API RefractoryRequirements May2011

7/31/2019 API RefractoryRequirements May2011

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Refractory Lining and Burner Brick Requirements

API 560

Revision Date: May 3, 2011 1

Scope

This section covers refractory lining requirements for fired heaters, air preheaters, ducting, stacks, andflue gas systems, for general refinery service, including materials selection, design, installation,installation quality control, curing and dryout. It also covers preparation for shipment and erection of

modular sections lined at a location separate from final erection. It does not apply to the design ofsteam reformers or pyrolysis furnaces.

Table of Content

1.0 References

2.0 Definitions3.0 Definition of operating parameters by heater components

4.0 Critical performance factors affecting refractory lining selection

5.0 Refractory lining system selection

6.0 Brick layer or gravity wall construction

7.0 Fiber construction

8.0 Castables/Plastics construction

9.0 Anchors and Anchor components

10.0 Quality control

11.0 Responsibilities

12.0 Preparation for Shipment

13.0 Dryout and Heatup/Cooldown Rates

1.0 References

1.1 API 936: Refractory Installation Quality ControlInspection and Testing of MonolithicRefractory Linings and Materials

1.2 ASTM C892: Standard Specification for High-Temperature Fiber Blanket ThermalInsulation

2.0 Definitions: The following definitions are added in this section as a supplement to those

provided in Section 3, Terms and Definitions in this edition of API 560/ISO 13705. A

comprehensive glossary of refractory terms is provided in Annex A of API 936.

2.1 AES (Alkaline Earth Silicate) fibers: Man Made Vitreous Fiber composed ofat least 18%

alkali earth oxides developed to meet the fiber exemption requirements spelled out in

97/69/EC of the Dangerous substances initiative in the EU. These fibers are exonerated

from the EU carcinogen classification on the basis of their low biopersistence. Also may

be known as Biofiber, Biosoluble or Low Biopersistence fiber.2.2 Alkaline hydrolysis: A potentially destructive reaction between green hydraulic setting

refractory concrete, carbon dioxide, alkaline compounds and water.

2.3 Anchor brick supported system: Lining supported by ceramic anchors held in place by a

metallic support system. Anchor bricks have convoluted surfaces designed to be filled in

with surrounding monolithic refractory to hold the lining in place.


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2.4 Ash: The non combustible residue that remains after burning a fuel or other

combustible material. This residue may be corrosive to steel or refractory linings and

foul tubes.

2.5 Anchors: Metallic or refractory devices attached to the shell casing that hold the lining

in place.

2.6 Block insulation: Light weight, preformed rigid block used as a backup layer because of

its high insulating properties.

2.7 Burner block/brick/tile/quarl: High temperature refractory burner components that

direct the burner flame.

2.8 Organic coating: Coating used between refractory lining and casing to resist corrosion

from condensing acids (e.g. mastic, epoxy. etc.)

2.9 Owner/Fabricator: The proprietor of the fire heater who has engaged one or more

parties to install or repair refractory.

2.10 Castable: A combination of refractory grain and suitable bonding agent that, after the

addition of a proper liquid, is installed into place to form a refractory shape or structure

that becomes rigid because of a chemical action.

2.11 Cold face: The surface of a refractory lining against the metal casing surface.

2.12 Cold joint: A joint formed in an otherwise monolithic lining that results from work

stoppage during refractory installation.

2.13 Compliance datasheet: A list of mechanical and chemical properties for a specified

refractory material that are warranted by the manufacturer to be met if and when the

product is tested by the listed procedure

2.14 Construction joint: A joint formed in a lining to mechanically decouple refractory

components without expansion allowance.

2.15 Contractor: The party or parties responsible for installing refractory in theOwner/Fabricator's equipment

2.16 Deflection/Target wall: A refractorywallused to redirect or shield portions of a furnace

from gas or radiant heat.

2.17 Expansion joint: A nonbonded joint in a lining system with a gap designed to

accommodate thermal expansion of adjoining materials, commonly packed with a

temperature resistant compressible material such as fiber.

2.18 Fiber: Fibrous refractory with RCF/AES composition and flexible handling characteristics,

including bulk, blanket, modules, paper, board, mat, wet blanket and pumpable/

sprayable fibers.

2.19 Ceramic Fiber: RCF fiber and its products.2.20 Fabricator: Company responsible for the overall fabrication of the fired equipment in

which refractory is installed.

2.21 Hot face: The surface of a refractory section exposed to the source of heat.

2.22 Installer: Company or individual responsible for installing the refractory lining.


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2.23 Low biopersistence: Materialshaving solubility in body fluids and designed to be

cleared from the lungs very quickly if they are inhaled. Clearance occurs through the

body's natural defense mechanisms.

2.24 Man Made Vitreous Fibers (MMVF): Amorphous silicate fibers including AES and RCF

manufactured from liquid melts at 1000C 1700C by drawing (continuous filaments),

spinning or blowing.

2.25 Module: Construction of fibrous refractory insulation in stacked/folded blankets or

monolithic form, commonly with an integrated attachment system.

2.26 Needled: A knitted structure for fiber to enhance handling and mechanical strength.

2.27 Owner/Fabricator: The proprietor of equipment who has engaged one or more parties

to install or repair refractory.

2.28 Qualification Test: Preinstallation evaluation of materials and/or applicators to verify

that materials purchased and equipment/personnel that will be installing the material

are capable of meeting specified quality standards.

2.29

Permanent linear change (PLC): A measure of a refractory's physical property that

defines permanent linear dimensional change as a result of initial heating to a specific

temperature

2.30 RCF (Refractory Ceramic Fibers): Man Made Vitreous Fibers (MMVF) whose chemical

constituents are predominantly Alumina and Silica.

2.31 Refractory Inspector: The party or individual whom the Owner/Fabricator has

contracted or otherwise designated to monitor refractory testing and installation work

performed by the contractor and refractory material manufacturer(s).

2.32 Rigidizers: Liquids applied to MMVF which produce a rigid hot face surface when dried.

2.33 Pumpable/Sprayable Fibers: Mixture of bulk fiber and wet binder suitable for pumping

or spraying.2.34 Shelf supported systems: In brick lining systems, a structural plate or angle

mechanically attached to the casing that has the function of supporting a lining section

or component.

2.35 Tiebacks: Mechanical fastening devices used to hold a vertically standing brick lining

structure in the upright position while permitting the lining to thermally expand and

contract.

2.36 Vacuum formed: A manufacturing process combining fibers and binder components and

using vacuum to form rigid, densified shape when dried.

2.37 Wet Blanket: Flexible, formable RCF blanket saturated with wet binder that sets on

heat exposure forming a rigid more durable structure comparable in hardness andchemistry to board.

3.0 Definition of operating parameters by heater components

3.1 Radiant Section: The refractory lining system provides thermal resistance to retain

process heat. The refractory lining system shall resist any high temperature ash

corrosion and must protect the metal shell against condensate corrosion related to fuel

gas sulfur content.


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3.2 Convection Section: The refractory lining system must provide thermal resistance and

corbels to ensure maximized heat transfer between the process tubes filling the

convection section and the hot gases. Fuel ash related hot face corrosion issues are

reduced in all but the lower portions of the convection section as the gases are cooled

while passing over the convection section tubes. Metal shell casing corrosion related to

the sulfur content in the fuel will continue to be an issue in this location. If some type of

sootblowing or small particle blasting is used to remove ash or soot buildup on

convection section tubes, the hot face refractory lining must be strong enough to resist

any indirect impingement related to particle blasting.

3.3 Breeching and Ducting (between convection section and stack): Refractory linings must

provide thermal resistance, mechanical integrity, and protect against metal shell

corrosion. Although the breech and ducting linings are exposed to relatively low

temperature during normal operation, they also provide fire protection if a tube

ruptures in the radiant or convection section.

3.4

Stacks: Refractory linings in the stack must provide thermal resistance, mechanical

integrity, and protect against metal shell corrosion.

3.5 Burner Block: Burner block must insulate the burner housing while not being adversely

affected by high temperature or thermal cycling related to startup and shutdown. Block

must resist flame impingement and corrosive impurities.

3.6 Gravity Walls: Free standing walls inside fired heaters to provide physical separation of

process areas within the furnace, typically between radiant sections operating at

different temperatures or between radiant and convection sections. In radiant sections

the walls also provide surfaces of radiation to improve heat transfer to the tubes.

4.0 Critical performance factors affecting refractory lining selection:

4.1 Design Temperature is a temperature used to make refractory selections. It is thecalculated hotface or interface temperature plus the required design margin of 165C

minimum (300F). Some minimum refractory design temperatures based on typical hot

face temperatures in furnace locations are the following:

4.1.1 Burner area: 1650C (3000F)

4.1.2 Target walls with flame impingement on one or both sides: 1540C (2800F)

4.1.3 Floor: 1370C (2500F)

4.1.4 Radiant and shielded section: 980C (1800F)

4.1.5 Convection section: 980C (1800F)

4.1.6 Breeching and Ducting: 510C (950F)

4.1.7 Air preheating system: 510C (950F)4.1.8 Access doors shall be protected from radiation by a refractory system of at least

the same temperature rating and thermal resistance as the adjacent wall lining.

4.2 Maximum Use Temperature: Maximum continuous temperature to which a refractory

may be exposed without excessive shrinkage or mechanical breakdown. It is also

sometimes referred to as the recommended use limit. or continuoususe

temperature.


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4.3 HotFace Temperature is the flue gas or the heated combustion air temperature at the

hot face of the lining. This is the temperature used for thermal calculations for

operating cold face temperature and heat loss..

4.4 Interface Temperature is the calculated temperature at the intersection of each

different layer of refractory material if multilayer or multicomponent refractory

construction is used.

4.5 Cold Face Temperature is the temperature at the casing calculated using the thermal

resistance of the lining and hot face temperature. The lining is designed to meet

specified thermal efficiency of the equipment and/or personnel protection

requirements.

4.6 Thermal Resistance is the ability of a refractory material to resist heat flow from the hot

face to the metal shell. A wide range of thermal resistances are possible by the

selection of refractories with different thermal conductivities and/or lining thicknesses.

4.7 Form: Refractories are available in a variety of forms, including:

4.7.1

ShapedSold as finished units, installed as building blocks

4.7.1.1 Brick/Tile

4.7.1.2 Fired Shapes

4.7.1.3 Fused Cast Shapes

4.7.2 Monolithic (Unshaped)Final shape formed upon application

4.7.2.1 Castables

4.7.2.2 Plastics

4.7.2.3 Mortars

4.7.3 Fiber

4.7.3.1 Bulk

4.7.3.2 Blanket4.7.3.3 Modular

4.8 Thermal Expansion allowance is required for shaped and monolithic lining materials.

This is achieved by expansion joints in the form of shrinkage cracks formed on the initial

firing of monolithic lining materials and/or regularly spaced open joints formed during

construction and filled with compliant refractory materials designed to accommodate

the full thermal expansion of the lining materials at design temperature.

4.9 Mechanical Strength: Most fired heater lining systems are supported by the casing via a

network of regularly spaced metallic or ceramic anchors for which they must be able to

support their own weight in relation to the anchors. Additionally there are rigid bridge

walls, target walls, arches and burner blocks which are mechanically self supportingand/or must be resistant to wear such as soot blasting abrasion.

4.10 Fuels Fired: The type of fuel fired and corrosive ash/impurities (e.g sulfur, alkali and

heavy metals) will guide selection of the type or form of refractory and the method of

construction for refractory linings.


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5.0 Refractory lining system selection guidelines

5.1 A large number of refractory lining systems are used in fired heaters. Table 1 presents 8

lining systems and rates them relative to each other as a general guideline for

conventional systems/materials. These guidelines should be used for lining selection in

combination with the understanding of the performance requirements for each portion

of the fired heater listed in 3.0 above.

Table 1: Lining System Decision Matrix Guidelines

Operating Conditions/Needs

Refractory Lining SystemsAshResistan

ce

Condensate

Corrosion

Temperatur

eResistance

Erosion/VelocityResistance

Maintenanc

e/EaseofRepair

DesignLife

EnergyCons

ervation

ReducedWeightofStructure

SpeedofIns

tallation

AES/RCF fiber (Includes modules and blanket) L L L L H L H H H

AES/RCF Fiber w/ Vapor Barrier L M L L H L H H M

AES/RCF Fiber w/ Castable Backup L H L L H L M H M

Dual Layer Monolithic M H M H M M M M L

Single Layer Monolithic M H H H M H L M M

Brick with Fiber or Block Backup H L H H L H M L L

Brick with Castable Backup H H H H L H M L LIFB (Insulating Firebrick) M L M M L M H M M

Performance Rating for Listed Conditions: LLow; MMedium; HHigh

6.0 Brick layer or gravity wall construction

6.1 All brick linings on vertical flat casing shall be tied back to, and supported by, the

structural steel framing members. All tie members shall be austenitic alloy material,

except that pipe supports located in the backup layer may be carbon steel. At least 15%

of the bricks shall be tied back. It is not necessary for the brick lining on the cylindrical

casing to be tied back if the radius of curvature of the casing keys the bricks.

6.2 Brick linings shall be supported by metal support shelves (lentils) attached to the casingon vertical centers typically 1.8 m (6 ft) high but not to exceed 2.3 m (12ft) based on

calculated loads and thermal expansions. Support shelves shall be slotted to provide for

differential thermal expansion. Shelf material is defined by the calculated service

temperature at the tip of the shelf; carbon steel is satisfactory up to 370C (700F).

6.3 Expansion joints shall be provided in both vertical and horizontal directions of the walls,

at wall edges and around burner tiles, doors and sleeved penetrations.


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6.4 Radiant chamber walls of gravity construction (Figure 1) shall not exceed 7.3m (24 ft) in

height and shall be at least highduty firebrick. The base width shall be a minimum of

8% of total wall height. The heighttowidth ratio of each wall section shall not exceed 5

to 1. The walls shall be self supporting and the base shall rest on the steel floor, not on

another refractory.

Figure 1: Illustration of Gravity Wall dimensional requirements

6.5 Gravity walls shall be of bonded, mortared construction. The mortar shall be air setting

and compatible with firebrick.

6.6 Vertical expansion joints shall be provided at gravitywall ends and required

intermediate locations. All expansion joints shall be kept open and free to move. If the

joint is formed with lapped brick, no mortar shall be used, that is, it shall be a dry joint.

6.7 Target walls with flame impingement on both sides (freestanding) shall be constructed

of superduty fireclay brick with at least a 1540C (2800F) rating. Bricks shall be laid

with mortared joints. Expansion joints shall be packed with ceramic fiber strips having a

maximum use temperature not less than 1430C (2600F).

6.8 Floor brick shall not be mortared. A 13 mm (0.5 in) gap for expansion shall typically be

provided at 1.8 m (6 ft) intervals. This gap may be packed with fibrous refractory

material having similarly maximum use temperature, in strip, not loose bulk, form. Floor

brick shall be a minimum 63 mm (2.5 in) thick of highduty firebrick.

6.9 Mortar joints shall cover all contact surfaces and be 2mm (1/16 inch) thick maximum.

6.10 Maintenance/Repair: The mechanical function of supports, tiebacks and expansion

joints must be taken into consideration when repairing brick linings. Repairs are


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generally made by replacing or refurbishing entire structural units such as the entire lift

of brick on a support from expansion joint to expansion joint and/or several courses of

brick at the top of a lift.

6.11 Brick and mortar types shall be specified by the owner, OEM or furnace fabricator.

6.12 For brick materials, suppliers shall provide Manufacturers Product Compliance Sheet

(sample attached), to guarantee the following physical properties:

6.12.1 Density

6.12.2 Strength (cold crush strength or Modulus of Rupture)

6.12.3 Porosity

6.12.4 Thermal Conductivity

6.12.5 Chemical Composition

6.12.6 Manufactured Defects (edge, corner, crater, cracks)

6.12.7 Dimensional tolerance and warping (*)

6.13 For brick materials, suppliers shall provide Manufacturers Product Compliance Sheet

(sample attached), to guarantee the following physical properties:

6.13.1 Strength (bond)6.13.2 Chemical Composition

6.13.3 Maximum grain size

7.0 AES/RCF Fiber Construction

7.1 Layered or modular construction may be used in all radiant and convection section

sidewalls and roofs subject to restrictions defined herein. Other sections may be lined

with fiber subject to Owner/Fabricator approval.

7.2 Fiber hot face shall not be used in the radiant section when fuels sodium and vanadium

exceed 100 parts per million total above 700C (1300F).

7.3 In layered construction, blanket shall be a minimum of 25 mm (1 in) thick, 128 kg/m3 (8

lb/ft3) density, needled material. Fiberboard, if applied as a hot face layer, shall not be

less than 38 mm (1.5 in) thick nor have a density less than 240 kg/m 3 (15 lb/ft3). Backup

layer(s) of fiber blanket shall be needled material with a minimum density of 96 kg/m3 (6

lb/ft3).

7.4 Dimensions for fiberboard used on the hot face shall be::

7.4.1 600 x 600 mm (24 in x 24 in) maximum if temperatures of flue gases are below

1100C (2000F) on sidewalls.

7.4.2 450 mm x 450 mm (18 in x 18 in) maximum if temperatures exceed 1100C

(2000F) or if used on the roof at any temperature.

7.4.3 Blanket shall be 24 wide maximum applied using an approved anchor layout

7.5 Metallic anchor parts that are not shielded by tubes shall be completely wrapped with

fiber patches or be protected by ceramic retainer cups filled with moldable fiber.

7.6 Fiber blanket shall not be used as the hot face layer if flue gas velocities are in excess of

12 m/s (40 ft/s). Wet blanket, fiberboard, or modules shall not be used as hot face

layers with velocities greater than 30 m/s (100 ft/s).


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7.7 Fiber blanket shall be installed with its longest dimension in the direction of gas flow.

The hotface layer of blanket shall be constructed with all joints overlapped. Overlaps

shall be in the direction of gas flow. Hot face layers of fiberboard shall be constructed

with tight butt joints.

7.8 Fiber blanket used in backup layers shall be installed with butt joints with at least 13

mm (1/2 in) compression on the joints. All joints in successive layers of blanket shall be

staggered.

7.9 Fiber blanket modules shall be installed in soldiercourse with batten strips (Figure 2).

Parquet pattern or soldiercourse may be used on arches.

7.10 Module systems shall be installed so that joints at each edge are compressed to avoid

gaps due to shrinkage.

7.11 Modules applied in arches shall be designed so that support hardware spans over at

least 80% of the module width (Figure 3).

Figure 2: Soldier course for blanket modules


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Figure 3: Anchor span required for arch section modules

7.12 Anchors shall be attached to the casing before modules are installed.

7.13 Support hardware shall be located in the module at a maximum distance of 50 mm (2 in)

from the module cold face.

7.14 Module internal hardware shall be austenitic stainless steel or nickel alloy (see Table 3).

7.15 Fiber linings should not be used for the lining of floors where maintenance traffic and

scaffolding construction are anticipated.

7.16 If fiber construction is used with fuels having a sulfur content exceeding 200 mg/kg (200

ppm by mass), the casing shall have an internal protective coating, specified or agreed

by the purchase, to prevent corrosion. The protective coating shall be rated for a 175C

(350F) service temperature.7.17 A 2mm vapor barrier of austenitic stainless steel foil shall be provided if the fuel sulfur

content exceeds 500 mg/kg (500 ppm by mass). The vapor barrier shall be installed in

soldiercourse and located so that the exposed temperature is at least 55C (100F)

above the calculated acid dew point for all operating cases. Vapor barrier edges shall be

overlapped by at least 175 mm (7 in); edges and punctures shall be overlapped and

sealed with sodium silicate or colloidal silica.

7.18 Fiber shall not be used in convection sections where soot blowers, steam lances or

water wash facilities are used.

7.19 Anchors shall be installed before applying protective coatings to the casing. The coating

shall cover the attachment studs so that uncoated parts are above the acid dewpointtemperature.

7.20 Maintenance/Repair: Typical patch repairs are shown in Figures 4 and 5 for blanket

lining systems and Figure 6 for a modular system.

7.21 Curing and Dryout: Refractory fiber linings require neither curing nor dryout before

commissioning.


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Figure 4: Typical blanket lining repair of hot face layer

Figure 5: Typical blanket lining repair of multiple layers


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Figure 6: Typical repair of modular fiber lining

8.0 Castables/Plastics Design and Construction

8.1 Design

8.1.1 Sidewall: Single or dual component with total thickness between 150 and 200

mm (68 inches).

8.1.2 Floor: Dual component with hot face layer sufficiently strong to support

scaffolding load of 21 Kg/cc (300 psi).

8.1.3 Roof: Single or dual component with total thickness between 150 and 200 mm

(68 inches).

8.1.4 Burner block; Brick or prefired castable with temperature resistance

8.1.5 Bull nose: Single or dual component with total thickness between 150 and 200

mm (68 inches).

8.1.6 Corbelling: Constructed integral with the hot face layer and containing anchors

consistent with the taller height of the corbelling.

8.2 Alkaline hydrolysis

8.2.1 Dryout and alkaline hydrolysis in castable refractory materials.

8.2.2 Alkaline hydrolysis occurs intermittently. It is a naturallyoccurring

phenomenon. Alkaline hydrolysis becomes a significant concern for castables

mixes having dried densities less than 1040 kg/m3 (65 lb/ft3 ).

8.2.3 For materials with dried densities greater than 1040 kg/m3 (65 lb/ft3), the

tendency for occurrence of alkaline hydrolysis is reduced.


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8.2.4 To minimize the possibility of alkaline hydrolysis, castables and gunning mix

linings should be moisturecured for 24 hours, then air dried for 48 hrs. When a

complete dryout is not possible after curing and air drying as a minimum the

following schedule can be followed. Within two weeks after curing and air

drying, the installed materials should be dried to 260C [500F (Hot face

temperature)]. The drying schedule should include a 55C/hour (100F/hour)

rampup to 260C (500F) hot face temperature with an eight hour hold period

upon reaching 260 C (500F). The dryout schedule should terminate with a

55C/hour rampdown to ambient temperature.

8.2.5 When refractorylined modules are stored for long periods, the linings should be

sealed for moisture and air and periodically inspected for alkaline hydrolysis.

8.3 Maintenance/Repair

8.3.1 A significant advantage of monolithic refractories is their ability to be

maintained by patch repairs. Patching should be made for the full lining or layer

thickness. Overlay repairs are not acceptable.

8.3.2 Defective areas found in the facing after curing shall be removed to the

insulating backup material, and the facing castable shall be reapplied as long as

retained anchors and backup are damage/defect free.

9.0 Anchors and Anchor Components

9.1 Anchors are required to hold refractory linings in place during unit operation. The

anchor material is to be selected based on the maximum temperature an anchor tip will

be exposed to as listed in Table 3.

Table 3: Anchor Metallurgy Required at the Listed Maximum Anchor Temperature

Maximum anchor temperatureAnchor Material C (F)

Carbon steel 455 850

TP 410S stainless steel 650 1,200

P 304 stainless steel 760 1,400

TP 316 stainless steel 760 1,400



TP 330 stainless steel 1,038 1,900

Alloy 601 (UNS N06601) 1,093 2,000

Ceramic studs and washers >1,093 >2,000


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9.2 Anchor Spacing and Selection

9.2.1 When brick linings are selected for use in radiant furnace walls, they must be

held against the wall and supported using shelf supports and/or tiebacks.

These anchoring types shall be detailed in the furnace design information.

9.2.1.1 Horizontal shelf supports, as a rule, are required on furnace walls,

and d less than 1.5 meters (58) apart. They are generally designed

to support 10 times the load weight, and have a shelf width which

supports50% of the hot face lining thickness.

9.2.1.2 For flat walls, 15% of the bricks shall be tied back. This frequency

may be reduced for cylindrical walls when the radius of curvature of

the casing keys the bricks linings.

9.2.2 When refractory monolithic linings are used for furnace linings, anchor spacing

should be as follows:

9.2.2.1 For roofs, anchor spacing should be 1.5 times the lining thickness.

9.2.2.2

For walls, anchor spacing should be 2 times the lining thickness.

9.2.2.3 For radiant furnace floors, anchors are not required unless the unit is

to be shipped prelined.

9.2.2.4 For dual layer linings, Y anchors shall be installed to hold the hot

face in place. Careful attention shall be given to the design and

metallurgy of this anchor type since a large portion of this anchor

will be exposed to the maximum temperature, which could

potentially lead to anchor failure. Spacing for the Y anchor on the

hot face shall be the same as that above for single layer linings based

on the hot face lining thickness.

9.2.2.5 For corbels that extend out beyond the convection section liningthickness intended to keep flue gases channeled in through the

convection section tubes, Y anchors should be used to hold the

corbels in place. These are used in combination with V anchors for

the single layer convection section wall linings.

9.3 Ceramic fiber blanket shall be 24 wide maximum applied using an approved anchor

layout with the following maximum spacing:

9.3.1 Distance from edge: 75 mm (3 in) maximum/ 50mm (2 in) minimum.

9.3.2 Overlapping Joints (4 overlap): 10 x 10 horizontal and 1012 vertical on walls

with 910 overhead (Figure 7). Tighter centers to be used in extreme conditions

(vibration or other)9.3.3 Blanket see Figure 8

9.3.4 Modules see Figure 9

9.3.4.1 Spacing 3X thickness

9.3.4.2 Diameter or equivalent section


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Figure 7 Butt (left) and Overlapping (right) Joints for Blanket Linings

Figure 8

Typical blanket lining anchoring systems


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Figure 9

Examples of modular fiber systems


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9.4 Stud Welding Qualification

9.4.1 All weld procedures and welders shall be qualified per ASME Section IX.

9.4.2 At the start of each shift sample test welds shall be performed by each welder.

A sample test shall entail stud welding five anchors on a clean scrap metal plate.

A hammer and bend test will be run each sample to ensure a sound full weld.

The bend test shall consist bending 15 degrees from vertical and back without

cracking.

9.4.3 All equipment settings shall be noted and checked after each work break.

9.5 Anchor/Hardware Inspection

9.5.1 All individual anchors shall be subject to inspection by hammer test and bend

test to ensure they are fully welded with proper spacing and configuration. A

minimum of 20% of the production anchors shall be randomly inspected and

tested. For stud welded anchors, 100% of the anchors shall be lightly hit with a

light hammer to produce a ringing sound without damaging the anchor or

threads.

9.5.2 The heater casing is clean, dry and rustfree to ensure sound welds.

10.0 Quality Control

10.1 Physical properties relevant to the types of refractory materials to be used in furnaces

are those listed in Table 2. These properties should be reviewed in light of the intended

service. They shall be tested to confirm that material batches manufactured for the job

meet Compliance Datasheet claims to the properties listed.

Table 2: Property Claims Documentation Required as Related to the Type of Refractory Selected

Properties Castable Brick Fiber

Chemical Composition X X X

Maximum Use Temperature X X X

Cold Compressive Strength X X

Density X X X

Permanent Linear Change X X X

Thermal Expansion Coefficient X X

Thermal Conductivity at Intended

Use Temperature

X X X

Hot Load Strength X

Note:1. Use temperature per ASTM C 27 (Brick), ASTM C 155 (IFB), ASTM C 401 (Castable), and ASTM C 892 (RCF).


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10.2 Packaging/Storage/Shelf Life

10.2.1 Monolithic refractory per API 936.

10.2.2 Brick and fiber shall be packaged to protect the refractory from being saturated

with water and from exposure to foreign chemicals that might penetrate the

structure and affect properties in service. They must also be protected from

mechanical abuse during shipment and handling.

10.2.3 Packaging and Marking, API Standard 936, paragraph 7.3 addresses packaging

and marking for monolithic refractory.

10.3 Material Safety Data Sheets

10.3.1 Refractory materials shall comply with all applicable federal, state, and local

codes and regulations on storage, handling, safety, and environmental

requirements.

10.3.2 The latest issue of the refractory manufacturers compliance data sheets,

application instructions, and MSDS shall be available at the installation site and

complied with during the installation of monolithic refractory linings.

10.4 Anchor Inspection and Testing

10.4.1 All anchor components shall be supplied with mill certifications for the heat

with that heat identified on the package and/or anchor component.

10.4.2 The composition of all welding consumables shall be identified on the package

and/or spool or welding rod.

10.4.3 Surface preparation

10.4.3.1 Per ASME SEC VIII D1 B PT UW32.

10.4.3.2 Spotground to a white metal surface.

10.4.4 Layout and spacing shall be verified as meeting specified requirements before

refractory installation.10.4.5 Job site verifications shall meet the following requirements:

Anchor Count PMI1 Weld Hammer Test2


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10.5 Brick/Tile Inspection and Testing

10.5.1 Each production lot of mortar shall be sampled and tested against the approved

compliance data after manufacture and prior to shipment. A lot of mortar whose

test results do not meet the approved Compliance Data is subject to re-test with

a different sample. If the re-test samples fail to meet the specified values the

entire lot shall be rejected.10.5.2 Each production lot of mortar shall be sampled and tested to confirm that the

materials to be installed meet compliance datasheet requirements for physical

properties within 10% of specified maximums and minimums.

10.5.3 After approval of physical properties samples selected for bricks in accordance

with the following table shall be tested for dimensions and physical defects and

accepted/rejected based on the following criterion:

Lot Size (pcs.) Sample Size

(pcs.)

Lot Retest or Rejected (on retest) if

Defective number of brick from sample


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10.5.4.3 Tolerance requirements for brick shall be:

Length


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10.5.5.5 The installation contractor shall provide test result information as

prepared by independent laboratory for all as required qualification

verification testing or for, as installed testing as required.

10.5.5.6 Where applicators are qualified based on experience record a

recording document from the contractor to be provided listing the

worker(s) their applicable experience record including attachments ofresume submitted with bid documentation where applicable.

10.5.5.7 The contractor shall supply documentation of daily quality audits for

workmanship against quality standards listed below.

10.5.5.8 The Quality Assurance Inspector shall log any discrepancies or

deviations from this and other project specifications and immediately

notify the OWNER and the contractor to determine corrective action.

10.5.6 Refractory Fire Brick and Fired Shape Applicator Qualification Criterion

10.5.6.1 Prior to starting work the contractor to provide a list to the Owner or

designate of all applicators that will be installing refractory brick and

fired materials, listing previous project references available for

contact and verification as to where they have had similar

installations. No applicator without acceptable refractory brick

installation experience and training shall be used to install bricks or

fired shapes.

10.5.6.2 Workers that will be installing brick and fired shapes shall have

personal safe work history for all types of brick construction defined

in the Work satisfactory to the OWNER or Inspector, and be trained

in the safe handling of all brick, mortar and equipment required for

the installation.

10.5.7 Inspection criterion for brick linings during installation are:

10.5.7.1 Bricks shall be handled without causing physical damage.

10.5.7.2 Bricks that have physical damage shall not be used without inspector

approval.

10.5.7.3 Insulation bricks that have had water damage or are wet shall not be

used without approval by OWNER or Inspector.

10.5.7.4 Insulating bricks removed from pallets or packaging shall be suitably

tagged to Identify material type (name, service temperature), and

sorted prior to install to provide inspection baseline and correct

installation.

10.5.7.5 Visual inspections shall be made to insure bricks are laid plumb, and

tapped tight to back-up or shell with no overlapping (lipping).

10.5.7.6 Mortar joints shall be spread evenly and completely and be 1/8 (3mm) thick.

10.5.7.7 Mortar for brick shall be properly labeled if not in manufacturer

supplied container.

10.5.7.8 Mortar supplied dry, shall be mixed in accordance to Manufacturers

recommendation and in accordance to installation procedures.


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10.5.7.9 Mortar supplied wet shall only be tempered with additional water

in accordance to Manufacturers recommendation and in accordance

to installation procedures.

10.5.7.10 Metallic hammers shall not be used to tamp any type of brick into

place.

10.5.7.11 Brick shall not be hammer cut or chipped to any size.

10.5.7.12 Excessive mortar on the face of any brick shall be removed by

methods approved by material Manufacturers and in accordance to

installation procedures.

10.5.7.13 Circle and arch closures shall be made in accordance to installation

procedures and key bricks or bricks adjacent to change of plane

shall not be cut smaller that 50% of any pre-pressed (cast) and fired

dimension.

10.5.7.14 Excessive force shall not be used to install bricks.

10.5.7.15 All power tools for sawing and boring of brick shall be calibrated for

trueness with documentation.

10.5.7.16 All expansion allowance to be located in accordance to pre-approved

construction detail drawings and shall be properly protected for size

and cleanliness during construction and filled in accordance to

installation procedures and project specifications.

10.5.7.17 Proper mortar type and consistency shall be used for all bricks

installed.

10.5.7.18 Methods for bricking around internally projecting welds, nozzle parts

or other shell irregularities shall be clearly documented and approved

by OWNER or designate prior to installation. Joints shall be

maintained within specification thickness and brick faces shall be

parallel in all such conditions.

10.5.7.19 Brick ties or supports shall be installed through holes bored in each

supported brick without stress cracking

10.5.8 Installation samples for wet and dry mortar shall be taken once per shift per pallet

only or as otherwise requested by Inspector or OWNER.

10.5.9 Brick shall only be sampled and tested at OWNER or Inspector discretion:

10.5.9.1 as required for physical property testing

10.5.9.2 after visual inspection and or rough handling make them suspect

10.6 RCF/AES Inspection and Testing

10.6.1 RCF and AES materials may be tested to confirm that the material batches

manufactured for the job meet the compliance datasheet. For materialqualification purposes, specific provision for sampling shall be agreed upon

between supplier and purchaser. Purchaser may substitute manufacturers

production and release quality control data in lieu of independent laboratory

testing. Unsatisfactory test results are cause for rejection.

10.6.2 Compliance datasheets shall be developed for any RCF or AES material

commonly used or marketed to the refining and petrochemical industry. The


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manufacturer shall prepare standard compliance datasheets in advance and

retain on file for immediate transmission to the purchaser. Each compliance

datasheet shall include a statement of identification as a compliance datasheet.

The compliance datasheet shall include a list of the test method and edition

(date) used for each value listed.

10.6.3 Standard compliance datasheets shall include values of bulk density, linear

shrinkage, chemical analysis, and thermal conductivity. For fibrous blanket, the

values on the compliance data sheet shall be based on the test methods listed in

the table below.

Table 3: Test Methods to Determine RCF/AES Properties

Properties Test

Method

Conditions Range

Bulk Density ASTMC892

AsReceived Condition (unfired) Provide an upperand lower limit

Linear

Shrinkage

ASTM

C892

Values to include testing at these

temperatures:

Manufacturers Recommended

Operating Temperature Limit or

Continuous Use Temperature Limit; and

Maximum Use Temperature as defined

by ASTM C892 for classification of types

Provide an upper

limit for each

temperature

Chemical

Analysis

ASTM

E1172

Provide an upper

and lower limit

Thermal

Conductivity

ASTM

C177 or

C201

Provide an upper

limit

Tensile

Strength

ASTM

C892

AsReceived Condition (unfired) Provide a lower

limit

10.7 Installation Workmanship

10.7.1 Installation drawings and procedures shall be reviewed prior to starting work.

Lining installation should follow the drawing.10.7.2 Lining anchors, hardware, and materials shall be dimensionally checked for

compliance to the work specification.

10.7.3 Anchor layout is plumb, level, and complies with specification tolerances.

10.7.4 In a layered blanket system, joints are tight and overlapped where specified.

10.7.5 Prior to coatings application, the shell surface preparation is in compliance with

the coating manufacturers installation specification.


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10.7.6 Prior to coatings application, anchors and anchor threads are protected from

overspray.

10.7.7 Blankets shall not be stretched.

10.7.8 Blankets butt joints shall have specified compression.

10.7.9 Hot face blanket layers shall be installed in lengths no less than 4 feet, and no

greater than 12 feet.10.7.10In board/blanket systems, the hot face board shall fit loosely against the blanket

and not place the board in a bind.

10.7.11Anchor retaining washers are installed, locked, and protected per specification.

10.7.12Hot face layers of board shall be constructed with tight butt joints.

10.7.13Special geometries require additional attention to anchor layout. This includes

corners, burner blocks, view ports, penetrations through the lining, and

terminations with other refractory systems.

10.7.14The anchor or stud pattern layout should account for the hot face layer anchor

requirements.

10.7.15Modules are tightly installed per specification before the banding is removed.

10.7.16Modules are tamped per manufacturers specification.

10.7.17Module batten strips are cut, folded, and compressed properly.

10.7.18Module orientation is correct (parquet versus soldier course).

10.7.19Cements and rigidizers used with RCF and AES are approved per the work

specification.

10.7.20There shall be no gaps in joints between modules in any directions.

10.7.21Small and irregular openings are filled.

10.8 Monolithic Refractory Inspection and Testing shall conform to API 936.

11.0 Responsibilities

11.1 Owner/Fabricator

11.1.1 The Owner/Fabricator shall prepare a detailed specification. The specificationshall include the following design details.

11.1.1.1 Lining products, thickness, method of application, and extent of

coverage.

11.1.1.2 Anchor materials, geometry, layout and weld details

11.1.1.3 Curing and dryout procedures, including constraints on dryout

heating (e.g. design temperature limits and/or maximum differential

temperatures that shall be maintained to avoid damaging the unit

and/or components).

11.1.2 The Owner/Fabricator shall provide quality requirements covering the following.

11.1.2.1 Physical property requirements to be used for qualification andinstallation quality control by specific product, installation method

and location where the product will be utilized.

11.1.2.2 Sampling frequency

11.1.2.3 Required lining thickness tolerances.

11.1.2.4 Criteria for hammer testing and the extent of cracking and surface

voids permitted.


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11.1.3 The Owner/Fabricator shall approve the engineering drawings, execution plan

and dryout procedure prior to any installation activity.

11.1.4 The Owner/Fabricator shall resolve the following:

11.1.4.1 exceptions, substitutions, and deviations to the requirements of the

execution plan, this standard, and other referenced documents;

11.1.4.2 conflicts between the execution plan, this standard, and other

referenced documents;

11.1.4.3 actual or potential work deficiencies discovered and submitted by

the inspector.

11.2 Contractor

11.2.1 The contractor shall prepare a detailed execution plan in accordance with this

standard and the requirements of the Owner/Fabricator's specification and

quality standards. The execution plan shall be prepared, submitted for the

Owner/Fabricators approval, and agreed to in full before work starts. Execution

details shall include:

11.2.1.1 designation of responsible parties;

11.2.1.2 designation of inspection hold points and the required advance

notification to be given to the inspector;

11.2.1.3 surface preparation and welding procedures;

11.2.1.4 procedures for material qualification, material storage, applicator

qualification, installation and quality control;

11.2.1.5 curing (including the curing compound, if any, to be used) and dryout

procedures for the completed lining system.

11.2.2 Submission to the Owner/Fabricator of all exceptions, substitutions, and

deviations to the requirements of the execution plan, this standard and otherreferenced documents. Owner/Fabricator's approval shall be secured before

implementation of the changes.

11.2.3 Scheduling of material qualification tests and delivery of those materials and

test results to the site.

11.2.4 Scheduling and execution of work to qualify all equipment and personnel

required to complete installation work, including documentation and

verification by the inspector.

11.2.5 Preparation and identification of all testing samples (preshipment, applicator

qualification, and production/installation) and timely delivery to the testing

laboratory.11.2.6 Advance notification to the Owner/Fabricator of the time and location where

work will take place so that this information can be passed on to the inspector.

11.2.7 Execution of installation work, including preparation of asinstalled samples as

required.

11.2.8 Provide inspector verified documentation of installation records, including:

11.2.8.1 product(s) being applied;


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11.2.8.2 pallet code numbers and location where applied;

11.2.8.3 installation crew members;

11.2.8.4 mixing and/or gunning equipment utilized;

11.2.8.5 location and identity of samples taken for installation quality control;

11.2.8.6 shell temperatures;

11.2.8.7 weather conditions and any other unusual conditions or

occurrences;

11.2.8.8 dryout records.

11.2.9 Accountability for installed refractories meeting specified standards.

11.3 Inspector shall be responsible for the following:

11.3.1 Ensure that material and applicator qualification test results are fully

documented.

11.3.2 Monitor qualification, production work and dryout (when applicable) conducted

by the manufacturer(s) and contractor to ensure compliance with job

specifications and agreedto quality practices.

11.3.3 Notify the Owner/Fabricator and the contractor of any work deficiencies or

potential deficiencies. Notification shall be made according to the job specific

requirements outlined in the procedures. Notification shall take place as soon as

possible, and shall occur within one working day after discovery of the

deficiency.

11.3.4 The inspector shall make no engineering decisions unless approved by the

Owner/Fabricator. Conflicts between the specified execution plan and the

actual installation procedures or installed refractory quality results shall be

submitted to the Owner/Fabricator for resolution.

11.3.5 Inspect and hammer test installed linings before dryout and after dryout (whenpossible), and report any anomalies to the Owner/Fabricator.

11.3.6 Check and verify that accurate installation and dryout records are being

documented by the contractor.

11.3.7 Record all nonconformances and/or potential problems to which the inspector

has alerted the contractor and Owner/Fabricator.

11.4 Manufacturer shall:

11.4.1 provide a compliance datasheet in accordance with for each product;

11.4.2 provide material/s that meets the approved compliance datasheet;

11.4.3 provide recommended dryout/startup procedures

12.0 Preparation for Shipment12.1 For shop and fieldapplied ceramic fiber linings, packaging shall prevent damage to fiber

due to physical abuse, rain, and wind effects during transportation and storage.

12.2 The contractor shall be responsible for all repair of damaged refractories that are within

his control of stiffening and protecting installed linings during handling and transport of

prelined components


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12.3 The contractor is shall be responsible for all repairs to refractory affected by alkaline

hydrolysis prior to initial dryout of the refractory lining being supplied.

13.0 Dryout and Heatup/Cooldown Rate

13.1 Linings systems with a monolithic hot face and/or layer shall be dried out per API STD

936 on initial heating.

13.2 Brick and monolithic linings already dried out may be heated or cooled at 100C/hr

maximum.

13.3 Fiber linings in blanket or modular forms shall be heated at 200C/hr maximum.

13.4 Neither brick nor fiber linings require dryout on initial heating.


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Manufacturers Product Compliance Data Sheet Mortar Materials

DATE SUBMITTED

EQUIP. No. __________________________________ EQUIP. NAME ________________________________

REFRACTORY MATERIAL _______________________________________________

REFRACTORY MANUFACTURER ______________________________________________

REFRACTORY SUPPLIER ___________________________________________________

WATER ADDITIONS

Total (L/100 kg) (gal/100 lb) ____________________min.max.

WORKABILITY** (%) Min. Usable Workability (%)

COLD BONDING STRENGTH (MPa) (psi)* 105 C (220 F)

Manufacturers Data _________ min.

Manufacturers Guarantee _________ min.

SCREEN SIZE (% RETAINED)*

Manufacturers Data max. min.

Manufacturers Guarantee max. _______min

CHEMICAL ANALYSIS (min/max)

Alumina Oxide Silica Oxide Iron Oxide Calcium Oxide Phosphorous Pentoxide


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Manufacturers Product Compliance Data Sheet Brick Materials

DATE SUBMITTED

EQUIP. NO. __________________________________ EQUIP. NAME ________________________________

REFRACTORY MATERIAL ______________________________________________________

REFRACTORY MANUFACTURER

REFRACTORY SUPPLIER ______________________________________________________

DENSITY (kg/m3) (lb/cu ft)

Manufacturers Data min. max.

Manufacturers Guarantee min. max.

COLD CRUSHING STRENGTH (MPa) (psi)

Manufacturers Data min.

Manufacturers Guarantee min.

POROSITY (%)

Manufacturers Data _______________________ min.

Manufacturers Guarantee min.

CONDUCTIVITY FACTOR "K" AT 538 C (1000 F) MEAN

Manufacturers Guarantee max.

CHEMICAL ANALYSIS (min/max)

Alumina Oxide Silica Oxide Iron Oxide Others

Date post:	05-Apr-2018
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API RefractoryRequirements May2011

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