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ABU DHABI GAS INDUSTRIES LTD. (GASCO) MATERIALS, INSTALLATION AND TESTING REQUIREMENTS OF REFRACTORY SYSTEMS

DGS-6531-020/FH

DESIGN GENERAL SPECIFICATION

MATERIALS, INSTALLATION AND TESTING REQUIREMENTS FOR REFRACTORY SYSTEMS

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0 26/05/01 JOHN DWYER A.KHALIK ABDUL AZIZ AL AMERI ISSUED FOR IMPLEMENTATION

A 16/05/01 JOHN DWYER A.KHALIK ABDUL AZIZ AL AMERI ISSUED FOR COMMENTS

Rev Date

WRITTEN BY

CHECKED BY

APPROVED BY

STATUS

DOCUMENT REVISIONS

Sections changed in last revision are identified by a vertical line in the left margin

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CONTENTS

1. GENERAL.................................................................................................................................................. 5 1.1 INTRODUCTION .................................................................................................................................. 5 1.2 PURPOSE ................................................................................................................................................ 5 1.3 DEFINITIONS ........................................................................................................................................ 5 1.4 EXCEPTIONS ............................................................................................................................................. 7

2. CODES AND STANDARDS............................................................................................................ 8

3.0 REFERENCE DOCUMENTS ............................................................................................................ 11

4.0 DOCUMENT PRECEDENCE............................................................................................................ 11

5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL................................................ 12

6.0 QUALITY ASSURANCE/QUALITY CONTROL...................................................................... 12

7.0 DOCUMENTATION............................................................................................................................ 13

8.0 SUBCONTRACTORS/SUBVENDORS ..................................................................................... 13

9.0 HANDLING........................................................................................................................................ 13

10.0 GENERAL DESIGN.......................................................................................................................... 14 10.1 MATERIALS .................................................................................................................................... 14 10.2 SURFACE PREPARATION AND MEMBRANE APPLICATION............................................................ 15 10.3 REFRACTORY MATERIAL ATTRIBUTES ..................................................................................... 15 10.4 INSPECTION AND TESTING........................................................................................................... 16

11. MONOLITHIC REFRACTORIES.................................................................................................. 17 11.1 DESIGN PARAMETERS ............................................................................................................... 17 11.2 SUPPLY OF REFRACTORY MATERIAL ........................................................................................... 17

11.2.1 Manufacture of refractory materials......................................................................................... 17 11.2.2 Preparations for shipment........................................................................................................... 17 11.2.3 Refractory shipment and storage ............................................................................................... 17

11.3 TRANSPORT AND HANDLING OF REFRACTORY LINED EQUIPMENT................... 18 11.4 INSTALLATION OF ALL TYPES OF MONOLITHIC REFRACTORY MATERIALS..18

11.4.1 General Requirements.................................................................................................................. 18 11.4.2 Mixing ............................................................................................................................................. 19 11.4.3 Applying.......................................................................................................................................... 19 11.4.4 Joints ............................................................................................................................................... 19 11.4.5 Internals.......................................................................................................................................... 20 11.4.6 Preparation for Startup ............................................................................................................... 20

11.5 INSTALLATION OF PLASTIC REFRACTORY MATERIALS........................................... 21 11.5.1 Preparation .................................................................................................................................... 21 11.5.2 Installation ..................................................................................................................................... 21 11.5.3 Trimming ........................................................................................................................................ 21

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11.6 INSTALLATION OF CASTABLE REFRACTORY MATERIALS...................................... 22 11.6.1 Preparation .................................................................................................................................... 22 11.6.2 Installation ..................................................................................................................................... 22 11.6.3 Trimming ........................................................................................................................................ 23

11.7 INSTALLATION OF GUNNING REFRACTORY MATERIALS........................................ 23 11.7.1 Preparation .................................................................................................................................... 23 11.7.2 Installation ..................................................................................................................................... 24 11.7.3 Trimming ........................................................................................................................................ 24

12.0 REFRACTORY BRICKS AND SHAPES................................................................................... 25 12.1 DESIGN.............................................................................................................................................. 25 12.2 CLASSIFICATIONS OF SHAPED REFRACTORY MATERIALS........................................................ 25

12.2.1 Shaped Insulating Refractory Materials................................................................................... 25 12.2.2 Dense Shaped Refractory Materials.......................................................................................... 26 12.2.3 Special Compositions ................................................................................................................... 26 12.2.4 Acid-Resistant Refractory Materials ......................................................................................... 26

12.3 BURNERS............................................................................................................................................. 26 12.4 REFRACTORY SHIPMENT AND STORAGE ...................................................................................... 26 12.5 INSTALLATION OF REFRACTORY BRICK CONSTRUCTIONS.................................... 27

12.5.1 General ........................................................................................................................................... 27 12.5.2 Temperature Control During Installation................................................................................ 27 12.5.3 Bricked Constructions.................................................................................................................. 27 12.5.4 Anchors ........................................................................................................................................... 28

12.6 INSPECTION.................................................................................................................................... 28 13.0 CERAMIC FIBER LINING SYSTEMS ................................................................................ 29

13.1 MATERIALS FOR CERAMIC FIBER BLANKET AND MODULES ............................ 29 13.2 ANCHORING FOR BLANKET AND MODULE INSTALLATION........................................................ 30 13.3 JOINTS OF CERAMIC FIBER BLANKET.......................................................................................... 30

13.3.1 Butt Joints ..................................................................................................................................... 30 13.3.2 Overlapped Joints........................................................................................................................ 31

14.0 SPECIFIC APPLICATIONS ......................................................................................................... 31 14.1 FIRED HEATERS................................................................................................................................. 31

APPENDIX 1 SPECIFICATION FOR MONOLITHIC REFRACTORY MATERIALS ............ 34 A1-1.0 Scope ........................................................................................................................................... 34 A1-1.1 Specification of Monolithic Refractory Materials .............................................................. 34 A1-1.2 Temperature...............................................................................................................................34 A1-1.3 Application................................................................................................................................. 34 A1-1.4 Applicable Standards ............................................................................................................... 34 A1-1.5 Material Limitations................................................................................................................. 35 A1-1.5.1 Exposure to Sulfur and Vanadium Components ................................................................. 35 A1-1.5.2 Other Limitations...................................................................................................................... 35

APPENDIX 2 SAMPLING AND TESTING MONOLITHIC REFRACTORY MATERIALS ..36 A2-1.0 Introduction ...............................................................................................................................36 A2-1.1 Sampling for Testing of Supplied Refractory Materials .................................................... 37 A2-1.2 Testing of Material Properties During Manufacture ......................................................... 38 A2-1.3 Sampling and Testing During Installation ........................................................................... 39 A2-1.4 Testing of Refractory Samples Taken During Application................................................ 40

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APPENDIX 3 REFRACTORY ANCHOR MATERIALS...................................................................... 44 A3-1.0 Scope ........................................................................................................................................... 44 A3-1.1 Design ......................................................................................................................................... 44 A3-1.2 Materials, Labor, and Equipment.......................................................................................... 44 A3-1.3 Materials .................................................................................................................................... 44 A3-1.4 Anchors....................................................................................................................................... 44 A3-1.5 Installation of Anchoring Systems ......................................................................................... 45 A3-1.6 Testing of Anchors and Their Welds ..................................................................................... 45 A3-1.7 Ceramic Anchors ...................................................................................................................... 46

APPENDIX 4 APPLICATOR'S PROCEDURE QUALIFICATION (APQ) .................................... 50 A4-1.0 Scope ........................................................................................................................................... 50 A4-1.1 Procedures ................................................................................................................................. 50 A4-1.2 Preparation and Setup of Equipment .................................................................................... 50 A4-1.3 APPLICATOR'S Qualification ............................................................................................... 51 A4-1.4 Performance Testing of Mixing Equipment ......................................................................... 52

APPENDIX 5 DRYING AND CURING MONOLITHIC REFRACTORY MATERIALS......... 53 A5-1.0 Application................................................................................................................................. 53 A5-1.1 Material, Labor, and Equipment............................................................................................ 53 A5-1.2 Curing ......................................................................................................................................... 53 A5-1.3 Drying and Firing..................................................................................................................... 55 A5-1.4 Drying ......................................................................................................................................... 55 A5-1.5 Firing of Chemically-Bonding Refractory ........................................................................... 55 A5-1.6 Firing of Hydraulically Bonding Refractory Linings and Plastic Moldable Refractory Linings.56 A5-1.7 Auxiliary Firing Equipment .................................................................................................... 57

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1. 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.

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:

COMPANY − ABU DHABI GAS INDUSTRIES LTD. (GASCO)

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..

CONTRACTOR − The party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project.

MANUFACTURER − The party which manufactures the refractory material.

PROJECT − To be defined.

SHALL − Indicates a mandatory requirement

SUBVENDOR − The party which carries out all or part of the design, procurement, installation and testing of the Refractory System as specified by the VENDOR/ CONTRACTOR.

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VENDOR − The party which manufactures and/or supplies equipment, technical documents/drawings and services to perform the duties specified by COMPANY/CONTRACTOR.

TECHNICAL DEFINITIONS:

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

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.

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.

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. This type of material offers ease of installation, compensates for shrinkage because of its compressed design, and requires no curing.

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 1500°C. 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 1500°C, 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.

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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.

CERAMIC FIBER MODULES − Blocks manufactured of continuously folded and compressed ceramic fiber blanket. This type of material offers ease of installation, compensates for shrinkage because of its compressed design, and requires no curing.

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 1500°C. 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 1500°C, 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

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• 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. 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, to the extent specified herein, form a part of this specification. When an edition date is not indicated for a code or standard, the latest edition in force at the time that VENDOR'S proposal is submitted shall apply.

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 Structural Welding

American Society for Testing And Materials (ASTM) ASTM C16 Load Testing Reffractory Brick 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 C27ASTM C27

Fireclay and High - Alumina Refractory BrickFireclay 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 Immeersion

ASTM C155 Standdard Classification of Insulating Firebrick

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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 C234 Comparing Concretes on the Basis of the Bond Developed with Reinforcing Steel

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 Standard Classification of Alumina and Alumina-Silicate Castable Refractories

ASTM C417 Thermal Conductivity of Unfired Monolithic Refractories

ASTM C467 Standard Classification of Mullite Refractories

ASTM C493 Bulk Density and Porosity of Granular Refractory Materials by Mercury Displacement

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

ASTM C560ASTM C560

Chemical Analysis of GraphiteChemical Analysis of Graphite

ASTM C573ASTM C573

Chemical Analysis of Fireclay and High-Alumina RefractoriesChemical Analysis of Fireclay and High-Alumina Refractories

ASTM C577ASTM C577

Permeability of RefractoriesPermeability 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 C605 Reheat Change of Fireclay Nozzles and Sleeves

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ASTM C673 Standard Classification of Fireclay and High-Alumina Plastic Refractories and Ramming Miixes

ASTM C704ASTM C704

Abrasion Resistance of Refractory Materials at Room TemperatureAbrasion Resistance of Refractory Materials at Room Temperature

ASTM C768ASTM C768

Drip Slag Testing Refractory Brick at High TemperatureDrip Slag Testing Refractory Brick at High Temperature

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

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

ASTM C860ASTM C860

Determining and Measuring Consistency of Refractory ConcretesDetermining and Measuring Consistency of Refractory Concretes

ASTM C862ASTM C862

Preparing Refractory Concrete Specimens by CastingPreparing Refractory Concrete Specimens by Casting

ASTM C865ASTM C865

Firing Refractory Concrete SpecimensFiring Refractory Concrete Specimens

ASTM C874 Rotary Slag Testing of Refractory Materials

ASTM C885 Test Method for Young’s 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 Immeersion

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

ASTM E177 Use of the Terms Precision and Accuracy as Applied to Measurements of a Property of a Material

ASTM E228 Linear Thermal Expansion of Solid Materials with a Vitreous Silica Dilatometer

International Organization For Standardization (ISO) ISO 1109 Classification of Refractory Products

ISO 1927 Classification of Prepared Unshaped Dense and Insulating Refractory Materials

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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 Quality System - Model for Quality Assurance in Design, Development, Production, Installation and Servicing

ISO 9003 Quality Systems - Model for Quality Assurance in Final Inspection and Test

ISO 9004 Quality Management and Quality System Elements - Guidelines

3.0 REFERENCE DOCUMENTS

The following reference documents, 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 the time that VENDOR’S proposal is submitted shall apply.

Sspecifications

DGS –6500-010 Hot Insulation

DGS –6500-020 Cold Insulation

DGS-6710-001 Preservation and Export Packing

DGS-6600-010 Painting Project Drawing

STD-200-00039 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

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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:

• Project Specifications and Standards

• Industry Codes and Standards

5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL Any technical deviations to the Purchase Order and its attachments 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 VENDOR’S proposed quality system shall fully satisfy all the elements of ISO 9001, “Quality Systems - Model for Quality Assurance in Design, Development, Production, Installation and Servicing,” ISO 9003, “Quality Systems - Model for Quality Assurance in Final Inspection and Testing” and ISO 9004, “Quality Management and Quality System Elements - Guidelines.” 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 CONTRACTOR’S 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 SUBVENDOR’S 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.

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7.0 DOCUMENTATION VENDOR shall submit the type and quantity of drawings and documentation for CONTRACTOR’S 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

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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 16767°C 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 and approved by the COMAPNY.

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 furnace or boiler outside casings is maintained between 60°C-80°C at the ambient air temperature. The wind velocity shall be assumed to be 2½ 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.

10.1.5 The design of refractory linings shall be such that the outer wall temperature of refractory lined equipment shall be maintained between 60°C and 80°C at the ambient air temperature. The wind velocity shall be assumed to be 2½

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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, Ssurfaces that have had anchors installed shall be shall be prepared in accordance with ISO 8501-1, Sa 1, Light Blast CleaningSteel Structures Painting Council SSPC-SP-10, Near White 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. MANUFACTURER’S 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.

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• 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 CONTRACTOR’S approval.

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

10.4 INSPECTION and testing The Ttinstallation of all refractory materials to rRefractory lined equipment shall be inspected by an experienced third party inspector who shallpersonnel to be approved by the COMPANY/ CONTRACTOR. The inspection shall will be done in accordance with Appendixces A1 and A2 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 unless operation of the equipment follows immediately..

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.

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11. 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.

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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. 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.

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. 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/APPLICATORMANUFACTURER 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 APPLICATOR’S 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.

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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 (10°C - 25°C) 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.

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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.

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.

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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

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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 5°C and 25°C.

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

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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.

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. MANUFACTURER’S recommendation for proper placement of these products shall be followed.

When using “vibra cast” products, proper substantial forms (inner and outer) must be provided with a means to attach external vibration devices. MANUFACTURER’S 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

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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

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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:

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.

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

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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 1500°C. 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.

Dense refractory materials are manufactured from base refractory materials with a total porosity of less than 45% and with a Ppyrometric Ccone Eequivalent (P.C.E.) of at least 1500°C. 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.

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 1482°C, 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.

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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 5°C and 25°C. Lower and higher temperatures will influence the correct curing of the mortar.

At temperatures below 5°C 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 25°C, the mortar shall be mixed in small quantities in some other location and kept between 15°C and 20°C 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.

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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 / COMPANY 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

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• 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 properly designed and installed ceramic fiber module lined heater can withstand temperatures of 1400°C. 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 MANUFACTURER’S 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 AND COMPANY 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.

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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 MANUFACTURER’S 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.

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.

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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 The use of ceramic fiber modules or ceramic fiber blanket with vacuum formed ceramic fiber special shapes are the preferred materials for use on heater walls and roofs. Radiant cells, convection sections and flue ducts may also be lined with monolithic or brick refractory materials.

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

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

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.

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Table 14.1: Refractories for Fired Heaters

Gas Fired Heaters Oil Fired Heaters

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.

14.2 Stacks The refractory system to be applied for lining of steel stacks shall be in accordance with drawing STD-200-00039, Anchoring of Lining for Steel Stacks.

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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

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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 mMoldables and pPlastic rRamming mMaterials, 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 A2-2.;

• For iInsulating and dDense rRefractory cCastables, 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 A2-2.

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 A2-2.

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 MANUFACTURER’S certificates for all refractory materials supplied.

Certificates shall attest that the materials comply with the MANUFACTURER’S data sheets and shall include the following information:

• Name of manufacturer*

• Material name*

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• 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 'fFacing' 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.

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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 1109

1927 2245 2246 10080

C27, C64, C155, C401, C467, C673

Refractoriness (PCE) 528 1146

C24

Refractoriness under load 1893 C16 Creep 3187 C546, C832 Permanent Linear Change (PLC) 2477

2478 C179, C113, C210, C605

Thermal Expansion C832 E228

Thermal Shock Resistance C38, C107C122, C180

Thermal Conductivity 8894-1/2 C182, C201C202, C417

Density (Bulk, True)

5016 5017 5018 8840

C20, C135, C234 C357, C493, C559 C604, C830 C914

Cold Crushing Strength 8895 10059

C93, C133

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Table A2-1

Properties of Refractory Materials

Available Test Methods According To:

ISO ASTM Modulus of Rupture 5013

5014 C93, C133C198, C583xxxxC491

Abrasion Resistance C704 Porosity (Apparent, True)

5016 5017

C20, C830C491

Young's Modulus C885 Sieve Analysis C92 Chemical Analysis DP 3403

10058 C560, C573

Workability, Moisture content (Ball-in-hand)

C92, C181C860

Gas Permeability 8841 C577 Resistance to Slags, Gases, Vapors

8890 C288, C768C874

Sampling and Preparation 5022 8656

C862, C865C903, C974

Installation C903 Dimensions 5019

5417 9205

C899

Vocabulary R836

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

≤ = 125100 Extra light weight Light weight

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

1250-175800 MW Minimum 2, plus 1 for every 25 tons (or part thereof)

>Over 175800 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

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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 PropertiA2-1.2 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

TrueApplied 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%

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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 110°C

• 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 APPLICATOR’S 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 APPLICATOR’S 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.

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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.

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FIGURE A2-1 TEST PANELS

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FIGURE A2-2 PRESHIPMENT 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, ρt

(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, σ

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FIGURE A2-3 TEST REPORT

Application

TEST REPORT Type: Retesting application

Retesting preshipment Product Name: Manufacturer:

Manufacturer’s Logo Contractor: Applicator’s code:

(marked behind sample number)

Date: Order number: Serial number: Sample Mixing after drying at 110°C after firing for 5 hrs at x°C Number Water ρa χa CCS PLC χa CCS PLC

% (wt) kg/m3 % N/mm2 % % N/mm2 %

Mean

2 * STANDARD DEVIATION

ρa = bulk density

χa = apparent porosity

x = test temperature

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APPENDIX 3 REFRACTORY ANCHOR MATERIALS

A3-1.0 Scope This Appendix specifies the requirements for singular stainless steel and ceramic anchors for application of unshaped refractory materials (other than ceramic fiber modules) in equipment.

A3-1.1 Design The monolithic refractory lining uses metal anchors in the form of V-anchors type to retain the lining firmly to the steelwork to be lined. The lining is applied by either casting in forms, or by gunning.

A3-1.2 Materials, Labor, and Equipment

When supply of material forms a part of the contract, the VENDOR shall obtain the anchor MANUFACTURER'S test certificates for the actual material to be used. These shall be submitted to the CONTRACTOR for acceptance prior to the commencement of the work. Welders and welding procedures shall meet the requirements as stated in A3-1.5c.

A3-1.3 Materials

The selection of anchorage material depends on the operating temperature and shall be confirmed by calculations. The material selection is summarized in the following table.

Table A3-1 Selection of Materials for Anchorage

Temperature of Anchor Tip

Type of Anchor Material

Consumable For SMAW Welding

Base Metal Electrode < 450° C Carbon steel (CS) CS E7018 < 800° C AISI 304 (18Cr/8Ni) CS E309L

< 1100° C AISI 310 (25Cr/20Ni) SS E309L > 1100° C Ceramic N/A

A3-1.4 Anchors

The anchors are generally placed in square arrangement, staggered perpendicularly to each other, with dimensions as given in Figure A3-1.

The arrangement dimension shall be varied based on the inner surface of the refractory lining, particularly for ducting (square or round), piping and the outside of curvatures.

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The anchors components of the lining system shall belong to one or are a combination of the following types:

a. V-anchors are made of 6 mm diameter wire, V-shaped with equal prongs and corrugated ("waved"). They are available in heights from 40 to 250 mm. The anchor height shall be 10-20 mm less than the nominal thickness of the refractory layer to be placed (Figure A3-2).

V-anchors suitable for stud welding are basically ordinary V-anchors, adapted to stud welding equipment. They shall be supplied with the required ceramic ring for proper fitting (Figure A3-3).

Double shaped or Y-anchors shall be used in double layer systems, or thick layers (over 150 mm) Figure (A3-3).

b. S-bars, Hexcel anchors and Tacko-anchors, are normally prefabricated and are supplied according to the Licensor’s standards.

c. Special shaped ceramic anchors are available in a wide variety. The VENDOR shall provide detailed design drawings and test results or other data to support the performance of the ceramic anchoring system used. The anchor pitch should be as shown in Figure A3-1. However, for ceramic anchors "D" is the distance between the edges of adjacent anchors, with a minimum distance of 150 mm. The material of the anchor claws shall be in accordance with the Table A3-1.

A3-1.5 Installation of Anchoring Systems a. Inspection and approvals

All work shall be subject to inspection and approval by the CONTRACTOR. The VENDOR shall not apply any metallic materials to surfaces without prior approval by the CONTRACTOR.

b. Surface Preparation

The surface on which any anchor component is to be welded shall be cleaned of grease, mill scale, loose rust, or other foreign materials prior to installation of anchoring..

c. Welding Procedures

Welders and welding procedures shall be qualified per ASME Section IX. Welding consumables shall be selected and stored in accordance with ASME Section II, Part C, and manufacturers of materials recommendations and subject to COMPANY CONTRACTOR approval.

A3-1.6 Testing of Anchors and Their Welds Anchors and welds shall be such that an anchor can be bent over 90° and returned to its original position without failure of anchor or weld. This testing shall be executed at random during anchor installation on at least 5% of the anchors.

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Prior to the application of refractory, all anchors shall be hammer tested to ensure sound welding. A light hammer (approximately 200 gm) shall be used to tap each anchor end sharply, without bending it. Each anchor having a dull, flat sound shall be replaced.

A3-1.7 Ceramic Anchors Ceramic anchors used in rammed plastic refractory linings shall be placed after premolding with dummy forms located in square arrangements. The anchor claws shall be placed such that expansional movements of the inserted anchor bricks are not restricted. Special care shall be taken to prevent damage when handling the anchor bricks. Broken anchor bricks shall be replaced.

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FIGURE A3-1 ANCHORS FOR (INSULATING) REFRACTORY MATERIALS

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FIGURE A3-2 DIMENSIONS FOR V-ANCHORS FOR SINGLE AND DOUBLE LAYERS

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FIGURE A3-3 DIMENSIONS FOR V-ANCHORS FOR STUD WELDING ONLY

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APPENDIX 4 APPLICATOR'S PROCEDURE QUALIFICATION (APQ)

A4-1.0 Scope

This Appendix specifies the procedure for the qualification of APPLICATORS for the installation of monolithic refractory materials. This procedure is divided into three major parts, namely:

• The qualification of APPLICATOR'S personnel for all monolithic refractory materials commonly used in refinery equipment, for which a certificate shall be issued with one year validity;

• The qualification of APPLICATOR'S personnel to execute a specific job, in conjunction with the equipment to be used for that job;

• The testing procedure for mixing equipment which shall be used for a specific job.

A4-1.1 Procedures

Prior to the installation of a lining, the APPLICATOR shall perform procedure tests to demonstrate that his working methods, equipment and team of operators can produce refractory linings in accordance with this specification.

A successful test qualifies the procedure and the operators for the installation of the actual lining. A record shall be made of the complete test procedure, including:

• Details of the test pieces, setup, equipment, and equipment settings

• Names of the operators

• Refractory batch identification

• Mix details and temperatures

• Test data and results

• Acceptance by CONTRACTOR

A4-1.2 Preparation and Setup of Equipment

Prior to APQ testing, the APPLICATOR shall make arrangements to perform tests without interruptions, taking into account the use of tarpaulin covers, storage of materials and set-up of equipment. Supply of materials and disposal of waste and litter are essential parts of the preparations.

The APPLICATOR shall provide all materials for proper execution of the tests, such as tools, boxes, panels, and shall line up facilities as required. The application of refractory materials shall reflect actual installation conditions as much as possible.

When use is made of gunning equipment, at least half the required hose length for the production application shall be used. Mixers and equipment for premoistening

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and conveying shall be checked and tested by the CONTRACTOR prior to qualification to confirm that they are working satisfactorily.

A4-1.3 APPLICATOR'S Qualification

a. APQ for Plastic, moldable refractory materials

The APPLICATOR(s) shall prepare a 280 x 180 x 75 mm (minimum dimensions) sample in a hardwood box, pneumatically rammed, placed in approx. 25 mm thick layers, to demonstrate accurate filling and workmanship. (see Figure A2-1). tThe bHE ox should contain an anchor system (type and layout) similar to that being used on the actual installation.

From the finished, trimmed and weighed sample the apparent density shall be calculated and shall meet the value specified on the MANUFACTURER'S data sheet with the tolerances for true density as specified in (Table A2-2). The APQ test shall then consist of removing the sample from the box and visually checking completeness of the filling, compaction, and "knitting" by breaking the sample into small pieces.

Although some porosity is inevitable, it is required that any porosity is evenly distributed. Satisfactory knitting is considered achieved if the sample breaks into small pieces, i.e. no flaws present which cause major fractures when breaking.

b. APQ for castable refractory materials

Each team of mixer operators and APPLICATORS shall prepare either a standard shape (230 x 114 x 64 mm minimum dimensions) or a box specimen (280 x 180 x 75 mm minimum dimensions) in a hardwood box. The Bbox should contain the same anchor system (type and spacing) as to be used in the actual installation. The specimen shall be placed by hand in approximately 25 mm thick layers, subsequently poked to achieve accurate filling and good workmanship. Vibrators shall not be used with castables having a bulk density of less than 1750 kg/m3.

During installation of dense and medium weight refractory materials, the APPLICATOR shall check the consistency of the ready mixed refractory material using the "Ball-in-Hand" method (ASTM C860). In the cast of a viibra cast installation, a similar form and vibration system should be modeled with a similar anchor system.

APPLICATOR'S test samples shall be stored to set and dry. From the sample, test specimens shall be cut and tested as described in Appendix 2.

c. APQ for gunning refractory materials

Each team of mixer, gunning machine operators, nozzle - men and helpers shall prepare a panel, approx. 1.5 m x 1.5 m, provided with standard anchoring (V-shape, diameter 6 mm, height 100 mm, pitch 150 mm). Minimum application thickness shall be 120 mm. The test panel should be a reflection of the anticipated production job and should be positioned in the most difficult position that will be gunned in the actual installation, i.e., overhead.

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Additionally, each team shall prepare test specimens by gunning one or more panels, 500 x 500 x 114 mm minimum dimensions, without anchoring, as shown in Figure A2-1.

Rebound samples shall be taken for calculation purposes and for information on the gunning performance.

During the preparation of the panels and test specimens the nozzle-men shall not change the settings for gunning, water quantity and pressure level. Gunning shall continue until the panels are completed; after trimming, the panels shall be left to set.

Before the panels harden they shall be visually examined by the CONTRACTOR; gentle knocking shall not reveal any air inclusions or voids. Pieces taken from the sample shall show an even distribution of the granulates and shall demonstrate the absence of laminations.

The test panels shall then be stored for further drying. From the samples, suitable test specimens shall be cut according to Figure A2-1 and tested as described in Appendix 2.

A4-1.4 Performance Testing of Mixing Equipment

The correct working/mixing of refractory materials shall be tested at least twice daily.

A small amount (e.g. 5 kg) of a dry refractory material shall be mixed according to the applicable work procedure, but instead of adding liquid or water, the same amount of a suitable liquid paint or dye, contrasting with the color of the refractory material, shall be used.

After spreading out the mixed material on a flat clean area, an even coloration shall be visible and concentrated lumps or "dry nests" shall not be visible. After completion of the test, the mix shall be removed and all equipment and tools used shall be thoroughly cleaned.

Should the test fail, then corrective action is required on the mixing equipment and a retest made.

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APPENDIX 5 DRYING AND CURING MONOLITHIC REFRACTORY MATERIALS

A5-1.0 Application This appendix specifies the requirements for curing, drying and firing of newly installed monolithic refractory linings in equipment. It also applies to cooling and reheating, and to drying and firing after lining repairs.

A5-1.1 Material, Labor, and Equipment The VENDOR shall supply all material, labor and equipment necessary to complete the work.

A5-1.2 Curing

a. General

After application, refractory materials shall be protected against freezing and extreme hot weather conditions. During the curing period, installed hydraulic bonding refractories shall be kept moist to avoid cracking or other damage due to quick evaporation of the moisture needed for the hydration reactions of the refractory.

As an alternative to the moist-curing method, an impermeable organic resin type of membrane curing compound may be applied to the refractory surface. The membrane curing compound should be in accordance with ASTM C309 and shall be applied after the lining has achieved its initial set. The curing compound shall be nonflammable when dry and its color shall contrast with the color of the refractory material.

The film thickness shall be 150 to 200 microns.

Adequate ventilation shall be provided to exhaust the fumes while the curing compound dries.

Curing compound shall not be applied to any refractory surface which will come into contact with refractory that will be applied later.

b. Temperature Conditions

For a period of at least 24 hours after refractory application, the shell and internal temperatures in the areas of newly applied refractory, resulting from ambient conditions and/or from heat of hydration, should be maintained between 10°C and 25°C.

If shell and internal temperatures of higher than 28°C are anticipated, the shell shall be cooled by clean water spray or by covering the outside with tarps or carpeting which shall be kept wet. The internal temperature shall be reduced by forced air circulation when outside ambient conditions permit.

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Because forced air circulation will also accelerate dry-out during curing, special attention (e.g. fine water spraying of dry spots) shall be paid to areas still in their curing stage.

Attention shall be paid to maintain ventilation in order to avoid condensation on parts to be subsequently lined.

If shell and internal temperatures lower than 4°C are expected, the temperature of the shell shall be raised by application of an external insulating membrane and the internal temperature increased by circulation of warm air. Live steam shall not be used. The shell temperature shall be measured hourly and recorded during installation and curing.

c. Curing of Plastic, Moldable Refractory Materials

These materials normally contain little free water and do not need a special curing period. Air-hardening plastic materials can normally be left for longer periods without firing, provided that sufficient precautions are taken when shell or internal temperatures are outside the range of 10°C to 25°C (A5-1.2b above). Under those conditions, complicated applications should be left temporarily in their original molds. Although minimum air ventilation is required to avoid condensation, it should not be such as to cause unacceptably fast dry - out.

Chemically bonding plastic materials are hygroscopic and shall either be fired up to 250°C minimum immediately after installation, or adequately protected against moisture absorption by, for example, using a curing compound (A5-1.2a above), or covering with plastic sheets.

Plastic sheeting or tarpaulins shall be used to minimize refractory damage. Water spray shall not be used on chemically bonding refractories.

d. Curing of chemically bonding castable refractory

The material shall be allowed to air-set and shall not be cured by water spraying. The use of an impermeable membrane, resin-type curing compound is also prohibited. The use of tarpaulins to protect the fresh refractory from dust and damage is allowed.

Temperature restrictions and monitoring requirements defined in the manufacturers workability guidelines shall be implemented during the curing period. Suitable means of heating or cooling the refractory lining during this period shall be provided if required.

e. Curing of hydraulically-bonding castable refractory and gunned refractory

Hydraulically-bonding refractory lining and gunned refractory lining shall be cured. The curing shall be started as soon as the exposed refractory surface appears dry to the touch (which is normally one to eight hours after application, depending upon atmospheric conditions). At this time a fine spray mist of clean, cool water shall be applied to the surface. The water spray shall be applied at sufficiently frequent

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intervals to preclude drying of the lining and shall continue for at least twenty four hours after the last portion of the lining has been applied. Adequate drainage shall be provided to allow excess water to run off without puddling.

If approved by the CONTRACTOR, as an alternative to the water cure method, an impermeable organic resin type membrane curing compound (A5-1.2a above) may be applied to the refractory surface. The membrane curing compound shall be applied after the casting has achieved its initial set.

An impermeable membrane shall not be applied to any surface on which refractory will be applied later.

For a period of at least 36 hours after refractory application, the shell and internal temperatures in the areas of the newly applied refractory (resulting from ambient conditions and/or from heat of hydration) shall be maintained between 10°C and 30°C. If necessary this shall be achieved by either cooling the shell with a water spray (and forced air circulation if ambient conditions permit) or raising the temperature by applying an insulating membrane and circulating warm air. The shell temperature shall be measured at four-hour intervals and recorded during the curing period.

Direct sunlight is not allowed on any fresh refractory within 36 hours of installation.

A5-1.3 Drying and Firing The MANUFACTURER’S detailed drying and firing procedures, including points of temperature measurement and full description of working methods, shall be submitted by the APPLICATOR to the CONTRACTOR for approval.

All refractory linings that will be subjected to sub-zero (°C) conditions (including prefabricated sections in storage) shall either have been fully dried and heat treated prior to exposure to such conditions or be kept warm during exposure to such conditions, to avoid freezing of the refractory.

Freezing weather conditions are harmless to the refractory if it has been fully dried and heat treated.

A5-1.4 Drying After the curing period, all refractory shall be air-dried for at least 24 hours by natural or forced ambient (minimum temperature 10°C) air circulator before heat is applied: During the drying period, adequate venting shall be provided for escape of moisture from the freshly installed material.

During and immediately after the drying out period is the appropriate moment for inspection of the completed refractory lining.

A5-1.5 Firing of Chemically-Bonding Refractory After air drying the chemically bonding refractories must be heated. The heat treatment is required to develop the chemical bond in the refractory, which is essential for good performance. See Figure A5-1 for typical firing schedule. Under atmospheric dry-out conditions the materials generally harden by air setting. This

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provides enough strength for transportation, handling and placing the lined equipment inside the unit.

External insulation may be used to promote dry-out.

The cooling rate after heat dry-out shall not exceed 60°C per hour.

A5-1.6 Firing of Hydraulically Bonding Refractory Linings and Plastic Moldable Refractory Linings The VENDOR shall establish the dry out requirements in accordance with the MANUFACTURER'S recommendations and the requirements of this specification. The more stringent requirements shall prevail. After air drying the linings shall be heat treated.

Before the dry-out operation begins, sufficient temperature measuring devices shall be installed to monitor gas temperature throughout the lined area to be dried. It is essential that these be located near or at the point of entry of hot gases, near or at the point of exit of the gases and at a sufficient number of intermediate points. In addition, temperature measurements at approximately midway inside the insulating refractory are required.

To ensure that any equipment failure causes no more than a very short disruption in the dry-out schedule, the VENDOR shall ensure there are sufficient spare heaters and other items of equipment critical to the dry-out available at the job site.

If dry-out is interrupted for more than 15 minutes, the drying schedule shall be restarted at the temperature level of the point at the hot face of the lining with the lowest temperature and shall not be continued from the point of interruption.

The circulating hot air temperature shall be maintained at such levels that the metal shell temperature always remains at least 50°C below the metal design temperature at any metal temperature monitoring point. The controlling temperature in any drying activity shall be the temperature at the refractory hot face. If steaming is observed after time has elapsed at any hold point, continue to hold the temperature until the steaming ceases.

Heat shall be applied to increase the temperature in the following major steps, Figure A5-1.

Step 1) The air temperature shall be raised gradually at a rate not exceeding 15°C per hour until all temperature monitoring points in the flue gas and at the refractory hot face are between 100°C and 120°C. This temperature range shall be held for at least 12 hours.

Step 2) The flue gas temperature shall be increased smoothly at a rate not exceeding 30°C per hour until all the gas temperature monitoring points in the flue gas and at the refractory hot face are within 15°C of each other and are at a temperature between 300°C and 400°C. The gas temperature shall be held in this range for at least two hours per 25 mm of lining thickness (8 hours minimum).

Step 3) The flue gas temperature shall be increased to operating temperature level at a rate not exceeding 30°C per hour until all the temperature monitoring points in the flue gas and at the refractory hot face show the same value (within 15°C). This temperature shall be maintained for 1.5 hours per 25 mm of lining thickness, with a minimum of 4 hours.

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Step 4) For systems which have previously gone through steps 1-3 (and for systems which are being restarted after a shutdown in which only minor refractory repairs have been effected) the system may be brought quicker to operating temperature (at a rate of 60°C per hour maximum).

In cooling after initial dry-out, a gas cooling rate of 60°C per hour should not be exceeded.

A5-1.7 Auxiliary Firing Equipment Linings of complicated equipment or interconnected manufacturer equipment may require to be dried and fired using an auxiliary burner unit. The VENDOR shall install this unit as close as possible to the combustion air entry of the lined equipment. This may be the combustion air ducting, ensuring sufficient and intensive air circulation, and allowing temperature to be increased at a rate as described above.

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FIGURE A5-1 CURING, DRYING AND FIRING OF MONOLITHIC REFRACTORY MATERIALS

(Refractory MANUFACTURER’S schedule to be used when major differences are apparent)

1.NOTE: ALL REFRACTORY IS TO BE COOLED DOWN IN A CONTROLLED MANNER AT 60°C/HR MAXIMUM.

DGS-6531-020

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