSDS) for all refractory materials to be used2) Installation procedures for each type of refractory material, including type of anchor

to be used, amount of water (also predamp water for gun mixes), amount of metal fiber to be added, mixing time, tempering time if applicable, placement of equipment

3) Installation schedule for tracking each individual refractory installation.4) Curing and dryout schedule5) Brand name of curing compound to be applied to castable surface6) Type of mortar to be used for brick, type and thickness of mortar joints, bonding of

brick walls7) Quality control plan

5. The Purchaser will provide the installation Supplier with Project Documents.



PART B : MATERIALS OTHER THAN REFRACTORYCERAMIC FIBER FOR FIRED HEATERS

1.0 SCOPE1. This part of the specification covers refractory materials other than RCF and installation

methods used with these other materials.2. Inspection and testing of castables and certain types of brick (used in fired heaters) are also

included.

2.0 MATERIALS

2.1 Castable Refractory Material1. Drawing GC-N1268 shows various types of monolithic refractories that are

acceptable. 2. The physical and chemical properties of the refractory material shall, as a minimum, meet the

values of GC-N1268.3. All refractory material shall be prequalified in accordance with IRM-SU-4785.4. L-H-V-type castables shall not be used for these applications.

2.2 Insulating Firebrick (IFB)1. Only commercial IFB with a 2300°F or higher temperature rating shall be used. Refer to

ASTM Specification C 155-70.2. The manufacturer's quality control data for the IFB selected shall be supplied to the

Purchaser's representative for review. 3. If there are concerns about one or more physical properties, the Purchaser will send a small

representative sample to an independent laboratory for reheat and compressive strength testing (preferably, before shipment to the jobsite).

4. Dimensions of the IFB shall meet the requirements of ASTM C 909-81. 5. Dimensional tolerances shall be ± 1/16 inch.

2.3 Brick and Shapes (other than IFB)1. Only super-duty firebrick shall be used in the construction of bridge and divider walls.2. Dimensions of firebrick used in the construction of walls shall meet the requirements of

ASTM C 909-81. a. Dimensional tolerances shall be ± 1/16 inch on all dimensions. b. Brick not meeting these requirements will be rejected at the jobsite.

3. Dimensions of special shapes shall meet the following requirements:a. ± 1/16-inch tolerance on dimensions < 36 inches.b. ± 1/8-inch tolerance on dimensions > 36 inches.

2.4 MortarMortars shall have adequate refractory properties and be chemically compatible with the brick being laid.



2.5 Metallic Components

2.5.1 General Requirements1. The installation Supplier shall select metallic components on the basis of the

following two components:a. the maximum long-term exposure temperature to which any part of the

component will be exposedb. sulfur content of the fuel, as shown in Tables 1A and 1B of GD-N1262 (these

tables also cover metallurgy requirements for RCF anchorage).2. Anchors and studs of austenitic stainless steel shall be supplied in the fully

solution-annealed condition.

2.5.2 Independent Anchors for Castable Linings1. Acceptable independent anchors for single and two-component castable linings are

shown in Detail 1 of GD-N1269.2. For thick, single-component linings, the independent anchor height shall be

approximately 75% of the lining thickness. a. In all cases, refractory cover over the anchor tip shall be 1 inch minimum. b. In other words, for a 4-inch thick lining, the anchor height should be

approximately 3 inches.c. The tip temperature of the anchor must not exceed the maximum use temperature

of the metal as shown in Table 1 of GD-N1269.3. Anchors for two-component linings shall be in accordance with Detail 2 of

GD-N1269.4. Other independent anchoring systems for refractory linings may be proposed by fired

heater suppliers and refractory installation Suppliers and are subject to approval by the Purchaser.

2.5.3 Anchorage Systems for IFB Linings1. If the anchorage system is designed by the installation Supplier, the type of anchors,

hangers and/or anchorage systems used to hold IFB linings (both walls and arches) in place shall be clearly detailed on project drawings and approved by the Purchaser before the job is started.

2. Locations and/or exact spacings for individual anchors shall be clearly defined on project drawings.

2.5.4 Support Shelves1. Complete details on structural members used as support shelves for IFB and other

linings shall be shown on the project drawings and approved by the Purchaser before the job is started.

2. The details shall include:a. Type of metalb. Dimensions



c. Spacingd. Attachment methode. Slits for thermal expansion, if required.

2.5.5 Metal Fiber Reinforcement1. Metal fibers shall be used to reinforce linings in areas where mechanical abuse or

thermal shock is a design consideration.2. Metal fibers shall be stainless steel Type 302 or 304 and shall meet the following

requirements:a. Gunned Refractory Installation.?Fibers shall be 0.020-inch diameter by 1 inch

long, made by a "melt-extraction" process, with chemical requirements per ASTM A 743/A 743M.

b. Proposals to use other alloys or metal types shall be submitted to the Purchaser representative for approval.

2.6 Block Insulation1. Block insulation shall be used as back-up material (to IFB or other refractory) only in fired

heaters and furnaces where sulfur content of the fuel is relatively low (< 0.2%).2. Block insulation shall be rated by ASTM procedures for a minimum temperature of 1800°F,

well above anticipated hot face temperatures.

3.0 STORAGE AND HANDLING OF REFRACTORY MATERIAL

3.1 Moisture Protection1. Refractory material shall be protected from moisture during shipping, handling, and storage.2. Refractory material shall be stored indoors on dry concrete slabs unless approved otherwise by

Purchaser.3. If refractory material must be stored out of doors, the material shall be set on concrete slabs or

compacted shell, stone, or other hard durable surfaces which are sloped to ensure water drainage away from the storage area.

4. Refractory material shall not be stored outdoors on grass, soil, or any soft uncompacted surfaces or in an area where water has, or may collect or stand.

5. If refractory material is stored outdoors, the factory shrinkwraps shall be left undamaged and, in addition, the pallets shall be covered completely with water resistant tarpaulins free from holes, tears, or other defects which may prevent the covers from protecting the pallets from moisture.

6. The tarpaulins shall be stretched or sloped to prevent water from standing or collecting on top or around the bottom of the storage area.

3.2 Water Contaminated Materials1. Any material or pallets of material showing evidence of water contamination shall be rejected

prior to use, regardless of the date of the prequalification (or requalification) testing.2. Any individual container of refractory material containing lumps resulting from moisture

penetration shall be discarded.



3.3 Shelf LifeRefractory material not used within six months of prequalification testing shall be requalified before installation in accordance with the requirements of Section 3.0 of IRM-SU-4785.

3.4 Handling RequirementsAll refractory material shall be handled carefully during storage and transfer to minimize damage to the pallet shrinkwraps and individual containers.

4.0 INSTALLATION OF ANCHORS AND OTHER METALLIC COMPONENTS

4.1 Welder QualificationWelders shall be qualified in accordance with ASME IX Section QW-181.2 and QW-462.4(b).

4.2 Surface PreparationThe surface shall be prepared per Drawing GD-N1269.

4.3 Vee Anchors for Castable Linings1. Vee anchor pattern, orientation, and spacing of anchors for one- and two-component linings

shall be as shown on Detail 4 of GD-N1269.2. During layout of anchor locations, the center punch marks (showing where anchors are to be

installed) shall be encircled in crayon beyond the affected area to make the marks easier to see.3. Anchors shall be welded per Detail 5 of Drawing GD-N1269.

a. Table 2 on the drawing lists recommended consumables and preheat requirements. b. See Section 10.0 for inspection requirements.

4.4 Installation Requirements - Metal Fiber Reinforcement1. Castable linings in the convection section of fired heaters and process furnaces shall

contain metal fibers.2. When metal fibers are used, the fiber shall be uniformly distributed in the refractory castable.

a. Fibers added in the field shall be added after the refractory has been placed in the mixer but before the addition of water.

b. Fibers shall be introduced as a rain of individual fibers through a vibrating screen to prevent clumping of the fibers.

c. Wire mesh for the screen box should have ½-inch (square) nominal openings.3. For insulating and semi-insulating castables (the types used in fired heaters), 5 pounds of

stainless steel fiber shall be used per 100 pounds of dry castable.

4.5 Installation Requirements - Anchorage System for IFB Lining1. The design of IFB walls and arches and anchorage systems for these installations shall be

clearly shown on project drawings. 2. The IFB anchors shall not be attached (or welded) directly to the shell.3. Angle clips, nuts, or other shell attachments (anchor connectors to hold the cold end of the IFB

anchor) shall be carefully positioned and welded to the shell as per project drawings.



4.6 Anchor Welding Hold Point1. Welded anchor and/or anchor connector installation constitutes a hold point. 2. The refractory cannot be installed without prior inspection of these components.

5.0 INSTALLATION OF CASTABLE LININGS IN FIRED HEATERS

5.1 General Requirements1. Hydraulically bonded castables shall be installed and cured only when ambient temperatures

at the installation area are between 50°F (10°C) and 95°F (35°C).2. All water used for mixing refractory material shall be clean, potable, and have no more than

200 ppm chloride, and shall be within the specified temperature range 50°F (10°C) and 95°F (35°C).

3. To compensate for wetting of fibers in metal fiber reinforced linings or to attain the required consistency for casting during hot weather, the maximum amount of water used in casting applications shall not exceed 1.03 times the water used in the materials prequalification test samples for the respective batch of castable material.

4. Additives (other than metal fiber in some cases) shall not be added to the castable in the field.5. Mixers, guns, conveyors and all other equipment and tools shall be thoroughly cleaned prior to

use. The equipment shall be cleaned at each shift change and more often if needed.6. Castable refractory material shall be applied by casting, handpacking, or pneumatic gun

application. a. "Gunning grade" products shall be used for gun application. b. "Casting grades" shall be used for cast installations.

7. For cast or gunned refractory applications, shell nozzle necks shall be cast or handpacked first to within 1 inch of the inside of the shell to which they are attached. The remaining 1 inch shall be cast or gunned monolithically with the shell.

8. Refractory anchors and surfaces on which refractory material will be applied shall be checked for cleanliness and for compliance with other requirements of this specification prior to refractory installation.

9. In multi-layer linings, anchors for the hot face layer shall be clean and free of all back-up refractory material before application of the hot face layer.

10. Refractory-lined equipment shall not be moved or rotated until the refractory has taken a full set.

11. Equipment lined with hydraulic bonded castable shall not be moved for a minimum of 24 hours.

5.2 Weather ProtectionHydraulically bonded castables shall be installed and cured only when ambient temperatures at the installation area are between 50°F (10°C) and 95°F (35°C) unless the precautions stated in Section 5.2.1 and Section 5.2.2 are taken.



5.2.1 Cold WeatherWhen hydraulically bonded castables are being installed, the following cold weather protection procedures shall be initiated when ambient temperatures are below or expected to fall below 50°F (10°C) and 95°F (35°C):1. Castables shall be stored at 50°F (10°C) to 90°F (32°C)for 48 hours prior to use.2. When the shell or metal temperature is below 50°F (10°C), the interior and exterior of

the area to be lined shall be insulated or heated prior to and while the refractory is being placed, and shall be maintained at 60°F (16°C) or above for at least the first 48 hours after placement.

3. The procedures given in Section 12.4.2 of IRM-PU-4786 need to be carefully followed if linings are allowed to freeze.

4. Live steam shall not be used for heating.5. Warm water may be used to raise the temperature of the mix above 60°F (16°C).6. Refractory mixing, handling, and preparation areas shall be enclosed, heated, and

weatherproofed.

5.2.2 Hot WeatherWhen hydraulically bonded castables are being installed, the following hot weather pro-tection procedures shall be initiated when the ambient temperature is above 95°F (35°C):

1. When the shell or metal temperature exceeds 95°F (35°C), the exterior of the area to be lined shall be cooled by water spray and/or shading prior to and while the refractory material is being placed.

2. Cold or iced water shall be used to reduce the temperature of the mix to between 60°F (16°C) and 70°F (21°C) to prevent premature setting. No solid ice particles shall be present in the mix.

3. The mix temperature may also be reduced by storing the dry refractory castables in an air con-ditioned area prior to use.

4. During hot weather application, the material mixing and handling areas shall be shaded from the sun.

5.3 Surface Preparation1. All surfaces not cleaned per Section 4.2 shall be cleaned to meet SSPC SP-7 or NACE #4

standards for abrasive blasting or SSPC SP-3 for power tool cleaning. New metal surfaces that are free of rust, dirt, grease, or oil are acceptable for most linings covered under this specification.

2. Before beginning any part of refractory installation, the surface and work area shall be cleaned and prepped to ensure that the lining installation can proceed in an orderly and workmanlike manner without danger of incorporating dirt, debris or dehydrated material into the lining. Refractory material placed over or against improperly cleaned surfaces will be rejected.

3. Completion of cleaning prior to refractory application constitutes a hold point. Refractory material shall not be installed prior to written sign-off by the inspector.



5.4 Thickness Tolerances1. For single-component gunned linings and for the hot face layer of multi-component linings,

the final installed thickness shall be the designed thickness - zero inch, + 1/4 inch.2. Tolerances for the back-up lining in a two-component system shall be -1/4 inch, + zero inch.3. Tolerances for cast linings (e.g., floor) shall be + 1/4 inch of the design thickness.4. For gunned linings which incorporate metal shrouds, thickness tolerance shall be - zero inch,

+ 1/4 inch.5. For boilers, the proper distance between the boiler tubes and the refractory hot face shall be

maintained to assure the proper heat flux ratio.

5.5 Cast Installation of Hydraulically Bonded Castable Linings1. The water content used to mix castable refractory linings shall be kept at or near the levels

used for sample preparation during material prequalification. a. The installation Supplier's prequalification panel preparation shall be used to determine

the range of water content for each type of material. b. At no time is the castable manufacturer's recommended water ratio to be exceeded.

2. A paddle-type mixer shall be used.3. The size of individual mix batches shall be controlled such that the total duration between

mixing of castable with water and placement does not exceed 20 minutes. Mixing time shall not exceed 6 minutes.

4. An internal vibrator shall be used to facilitate compaction of wet-mixed castable, when feasible.

5.6 Gunned Installation of Hydraulically Bonded Castable Linings1. Nozzle-mix guns shall be used with maximum predampening in a paddle mixer. 2. Permission to use wet-mix guns must be obtained in writing from the Purchaser's

representative.3. When gunning insulating castables, application (hose) pressure shall be adjusted such that

excessive compaction of lightweight aggregates does not occur.4. Pneumatic gun application shall start at the lowest elevation and proceed upward to minimize

the inclusion of rebound material. When possible, apply the material in "bands" that are 5 to 6 feet high.

5. Depth gages of the proper size and/or shot boards shall be used to ensure that the castable is applied to the correct thickness.

6. When interruptions of more than 30 minutes' duration occur in the application of a layer of castable, or at the discretion of the inspector, the castable shall be cut perpendicular to the hot face where it has been applied to full thickness and at a point midway between anchors. The edge shall be scored after cutting and thoroughly wetted before application of the adjacent lining.

7. Gunning of castable refractory shall be on vertical walls or overhead. a. No gunning shall be done in the downhand position below 45 degrees from the horizontal. b. See Detail 6 of GD-N1269.



8. All rebound and loose material shall be removed from the surface of a completed band before proceeding with the next band. a. Adjacent anchors shall be cleaned off continuously during application. b. No rebound material shall be allowed to accumulate at any point where the lining has not

already been applied. c. All rebound material shall be removed and discarded to prevent its inclusion in the lining. d. Reuse of rebound material is absolutely prohibited.

9. Gunned refractory linings shall be installed full thickness in individual sections not exceeding 35 square feet to avoid lining laminations.

6.0 INSTALLATION OF INSULATING FIREBRICK AND FIRECLAY BRICK

6.1 Insulating Firebrick1. The installation Supplier shall ensure that qualified journeymen brick masons will install the

brick and/or shapes.2. IFB walls and arches shall be installed in accordance with the project drawings.3. IFB walls shall be properly anchored and shall be straight and level.4. Dipped mortar joints shall be used. The joints shall be less than 1/16 inch thick and normally

about 1/32 inch thick.5. Expansion joints shall be carefully formed and of the proper width.6. Horizontal expansion joints on high walls shall be provided in front of and immediately below

each (structural member) support shelf.7. Excess mortar shall not be used to level an individual row of IFB.8. All IFB cuts shall be made with a masonry saw and a bonded silicon carbide blade.9. Hook anchors shall be inserted carefully into IFB such that the brick is not cracked or

damaged.10. If block insulation is used as a back-up layer, IFB shall be pressed tightly against the block

thereby minimizing air gaps and voids. Fiber based insulating cement shall be used to fill large gaps between blocks and/or small, broken areas in the block insulation.

11. If insulating castable is used as a back-up layer, a small space shall be provided around the hook anchor within the castable layer such that the IFB wall is free to expand and contract slightly.

12. For installations with castable used as back-up insulation, no more than six brick courses shall be laid before castable is installed into the space between brick and casing.

6.2 Installation of Fireclay Brick

6.2.1 Floors1. Fireclay brick (regular firebrick) shall be laid flat (2 ½ inches thick) on top of the

insulating castable that lines the floor of the heater.2. High duty firebrick shall be used. 3. These firebrick shall be laid without mortar.



4. A thermal expansion gap between the floor brick and the walls shall be designed to allow for thermal expansion of the floor brick. This gap shall be filled with 6-lb. ceramic fiber blanket.

6.2.2 Divider or Bridge WallsDivider or bridge walls shall be erected in accordance with the project drawings. Requirements for these walls follow:1. Divider walls shall be straight (plumb) and level.2. Troweled mortar joints shall be used. These joints shall be between 1/32 inch and 1/

16 inch thick.3. Approved methods of bonding (e.g., alternate header and stretcher courses) shall be

used for the thicker (lower) parts of the wall.4. Excess mortar shall not be used to level an individual row of brick.5. Brick having one or more dimensions outside of the ± 1/16 inch tolerance shall be

rejected. The thickness dimension is most critical.6. Large 9-inch straight bricks shall be used to break joints.7. Workable (vertical) expansion joints shall be provided as per drawings.

7.0 AMBIENT TEMPERATURE CURING AND HIGH TEMPERATURE DRYOUT OF CASTABLE LININGS

7.1 Ambient Temperature Curing1. Curing of semi-insulating and insulating castables (types use in fired heaters) shall be

accomplished by application of a colored membrane curing compound applied to the castable surface within one hour of placement. a. Brand name and description of curing compound shall be submitted for approval to the

Purchaser's representative. b. Wax-based sealers are not permitted.

2. In lieu of curing compound, a fine water spray may be used. The surface shall be kept damp for a minimum of 24 hours after application. a. Spraying at approximately 2-hour intervals is required. b. Water spraying shall not start until the lining has taken its initial set.

3. For a minimum of 24 hours after placement, the refractory lining and surface to be lined shall be maintained between 50°F and 90°F. a. When feasible, refractory temperature shall be maintained between 80°F and 90°F. b. Suitable means for heating or cooling shall be provided, if necessary. c. Live steam however, shall not be used for heating.

4. Installed refractory linings shall not be allowed to freeze during placement or the curing period.

5. A minimum of 48 hours at temperatures >60°F is required for curing if the lining is to be allowed to freeze before dryout.



7.2 Controlled High Temperature Dryout1. This operation will normally be done at the refinery or other plant during startup of the heater.2. Heat-up rates not exceeding 100°F/hour should be used with castable or plastic installations.3. No limit on heat-up rates for ceramic fiber are imposed.

8.0 CREW PREQUALIFICATIONCrew prequalification is the installation Supplier's responsibility.

8.1 General Requirements1. Crew prequalification testing shall be undertaken at least one week prior to actual jobsite

refractory installation to allow time for curing and laboratory testing of prepared specimens.2. For preparation of samples, the crew shall use the installation Supplier's written installation

procedures that were approved by the Purchaser.3. Refractory anchors, metal fibers, and the method of mixing and application used for the test

panels shall be the same as specified on project drawings for the actual refractory lining.4. In the event of failure to pass this testing procedure, the crew and/or procedure shall be

changed and retested.

5. For individual applicators, retesting shall only be by consent of Owner. Only one retest will be allowed.

8.2 Castable Refractory Installation Crew

8.2.1 Cast or Handpacked Castables1. All personnel who will install refractory by casting or handpacking procedures shall

be qualified by preparing test panels and/or specimens per the requirements of this section.

2. If the castable is to be cast or handpacked, the sample panel box shall be prepared with the same refractory, anchors, and fiber additions as required by the installation. a. If the installation requires a thick handpacked lining, then the minimum test panel

size shall be 18 inches square. b. The panels shall be constructed so that the backs may be removed without

damaging the sample.3. Each installer shall prepare a test panel which will be tested and approved before the

worker is allowed to work on the project.4. If the installation requires a thick, monolithic lining, then the specimens shall be cut

from the panels and tested as per the requirements of gunned samples in Section 8.2.2.

8.2.2 Gun Applied Castables1. All nozzlemen shall be qualified by shooting one (1) 3-foot by 3-foot panel of each

material to be used. a. The thickness of the panel is to match job requirements. b. Each nozzleman must pass this test prior to commencing work.



c. The test panel shall be done with actual jobsite equipment at the highest elevation to be gunned on the job.

d. The panel shall be oriented in a 45-degree overhead position.2. The installation Supplier shall provide the test panel box with anchors as required.

a. The test panel box shall be constructed so that the back may be removed for refractory inspection without damaging the refractory.

b. See Detail 1 of Drawing GD-N1271.3. Each sample shall be tagged with the following information:

a. Name of nozzleman,b. name of gun operator, c. material used, d. batch and pallet number, ande. date and time prepared.

9.0 PRODUCTION SAMPLING

9.1 General1. Supplier shall collect production samples daily during the refractory installation.2. For gunned installations of Type D, E, F, G, H and I refractory, one (1) set of samples per

nozzleman, per shift, per material used shall be taken.3. For cast or handpacked installations of Types D, E, F, G, H and I refractory, one (1) set of sam-

ples per mixing station, per shift shall be taken.4. The samples shall be collected in such a manner that the sample is representative of the

installed lining.5. If the materials are prepared for installation by mechanical mixing and casting, then the

sample shall be collected from a mixer load of material that is to be installed in the equipment. a. If the material thus prepared will be installed by handpacking, hammering, or ramming,

then the sample shall be placed into the individual specimen molds using the same equipment and technique as the actual installation.

b. For cast or handpacked samples a shoebox mold should be used as shown in Detail 5B of GD-N1271.

c. See Section 10.5.1 for Sample Requirements.6. If the material is installed by gunning, then the sample collection box shall be hung on the wall

adjacent to where the nozzleman is working. a. The nozzleman will then fill the box without changing the water content or pressure and

without changing relative position from which he was gunning on the wall. b. A typical sample box is shown in Detail 4 of Drawing GD-N1271.

7. The installation Supplier is responsible for supplying all required molds and sample boxes for testing.



8. A log shall be maintained by the installation Supplier detailing the location from which the samples were taken. A map of the installation shall show which areas were installed, by individuals and by shift.

9. The log shall detail all pertinent information regarding sample preparation and the operating parameters at the time of sample collection, such as material used, batch and pallet number, ambient temperature, water content, mixing time, names of preparers, etc.

9.2 Field Curing of Production Samples1. The production samples shall be allowed to cure under the ambient conditions of the

installation area for 24 hours. 2. Curing compound should be used.3. After the onsite ambient air cure, the production samples shall be forwarded to the approved

laboratory for testing.

10.0 INSPECTION AND TESTINGThe provisions of this section are the Purchaser's responsibility.

10.1 Hold PointsThe following items shall constitute hold points, and work shall not proceed until the Purchaser's authorized inspector approves the work:1. Anchor installation,2. Cleanliness of lining surface prior to refractory installation, and3. Crew prequalification.

10.2 Crew Prequalification Inspection1. After the prequalification panels have been completed per Sections 8.2 and 8.3 and have set a

sufficient amount of time (>12 hours) the panel(s) shall be inspected to ensure:a. Refractory has been installed around anchors properly.b. There are no obvious laminations or junctions between separate batches.c. Reinforcing fibers, when used, are randomly distributed throughout the lining.d. Rebound has not been trapped in the lining (gunning).

2. Approval of the nozzleman and crew shall be based on: a. visual inspection of their installation method, b. destructive examination of the panels, and c. physical test results from samples per Section 11.5.3.

10.3 Anchor Inspection1. Inspector shall verify that welders are qualified in accordance with Section 5.1.2. All anchors and other metallic components installed under this specification shall be tested to

ensure compliance with specification for alloy, style, and size. 3. Minimum sampling shall be 1 per 1000 anchors of each design.



4. All installed anchors shall be subjected to 100% visual and hammer testing to ensure they are fully welded and properly spaced. a. Anchors shall also be checked for proper configuration. b. Anchors displaying evidence of incomplete welding or undercutting shall be rewelded or

replaced as directed by Purchaser's inspector at the Supplier's expense.5. Particular care shall be taken to ensure that all anchors are set to the specified height, and that

they are clean.

10.4 Inspection of Installed Castable Linings

10.4.1 GeneralThe owner's authorized inspector shall witness all phases of the refractory installation and testing and shall check frequently that the lining thickness is within tolerance.

10.4.2 Hammer and Visual Inspection - After Ambient Curing1. The inspector shall perform a visual examination and hammer sounding over 100% of

the surface of the cured refractory linings after the linings have set for 24 hours. 2. Hammer soundings shall be effected by striking the surface on 1-foot maximum

centers with a 12-ounce ball peen or similar hammer. 3. Any voids, rebound pockets, or otherwise defective areas larger than 6 square inches

and/or greater than 1/4 of the lining depth shall be repaired in accordance with Section 11.0 of this specification, as directed by the Purchaser's inspector.

4. For all installation techniques, inspection of construction "joints" shall be performed to ensure proper installation of new material against old, or freshly set material.

10.5 Testing1. Testing shall be performed by a qualified laboratory approved by the Purchaser.2. All testing shall be witnessed by an authorized agent of the Purchaser.3. Testing of crew prequalification samples.

a. The specimens cut from the prequalification panels shall be dried and tested per the requirements of Section 3.0 of IRM-SU-4785.

b. Unsatisfactory test results are cause for rejection.

10.5.1 Testing of production samples.1. Testing procedures for refractory materials cut from panels, or from cubes, bars, and

plates shall be per the requirements of Section 3.0 of IRM-SU-4785.2. The following properties shall be tested and reported:

a. Density (three 2" x 2" x 2" cubes per sample)b. Permanent linear change (one 2" x 2" x 9" bar per sample)c. Cold crushing strength (three 2" x 2" x 2" cubes per sample)

3. Acceptance/rejection criteria for production samples shall be based on the prequalification requirements as shown in Drawing GC-N1268.



4. If a production sample fails to display the required physical properties, then a retest shall be performed on a second sample taken from the same area represented by the failed sample.

5. Failure of a retest sample may be cause for rejection of that area of the installed lining.

10.6 Inspection of Firebrick and Special Shape Lining Installations1. During installation, the Purchaser's inspector and/or project engineer shall check on the

following important items:2. Brick walls shall be straight, level and properly anchored.3. All anchors shall be installed and the anchor system must comply with the design drawings.4. Individual rows of firebrick (and/or IFB) shall be level.5. Brick shall be kept clean (and free of dust) to facilitate bonding with the mortar.6. Mortar shall be chemically compatible with the brick being laid.7. Thickness of mortar joints shall be held between 1/32 inch and 1/16 inch.8. Expansion joints shall be installed per the design drawing. They must be kept clean (free of

debris) to allow thermal expansion movement of the wall (or other component).9. When packed expansion joints are called for, the joints shall be filled with suitable "packing"

material per design drawing.10. Proper shapes or brick shall be used for bullnose applications.11. Flue gas stop baffles shall be installed around burner blocks (in walls) and at other locations as

shown on the design drawing.12. All individual rings in cylindrical linings shall be properly keyed.13. The interior (hot face) surfaces of cylindrical linings shall be smooth and uniform.

a. Interior dimensions of the brickwork shall be maintained within prescribed tolerances. b. Minor variations in roundness of the casing shall be compensated for in the thickness of

the back-up layer (refractory or block insulation).

10.6.2 Final InspectionThe Final Inspection shall test the following:1. Tightness of the lining2. Dimensions3. Expansion joints

11.0 REPAIRS1. All areas requiring repairs shall be brought to the attention of the project engineer or project

manager. 2. The project engineer or project manager shall have the final decision as to the extent of repairs.



11.1 Castable Refractory Linings1. For one-component linings, or the back-up layer of multi-layer linings, the defective areas

shall be chiseled out completely to the shell or duct wall, and shall be reapplied per Detail 7 of GD-N1269.

2. For two-component linings, the defective areas found in the hot face layer shall be removed to the insulating back-up material, and the hot face layer reapplied.

3. Refer to Detail 7 of GD-N1269 for minimum required replacement area and edge preparation.



PART C : REFRACTORY CERAMIC FIBER LININGS FOR FIRED HEATERS

1.0 SCOPEThis part of the specification covers the requirements for materials and installation of refractory ceramic fiber (RCF) linings in fired heaters.

2.0 GENERAL REQUIREMENTS1. The Purchaser will provide the following information:

a. Locations within fired heater to be lined with RCF b. Normal operating temperaturec. Maximum operating temperatured. Maximum allowable shell temperaturee. Assumed ambient temperaturef. Gas velocities throughout fired heaterg. Type of fuel and furnace atmosphereh. Any limits on RCF thickness due to furnace geometry

2. The installation Supplier shall provide:a. Proposed lining system method(s) and materialsb. RCF thickness, K factors, heat loss calculationsc. Written installation procedures

3.0 MATERIALS

3.1 Anchors1. The anchor material for fired heaters burning "clean fuel" shall be chosen in accordance with

the temperature limits in Table 1A of GD-N1262. a. "Clean fuel" is defined as fuel containing less than 0.5% sulfur. b. "Temperature" is defined as the maximum long-term exposure temperature (adjusted to

reflect the gradient through the lining) of any part of the anchor. 2. The anchor material for fired heaters burning "dirty fuel" shall be chosen in accordance with

the temperature limits in Table 1B of GD-N1262. a. "Dirty fuel" is defined as fuel containing more than 0.5% sulfur. b. "Temperature" is defined as the maximum long-term exposure temperature (adjusted to

reflect the gradient through the lining) of any part of the anchor. 3. All Type 304, Type 310, RA 330, and Inconel 601 anchors shall be supplied in the fully bright

solution-annealed condition.4. The anchor supplier shall verify the material chemistry by submitting mill test reports for all

materials. 5. Also random chemistry checks shall be made on a minimum of 3 of every 1000 of each type of

anchor hardware.



3.2 Vapor Barrier Coating1. Vapor barrier coating shall be Stalastic (manufactured by Witco Corporation) or an approved

equal. 2. Either grade of Stalastic (trowelable, 61031 or sprayable, 61036) is acceptable.

3.3 RCF Products1. Manufacturer's data must show that the RCF to be used will shrink less than 3% at the fired

heater's maximum operating temperature. 2. Alternatively, the maximum use temperature of the RCF shall be set 300°F (149°C) lower than

the manufacturer's maximum recommended use temperature.3. Module systems and blanket/board systems can be proposed for any hot face temperature as

long as the requirements of Section 3.3, item 1 and item 2 are met. 4. Layered blanket systems are limited to 2000°F (1093°C) maximum hot face temperature in

addition to the limits of Section 3.3.5. RCF products are limited to the following maximum gas velocities:

a. Blanket: 30 ft/sec

b. Modules: 60 ft/secc. Boards and other vacuum formed shapes: 80 ft/sec

6. RCF products must have the following minimum densities:

a. Layered blanket systems: 8 lb/ft3 for the top two one-inch layers (closest to the hot face), 6 lb/ft3 for one-inch thick back-up layers.

b. Blanket/board systems: 10 lb/ft3 for the top 1-1/2 inch board layer, 8 lb/ft3 for any back-up blanket layers.

c. Module systems: Modules shall be made from blanket with a minimum density of 8 lb/ft3.

d. The minimum density of the compressed module shall be 9.3 lb/ft3.7. Maximum size of RCF materials shall be:

a. Modules: 12 inches x 12 inches x thickness, unless a larger size is approved by the Purchaser

b. Blankets: 24 inches wide x 1 inch thick unless otherwise approvedc. Boards: 18 inches x 18 inches x 1-1/2 for ceilings and 18 inches x 18 inches x 1-1/2 inches

or 24 inches x 24 inches x 1-1/2 inches for walls.8. RCF rigidizers shall not be used. Sprayable RCF shall not be used unless it is specified for

repairs or veneering.9. Only RCF mortars and cements that are recommended by the RCF manufacturer shall be used.

4.0 STORAGE AND HANDLING OF RCF LINING MATERIALS1. All RCF products shall be kept dry and protected from mechanical damage during the course

of the job.2. The Manufacturer's limits on shelf life of the vapor barrier coating shall be followed.



5.0 ANCHOR INSTALLATION1. Module anchoring systems must be able to be preattached to the shell before module

installation. 2. No systems requiring "blind" welding shall be used.3. The installation Supplier shall install the anchors in accordance with Drawing GD-N1262 or

GD-N1263, whichever applies.

5.1 Welder Qualification Testing1. Stud welding equipment must be properly adjusted to obtain a full fillet weld around the entire

stud base. 2. At least three trial stud welds shall be made using the anchor material for the job and a plate

the same thickness as the furnace shell. 3. These welds shall be bend tested by hitting them with a light hammer and bending them 15

degrees from vertical and back. 4. An additional three trial welds shall be made each time welding is started, including at the

beginning of the day, after a shift change, and after a break for any other reason. 5. If any welds crack, they fail the test, and an additional three welds must pass after adjustments

to the stud welding equipment are made.

5.2 Production Weld TestingThe actual production anchor welds shall be 100% hammer tested, as follows: 1. A stud shall be considered to have a good weld if, when the stud is hit with a light hammer it

produces a ringing sound similar to that obtained when the furnace shell is struck. 2. Any studs that don't produce such a sound, and any studs that bend or loosen upon hitting,

shall be removed and replaced. 3. Care shall be used during hammer testing so that studs are not damaged.

6.0 VAPOR BARRIER INSTALLATIONThe vapor barrier shall be installed to all surfaces beneath the RCF.

7.0 RCF INSTALLATION The RCF material shall be installed in accordance with Drawings GD-N1262 and GD-N1263, whichever applies.

IRM-SU-4789-E: Installation of Fired Heater...

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