API RefractoryRequirements May2011

Refractory Lining and Burner Brick Requirements API 560

Scope This section covers refractory lining requirements for fired heaters, air prehea ters, ducting, stacks, and flue gas systems, for general refinery service, including materials selection, design, installation, installation quality control, control, curing and dryout. It also covers preparation for shipment and erection of modular sections lined at a location location separate from final erection. It does not apply to the design of steam reformers or pyrolysis furnaces.

Table of Content

1.0

References Definitions 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 Heat‐up/Cool‐down Rates

References 1.1 1.2

2.0

1.0 2.0 3.0

API 936: Refractory Installation Quality Quality Control—Inspection and Testing Testing of Monolithic Refractory Linings and Materials ASTM C892: Standard Specification Specification for High-Temperature High-Temperature Fiber Blanket Blanket Thermal Insulation

Definitions: The following definitions are added in this section as a supplement to those provided in Section 3, Terms and Definitions in this 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 of at least 18% alkali earth oxides developed to meet the fiber exemption requirements spelled out in 97/69/EC of the Dangerous substances initiative initiative in the EU. These fibers are exonerated

from the EU carcinogen classification on the basis of their low bio ‐persistence. Also may be known as Bio‐fiber, Bio‐soluble or Low Bio ‐persistence fiber. 2.2

destructive reaction between green hydraulic setting Alkaline hydrolysis: A potentially destructive refractory concrete, carbon dioxide, alkaline compounds and water.

2.3

held in place by a Anchor brick supported system : Lining supported by ceramic anchors held metallic support system. Anchor bricks have convoluted convoluted surfaces designed to be filled in with surrounding monolithic refractory to hold the lining in place.

Revision Date: May 3, 2011

1

Refractory Lining and Burner Brick Requirements API 560 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

shell casing that hold the lining Anchors: Metallic or refractory devices attached to the shell in place.

2.6

block used as a backup backup layer because of Block insulation: Light weight, preformed rigid block its high insulating properties.

2.7

Burner block/brick/tile/quarl: High temperature refractory burner components that direct the burner flame.

2.8

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

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

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

mechanically decouple refractory Construction joint: A joint formed in a lining to mechanically components without expansion allowance.

2.15

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

2.16

Deflection/Target wall: A refractory wall used to redirect or shield portions of a furnace from gas or radiant heat.

2.17

Expansion joint : A non‐bonded 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 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.


2


Low bio‐persistence: Materials having 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 1000°C ‐ 1700°C 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

more parties Owner/Fabricator: The proprietor of equipment who has engaged one or more to install or repair refractory.

2.28

Qualification Test: Pre‐installation 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

Fibers (MMVF) whose chemical chemical RCF (Refractory Ceramic Fibers) : Man Made Vitreous Fibers constituents are predominantly Alumina and Silica.

2.31

individual whom the Owner/Fabricator Owner/Fabricator has Refractory Inspector: The party or individual contracted or otherwise designated to monitor refractory testing and installation work performed by the contractor and refractory material manufacturer(s).

2.32

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

2.33

fiber and wet binder suitable suitable for pumping Pumpable/Sprayable Pumpable/Sprayable Fibers: Mixture of bulk fiber or spraying.

2.34

plate or angle Shelf supported systems : In brick lining systems, a structural plate mechanically attached to the casing that has the function of supporting a lining section or component.

2.35

devices used to hold a vertically standing brick lining lining Tie‐backs: Mechanical fastening devices 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

saturated with wet binder that sets on on Wet Blanket: Flexible, formable RCF blanket saturated heat exposure forming a rigid more durable structure comparable in hardness and chemistry to board.

3.0

Definition of operating parameters by heater components 3.1

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


3


resistance and Convection Section: The refractory lining system must provide thermal resistance 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 convection section tubes. Metal shell casing corrosion related to the sulfur content in the fuel will continue continue to be an issue in this location. If some type of soot‐blowing 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 re sist any indirect impingement related to particle blasting.

3.3

section and stack): Refractory linings must must Breeching and Ducting (between convection section 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 t ube ruptures in the radiant or convection section.

3.4

resistance, mechanical Stacks: Refractory linings in the stack must provide thermal resistance, integrity, and protect against metal shell corrosion.

3.5

housing while not being adversely Burner Block: Burner block must insulate the burner housing affected by high temperature or thermal cycling related to startup and shutdown. shutdown. Block must resist flame impingement and corrosive impurities.

3.6

physical separation of Gravity Walls: Free standing walls inside fired heaters to provide physical process areas within the furnace, typically between radiant sections operating at different temperatures or between radiant and convection sections. 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

make refractory selections. It is the Design Temperature is a temperature used to make calculated hot ‐face or interface temperature plus the r equired design margin of 165°C minimum (300°F). Some minimum refractory design temperatures based on typical hot hot face temperatures in furnace locations are the following: 4.1.1

Burner area: 1650°C (3000°F)

4.1.2

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

4.1.3

Floor: 1370°C (2500°F)

4.1.4

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

4.1.5

Convection section: 980°C (1800°F)

4.1.6

Breeching and Ducting: 510°C (950°F)

4.1.7

Air preheating system: 510°C (950°F)

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

continuous temperature to which a refractory refractory Maximum Use Temperature : Maximum continuous may be exposed without excessive shrinkage or mechanical mechanical breakdown. It is also sometimes referred to as the “recommended “re commended use limit.” or continuous‐use temperature.


4


Hot‐Face 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 multi ‐component 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 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 mater ial 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 differe nt thermal conductivities and/or lining thicknesses.

4.7

including: Form: Refractories are available in a variety of forms, including: 4.7.1

4.7.2

4.7.3

4.8

Shaped‐‐Sold 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

Monolithic (Unshaped) ‐‐Final shape formed upon application 4.7.2.1

Castables

4.7.2.2

Plastics

4.7.2.3

Mortars

Fiber 4.7.3.1

Bulk

4.7.3.2

Blanket

4.7.3.3

Modular

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

systems are supported by the the casing via a Mechanical Strength: Most fired heater lining systems 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 supporting and/or must be resistant to wear such as soot blasting abrasion.

4.10

ash/impurities (e.g sulfur, alkali and Fuels Fired: The type of fuel fired and corrosive ash/impurities heavy metals) will guide selection of the type or form of refractory and the method of construction for refractory linings.


5


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 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

r i a p e R f o e s a E / e c n a n e t n i a M

e f i L n g i s e D

n o i t a v r e s n o C y g r e n E

e r u t c u r t S f o t h g i e W d e c u d e R

n o i t a l l a t s n I f o d e e p S

e c n a t s i s e R h s A

n o i s o r r o C e t a s n e d n o C

e c n a t s i s e R e r u t a r e p m e T

e c n a t s i s e R y t i c o l e V / n o i s o r E

AES/RCF fiber (Includes modules and blanket) AES/RCF Fiber w/ Vapor Barrier AES/RCF Fiber w/ Castable Backup Dual Layer Monolithic Single Layer Monolithic Brick with Fiber or Block Backup Brick with Castable Backup

L L L M M H H

L M H H H L H

L L L M H H H

L L L H H H H

H H H M M L L

L L L M H H H

H H M M L M M

H H H M M L L

H M M L M L L

IFB (Insulating Firebrick)

M

L

M

M

L

M

H

M

M

Operating Conditions/Needs→

Refractory Lining Systems↓

Performance Rating for Listed Conditions: L‐Low; M‐Medium; H‐High 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 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 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 casing on vertical centers typically 1.8 m (6 ft) high but not to excee d 2.3 m (12ft) based on calculated loads and and thermal expansions. Support shelves shall be slotted to provide for differential thermal expansion. Shelf material is defined by the calculated service service temperature at the tip of the shelf; carbon steel is satisfactory up to 370°C (700°F).

6.3

Expansion joints shall be provided in both ve rtical and horizontal directions of the walls, at wall edges and around burner tiles, doors and sleeved penetrations.


6


Radiant chamber walls of gravity construction (Figure 1) shall not exceed 7.3m (24 ft) in height and shall be at least high ‐duty firebrick. The base width shall be a minimum of 8% of total wall height. The height‐to‐width 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 Gravity Wall dimensional dimensional requirements

6.5

Gravity walls shall be of bonded, bonded, mortared construction. The mortar shall be air setting and compatible with firebrick.

6.6

Vertical expansion joints shall be provided at gravity‐wall ends and required intermediate locations. All expansion joints joints shall be kept open open and free to move. If the joint is formed with lapped brick, brick, no mortar shall be used, that is, it shall be a dry joint.

6.7

Target walls with flame impingement on both sides (free ‐standing) shall be constructed of super‐duty fireclay brick with at least a 1540°C (2800°F) rating. Bricks shall be laid with mortared joints. Expansion joints shall shall be packed with ceramic fiber strips having a maximum use temperature not less than 1430°C (2600°F).

6.8

Floor brick shall not be mortared. A 13 mm (0.5 in) gap for expansion shall typically 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 high ‐duty 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 function of supports, supports, tie‐backs and expansion joints must be taken into consideration consideration when repairing brick linings. Repairs are


7

Refractory Lining and Burner Brick Requirements API 560 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, supplier’s shall provide “ Manufacturer’s 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

6.13

7.0

6.12.6 Manufactured Defects (edge, corner, crater, cracks) 6.12.7 Dimensional tolerance and warping (*) For brick materials, supplier’s shall provide “ Manufacturer’s 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

AES/RCF Fiber Construction 7.1

Layered or modular construction may be used in all radiant and convection section sidewalls and roofs subject 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 r adiant section when fuels sodium and vanadium exceed 100 parts per million total above 700°C (1300°F).

7.3

In layered construction, blanket shall be a minimum of 25 mm (1 in) thick, 128 kg/m 3 (8 lb/ft3) density, needled material. Fiberboard, if applied as a hot face layer, shall not 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 1100°C (2000°F) on sidewalls.

7.4.2

450 mm x 450 mm (18 in x 18 in) maximum if temperatures ex ceed 1100°C (2000°F) or if used on the roof at any temperature.

7.4.3 7.5

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

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 ex cess 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).


8


Fiber blanket shall be installed with its longest dimension in the direction of gas flow. The hot‐face layer of blanket shall be constructed with all joints overlapped. Overlaps shall be in the direction of gas flow. 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. joints. All joints in successive layers layers of blanket shall be staggered.

7.9

Fiber blanket modules shall be installed in soldier ‐course with batten strips (Figure 2). Parquet pattern or soldier‐course 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


9

Refractory Lining and Burner Brick Requirements API 560 Figure 3: Anchor span required for arch section modules 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 175°C (350°F) 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 soldier‐course and located so that the exposed temperature is at least 55°C (100°F) above the calculated acid dew point 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 installed before applying protective coatings to the casing. The coating shall cover the attachment studs so that uncoated parts are above the acid dew‐point temperature.

7.20

Maintenance/Repair: Typical patch repairs are shown in Figures 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 dryout before commissioning.


10

Refractory Lining and Burner Brick Requirements API 560 Figure 4: Typical blanket lining repair of hot face layer

Figure 5: Typical blanket lining repair of multiple layers


11

Refractory Lining and Burner Brick Requirements API 560 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 component with total thickness thickness between 150 and 200 mm (6‐8 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 component with total thickness between 150 and 200 mm (6‐8 inches).

8.1.4

Burner block; Brick or pre‐fired castable with temperature resistance

8.1.5

Bull nose: Single or dual component component with total thickness between 150 and 200 mm (6‐8 inches).

8.1.6

Corbelling: Constructed integral with the hot hot face layer and containing 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 naturally naturally ‐occurring phenomenon. Alkaline hydrolysis becomes a significant 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 r educed.


12

Refractory Lining and Burner Brick Requirements API 560 8.2.4

To minimize the possibility of alkaline hydrolysis, castables and gunning mix linings should be moisture ‐cured 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 be followed. Within two weeks after curing and air drying, the installed materials should be dried to 260°C [500°F (Hot face temperature)]. The drying schedule should include a 55°C/hour (100°F/hour) ramp‐up to 260°C (500°F) hot face temperature with an eight hour hold period upon reaching 260° C (500°F). The dryout schedule should terminate with a 55°C/hour ramp‐down to ambient temperature.

8.2.5

When refractory‐lined 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 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 te mperature an anchor tip will be exposed to as listed in Table 3. Table 3: Anchor Metallurgy Required Required at the Listed Maximum Anchor Temperature

Anchor Material Carbon steel

Maximum anchor temperature °C (°F) 455 850

TP 410S stainless steel

650

1,200

P 304 stainless steel

760

1,400

TP 316 stainless steel

760

1,400


815

1,500


927

1,700


1,038

1,900

Alloy 601 (UNS N06601)

1,093

2,000

Ceramic studs and washers

>1,093

>2,000


13


Anchor Spacing and Selection 9.2.1

When brick linings are selected for use in radiant furnace furnace walls, they must be held against the wall and supported using shelf supports and/or tie ‐backs. These anchoring types shall be detailed in the furnace design information. 9.2.1.1

Horizontal shelf supports, as a rule, are required on f urnace 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 pre ‐lined.

9.2.2.4

For dual layer linings, “Y” anchors shall be installed to hold the hot face in place. Careful attention shall 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. failure. Spacing for the “Y” anchor on the hot face shall be the same as that t hat 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 lining thickness 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 10 ‐12” vertical on walls with 9‐10” 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


14


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

Figure 8 Typical blanket lining anchoring systems


15

Refractory Lining and Burner Brick Requirements API 560 Figure 9 Examples of modular fiber systems


16


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 e ach sample to ensure a sound full weld. The bend test shall consist bending 15 degrees from vertical and back without cracking.

9.4.3 9.5

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

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. configuration. A minimum of 20% of t he production anchors shall be randomly inspected and tested. For stud welded anchors, 100% of the anchors shall be lightly lightly hit with a light hammer to produce a ringing sound without damaging the anchor or threads.

9.5.2 10.0

The heater casing is clean, dry and rust ‐free to ensure sound welds.

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 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 Hot Load Strength

X

X

X

X

Note: 1.

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


17


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 be ing saturated with water and from exposure to foreign chemicals that might penetrate the structure and affect properties properties in service. They must also be 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 manufacturer’s 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 UW–32.

10.4.3.2

Spot‐ground 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

<25

25%

100%

25‐50

10%

50%

50‐500

5%

25%

500‐3000

1%

5%

1.0 2.0


Count per manufactured batch Count per type/installation

18


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 Re‐test or Rejected (on re‐test) if Defective number of brick from sample

<50

8

2

51‐90

13

3

91‐150

20

4

151‐280

32

6

281‐500

50

8

501‐1200

80

11

1201‐3200

125

15

3201‐10000

200

22

≥

Note Lot is a group of bricks manufactured from same identified production batch pressed, fired and finished (as required) under same manufacturing process at same time.

10.5.4 Brick to be tested as purchased to confirm that the brick meet dimensional and defect tolerances. 10.5.4.1

ASTM C134 using a digital caliper to an accuracy of ±1 mm (0.04 inch) and reported to the nearest ± 0.5 mm (0.02 inch) Dimensional control shall be based on individual bricks (unless otherwise indicated as in the case of assemblies).

10.5.4.2

Alternatively, measurements of lay‐ups may be used to control a linear dimension (e.g., the height of bricks by a lay ‐up of 10 bricks) as well as the radius of curvature of an assembly of tapered bricks.


19

Refractory Lining and Burner Brick Requirements API 560 10.5.4.3

Tolerance requirements for brick shall be: Length <6” (155mm)

± 1%

Length ≥6” (155mm)

± 2%

Thickness

± 1.6 mm (1/16”)

Taper (Δ between largest and

± 1 mm (0.04”) for tapered length

smallest measure)

< 155 mm (6”) ± 1.6 mm (1/16”) for tapered length ≥155 mm (6”)

Warpage (largest Δ from a

± 1.6 mm (1/16”) for diagonal

straight edge across the diagonal of a brick face) 10.5.4.4

Laminations: The bricks shall be free of internal laminations. The hammer test can be used to indicate the possible occurrence of such laminations. On a cut surface of a representative brick, laminations if present must be clearly visible.

10.5.4.5

Fins at corners and edges shall be no more that 1.00 mm (0.04 inch) high maximum.

10.5.4.6

Cracks visible on the surface of the brick shall be not larger than 19 mm (0.8 inches) in length, deeper than 2 mm (0.1 inch) and wider than 0.25 mm (0.01 inch).

10.5.4.7

Edge and Corner Damage: A brick shall have no more than three corner and/or edge defects for which the total dimensions equal 28mm (1‐1/8”). Any bricks with more than five defects, corner or edge flaws, shall be rejected.

10.5.5 Inspection and Test Documentation 10.5.5.1 Manufacturer Product Compliance Data sheets, to be provided by the material Vendor with minimum / maximum specified product property values for each type of Refractory brick, or mortar. 10.5.5.2 Product Qualification Material Test Result Sheets (MTR) to be provided by the manufacturer all products prior to any shipment. Document shall be fully traceable to individual product packaging and or labeling. 10.5.5.3 The installation contractor shall keep a refractory installation record for each shift, the record shall properly identify name and individual lot of products applied, applicator(s) or foreman names with the location within the unit(s) for each material lot installed. 10.5.5.4 The installation contractor shall prepare refractory test sample record and properly tag and store al l samples or specimens for as installed testing as required. Record shall include location within the unit(s) where the material has been installed.


20


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 of resume 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” (3 mm) 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 Manufacturer’s recommendation and in accordance to installation procedures.


21


Mortar supplied wet shall only be “tempered” with additional water in accordance to Manufacturer’s 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 Manufacturer’s 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 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 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 a nd 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 teste d to confirm that the material batches 10.6.1 RCF and AES materials may be tested manufactured for the job meet the compliance compliance datasheet. For material qualification purposes, specific provision for sampling shall be agreed upon between supplier and purchaser. purchaser. Purchaser may substitute substitute manufacturer’s 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 petrochemical industry. The


22

Refractory Lining and Burner Brick Requirements API 560 manufacturer shall prepare standard compliance datasheets in advance and retain on file for immediate transmission to the purchaser. Each compliance 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 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

Conditions

Range

Method Bulk Density

ASTM

As‐Received Condition (unfired)

C892

Provide an upper and lower limit

Linear

ASTM

Values to include testing at these

Provide an upper

Shrinkage

C892

temperatures:

limit for each

•

•

Manufacturer’s Manufacturer’s Recommended Recommended Operating Temperature Limit or Continuous Use Temperature Limit; and

temperature

Maximum Use Temperature as defined by ASTM C892 for classification of types

Chemical

ASTM

Provide an upper

Analysis

E1172

and lower limit

Thermal

ASTM

Provide an upper

Conductivity

C177 or

limit

C201 Tensile

ASTM

Strength

C892

10.7

As‐Received Condition (unfired)

Provide a lower limit

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 over lapped where specified. 10.7.5 Prior to coatings application, the shell surface preparation is in compliance with the coating manufacturer’s installation specification.


23


10.8 11.0

10.7.6 Prior to coating’s 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. 10.7.10 In board/blanket systems, the hot face board shall fit loosely against the blanket and not place the board in a bind. 10.7.11 Anchor retaining washers are installed, locked, and protected per specification. 10.7.12 Hot face layers of board shall be constructed with tight butt joints. 10.7.13 Special geometries require additional attention to anchor layout. layout. This includes corners, burner blocks, view ports, penetrations through the lining, and terminations with other refractory systems. 10.7.14 The anchor or stud pattern layout should account for the hot face layer anchor requirements. 10.7.15 Modules are tightly installed per specification before the banding is removed. 10.7.16 Modules are tamped per manufacturer’s specification. 10.7.17 Module batten strips are cut, folded, and compressed properly. 10.7.18 Module orientation is correct (parquet versus soldier course). 10.7.19 Cements and rigidizers used with RCF and AES are approved per the work specification. 10.7.20 There shall be no gaps in joints between modules in any directions. 10.7.21 Small and irregular openings are filled. Monolithic Refractory Inspection and Testing shall conform to API 936.

Responsibilities 11.1

Owner/Fabricator 11.1.1 The Owner/Fabricator shall prepare a detailed specification. The specification shall include the following design details. 11.1.1.1

Lining products, thickness, method of application, and ex tent 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 and installation 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.


24

Refractory Lining and Burner Brick Requirements API 560 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/Fabricator’s 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 other referenced 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) 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 as‐installed samples as required. 11.2.8 Provide inspector verified documentation of installation records, including: 11.2.8.1


product(s) being applied;

25


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 agreed ‐to 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 (when possible), 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 non‐conformances 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 Shipment 12.1

For shop and field‐applied 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 pre‐lined components


26


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 Heat‐up/Cool‐down 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 100°C/hr maximum.

13.3

Fiber linings in blanket or modular forms shall be heated at 2 00°C/hr maximum.

13.4

Neither brick nor fiber linings require dryout on initial heating.


27


Manufacturer’s Product Compliance Data Sheet ‐ Mortar Materials DATE SUBMITTED

EQUIP. No. ________________ ________________________ ________________ __________ __

REFRACTORY REFRAC TORY MATERIAL

EQUIP. NAME ________________ ________________________ ________________ ________

_______________________________________________ _______________________ ________________________

REFRACTORY REFRAC TORY MANUFACTURER MANUFAC TURER REFRACTORY REFRAC TORY SUPPLIER SUPPLIE R

______________________________________________ ______________________ ________________________ _____________________________________________ _____________________ ______________________________ ______

WATER ADDITIONS Total (L/100 kg) (gal/100 lb) max.

__________________ ____________________min. __min.

WORKABILITY** (%)

Min. Usable Workability (%)

COLD BONDING STRENGTH (MPa) (psi) *

105 C (220 F)

Manufacturer’s Data

_________

min.

Manufacturer’s Guarantee

_________ _________

min.

SCREEN SIZE (% RETAINED) * Manufacturer’s Data

max.

min.


max. _______ min

CHEMICAL ANALYSIS (min/max) Alumina Oxide

Silica Oxide


Iron Oxide

Calcium Oxide

Phosphorous Pentoxide

28


Manufacturer’s Product Compliance Data Sheet ‐ Brick Materials DATE SUBMITTED

EQUIP. NO. _______________ _______________________ ________________ ___________ ___

REFRACTORY REFRAC TORY MATERIAL

EQUIP. NAME _______________ _______________________ ________________ _________ _

____________________________________________________ __________________________ ____________________________ __

REFRACTORY MANUFACTURER REFRACTORY REFRAC TORY SUPPLIER SUPPLIE R

_______________________________________________ ________________________ ______________________________ _______

DENSITY (kg/m3) (lb/cu ft) Manufacturer’s Data

min.

max.


min.

max.

COLD CRUSHING STRENGTH (MPa) (psi) Manufacturer’s Data

min.


min.

POROSITY (%) Manufacturer’s Data

_________________ _______________________ ______ min.


min.

CONDUCTIVITY FACTOR "K" AT 538 C (1000 F) MEAN Manufacturer’s Guarantee

max.

CHEMICAL ANALYSIS (min/max) Alumina Oxide


Silica Oxide

Iron Oxide

Others

29

API RefractoryRequirements May2011

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