jeres n 110 installation requirement castable refractories

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JERES-N-110 Installation Requirements

Castable Refractories

Revision 0

Responsibility JER Engineering Division

29 April 2008

Jubail Export Refinery Engineering Standard


JERES-N-110 Rev. 0

Installation Requirements – Castable Refractories 29 April 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

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Revision Tracking

Revision Revision Date Scope of Revision

0 29 April 2008 Issued for bid package.

04 18 April 2008 Consistency with JERES-N-100.

03 10 April 2008 Expanded sampling, qualification and testing; added FCC requirement

02 31 March 2008 Issued for bid package for review.

01 14 May 2007 The first official JERES-N-110 is issued.

00 5 February 2007 First draft issued is based on Saudi Aramco SAES-N-110 “Installation Requirements – Castable Refractories” issue date November 30, 2004. Document was modified to incorporate amendments and modifications.


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Table of Contents

Section Contents Page

1 Scope 4

2 Conflicts, Deviations and Clarifications 4

3 References 5

4 Definitions 7

5 Responsibilities 9

6 Documentation 9

7 Prequalification by Installer 10

8 Material Storage and Handling 13

9 Surface Preparation 13

10 Installation 13

11 Curing and Dry Out 19

12 Production Sampling and Testing 20

13 Inspection and Repair 23

Appendix

A Figure 1 – Refractory Installation Checklist 27


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1 Scope

1.1 This standard establishes the minimum mandatory requirements for installation, testing and inspection of hydraulic-setting refractory systems for pressure vessels, boilers, process heaters, stacks, breechings, heat exchangers, flare tips, sulfur recovery unit equipment and piping. For vessels and transfer lines application in Fluid Catalytic Cracking units, refer to JERES-N-150.

1.2 For equipment and refractory systems not covered by this standard, the Company Representative shall be contacted for guidance in determining the extent to which this standard is applicable.

1.3 This entire standard may be attached to and made part of purchase orders.

1.4 This standard covers the installation of new hydraulic-setting castable refractory and the repair of existing hydraulic-setting castable refractory.

2 Conflicts, Deviations and Clarifications

2.1 Any conflicts between this standard and other applicable Company Engineering Standards (JERES), Material Specifications (JERMS), Standard Drawings (JERSD), Engineering Procedures (JEREP), Company Forms or Industry standards, specifications, Codes and forms shall be brought to the attention of Company Representative by the Contractor for resolution.

Until the resolution is officially made by the Company Representative, the most stringent requirement shall govern.

2.2 Where a licensor specification is more stringent than those of this standard, the Licensor’s specific requirement shall apply.

2.3 Where applicable Codes or Standards are not called by this standard or its requirements are not clear, it shall be brought to the attention of Company Representative by Contractor for resolution.

2.4 Direct all requests for deviations or clarifications in writing to the Company or its Representative who shall follow internal Company procedure and provide final resolution.


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3 References

The selection of material and equipment, and the design, construction, maintenance, and repair of equipment and facilities covered by this standard shall comply with the latest edition of the references listed below as of the CUT-OFF DATE as specified in the Contract unless otherwise noted.

3.1 Company References

Company Engineering Standards

JERES-N-100 Refractory Systems JERES-N-150 Erosion Resistant Refractory Lining in FCC Piping and Vessels

JERES-W-010 Welding Requirements for Pressure Vessels

Company Standard Drawings

JERSD-N-0002 Hexsteel Details

JERSD-N-0003 Anchoring Details for Castable Refractory

JERSD-N-0007 Support Details at Nozzles and Manways for Castable Refractory

JERSD-N-0009 Refractory Repairs and Terminations

Commentary Note:

The Company Drawings listed above and referenced in this standard shall be used as guide for the generation of detailed refractory system drawings specific for each application.

Company Inspection Requirement

JERITP-N-328110 Refractories: Hydraulic-Setting, Castable, Pressure Vessels-Boilers-Process Heaters-HEX’s, Piping and Flare Tips

3.2 Industry Codes and Standards

American Society of Mechanical Engineers

ASME SEC IX Welding and Brazing Qualifications


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American Society for Testing and Materials

ASTM A820 Standard Specification for Steel Fibres for Fiber Reinforced Concrete

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

ASTM C24 Standard Test Method for Pyrometric Cone Equivalent (PCE) of Fireclay and High Alumina Refractory Materials

ASTM C71 Definitions of Terms Relating to Refractories

ASTM C113 Standard Test Method for Reheat Change of Refractory Brick

ASTM C133 Test Methods for Cold Crushing Strength and Modulus of Rupture of Refractories

ASTM C134 Test Methods for Size and Bulk Density of Refractory Brick and Insulating Firebrick

ASTM C201 Standard Test Method for Thermal Conductivity of Refractories

ASTM C577 Permeability of Refractories

ASTM C583 Modulus of Rupture of Refractory Materials at Elevated Temperatures

ASTM C704 Abrasion Resistance of Refractory Materials

ASTM C860 Standard Practices for Determining and Measuring Consistency of Refractory Concretes

ASTM C862 Practice for Preparing Refractory Concrete Specimens by Casting

ASTM C865 Firing Refractory Concrete Specimens

ISO Standards

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


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

ISO 5014 Refractory products-Determination of modulus of rupture at ambient temperature

ISO 5016 Shaped insulating refractory products-Determination of bulk density and true porosity

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

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

Steel Structures Painting Council

SSPC SP 6 Commercial Blast Cleaning

SSPC SP 7 Brush Blasting

4 Definitions

4.1 Definitions presented in this Standard and other JER documents have precedence over other definitions. Conflicts between various definitions shall be brought to the attention of Company Representative by the Contractor for resolution.

Company: Jubail Export Refinery.

Company Representative: A designated person from the Company or an assigned third party representative.

Company Inspector: A designated person or an agency responsible for conducting inspection activities on behalf of the Company.

4.2 List of Definitions

Anchors: “V” or “Y” shaped hardware that supports and holds castable refractory in place.

Curing: The initial ambient temperature holding period following refractory placement. Curing is required to displace all free water prior to dryout.


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Dryout: The initial controlled heating of refractory linings raised to temperatures near their service temperature after curing. Dryout is to achieve the required physical properties of the lining at its service temperature.

Equipment Manufacturer: The company that is responsible for the fabrication of process heaters, pressure vessels, heat exchangers, piping and flare tips to which refractory is installed.

Hexsteel and “S” bars: Metal supports for extreme erosion-resistant castable refractory.

Metal Fiber Reinforcement: Stainless steel needles added to monolithic refractory castables to increase strength.

MSDS: Material Safety Data Sheets for refractory material, supplied by the Refractory Manufacturer

RCF: Stands for Refractory Ceramic Fiber

Refractory Inspector: The person or company authorized by the Jubail Export Refinery Inspection Department to inspect refractory installations to the requirements of this standard.

Refractory Installer: The company that is responsible for the installation of refractory systems.

Refractory Manufacturer: The company that manufactures refractory products from raw materials.

Refractory Systems: A lining system that is designed to high temperatures, hot gases, and the action of erosive materials. Components include anchors, reinforcement, vapor barriers, and refractory materials needed for complete installation.

Vapor Barrier: A high-temperature coating that is applied to the shell of equipment to protect the steel from condensing corrosive gases.

Vapor Stops: A metal ring that is welded to the shell of equipment to prevent gas bypassing.

Vibration Casting: Castable installation technique where by refractory is mixed with water and placed in a formed enclosure with the aid of vibrator which causes


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the refractory to become “fluid like” and thereby flow and consolidate to the desired shape of the formed enclosure.

5 Responsibilities

5.1 The Refractory Installer is responsible for installing refractory systems in accordance with the requirements of this standard and of the specific requirements of the Refractory Manufacturer and the Equipment Manufacturer.

5.2 The Refractory Installer is also responsible for preparing a complete installation procedure, for approval by Company, in accordance with the requirements of the Refractory Manufacturer, the Equipment Manufacturer, and this standard.

5.3 The Equipment Manufacturer is responsible for preparing fully detailed engineering drawings of the refractory system. As a minimum, the drawings shall include anchorage design including spacing and orientation, refractory thickness, all materials, surface preparation, and welding details. Company shall review and approve the drawings.

6 Documentation

The Installer shall submit the following information to the Company Representative for approval prior to start of installation:

Experience and reference list.

List of qualified operatives with applicable certified documentation.

Detailed installation procedures indicating the following:

Application procedure

Type of framework

Maximum age of products prior to their usage

List of all equipments to be employed indicating type, make and capacities

Mixing procedure

Sampling and testing to be performed, including an identification/traceability map showing the type of material, batch number, sample number and location in each lined section;

Operator qualification testing to be performed

Repair procedures


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Method of curing

Quality control data sheets indicating the following:

Cold crushing strength

Modulus of Rupture

Permanent Linear change (PLC) and reheat thermal expansion (RTE)

Erosion loss (not required for insulating castables)

Thermal conductivity values for the intended service temperature

Bulk density after drying to 110°C.

Reheat thermal expansion

Percentage of water to be used for mixing and installation

Volumetric yield (without losses)

Type of binder, aggregates and maximum grain size

Type of packaging for shipment

Requirements for storage and expected shelf-life

Maximum long-term service temperature (°C)

Chemical composition (confirm rapid fire Technology RFT fibers are used)

Method of dry-out, equipment to be used and dry-out curve

7 Prequalification by Installer

Procedure and crew prequalification testing shall be carried out by the Refractory Installer prior to any lining. This requirement shall be satisfied by gunning, casting or vibration casting a panel to the production thickness.

Documented evidence of the application crew’s prequalification shall be made available to the Refractory Inspector prior to production.

Unless otherwise specified, the Installer shall prequalify his personnel as follow:

7.1 Prequalification for Gunite application

For each material and each brand to be used, each “nozzleman” shall “gunnite” a test panel measuring at least 1000x1000mm and equal in thickness to the production thickness of lining. The test panel position shall be the same as the equipment


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position during production application. For example, for a vertical wall production application, the test panel shall be “gunnited” in the vertical position.

The panel shall be constructed of steel, wood or plastic and have removal sides and backing plate. The anchors shall be bolted to the panel to enable removal of the castable after the test. An area within the panel should be left free of anchors enabling a section of the panel to be cut away.

The test panel should be allowed to air-cure for 24hours or as per manufacturer specification.

The refractory shall be hammer tested, removed from the panel and cut into four sections to be examined for voids, dry material, laminations and the dispersal of fibers (when used).

A section measuring at least 250x250mm will then be cut out from the panel and sent to the laboratory for testing.

The following samples shall be cut from the above block for testing:

3 Cold Crushing Cubes: 50x50x50mm for heat insulating, erosion resistant and extreme duty refractory.

1 Permanent Linear Change bar 250x50x50mm for heat insulating and erosion resistant material.

2 Erosion plates: 114x114x25mm for erosion resistant and extreme duty material.

Satisfactory test results as per the values of Table 2, Appendix B, JERES-N-100 will serve to qualify the nozzleman, the mixing and the installation procedure. For acceptable values in FCC unit application, refer to JERES-N-150.

7.2 Prequalification for vibrocast/freeflow application

A mock-up sample simulating the actual production installation shall be made using mechanical vibrator on the prequalified refractory materials, vibrating equipment, mixing and application procedure prior to production installation.

As a minimum, the mock-up test piece shall be an elbow with an internal diameter of at least 900mm and shall have at least two simulated nozzles of 500mm diameter welded to the shell. One shall protrude the lining thickness, and the other flush with the lining thickness. Do not use vibrators for freeflow castables.


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The test should demonstrate that the vibrator is capable of moving the castable with the specified water content and that the form does not move or collapse and that they are readily removable and would provide a suitable finish.

During the mock-up, a sample box measuring at least 250x250x100mm will be placed on the test-piece and vibrated in a similar fashion.

After leaving the test piece the sample box shall be allowed to cure for 24hours or as per Manufacturer recommendation. The forms shall be removed and the vibrocast hammer tested. The sample is visually examined for surface defects, void or dry in-fill areas. If refractory is metallic fiber reinforced, the test panel shall be cut into four pieces. The cut edges will be examined for dispersion of metallic fibers, laminations, inclusions and voids. Satisfactory results shall qualify both the crew and the application technique.

The sample shall be sent to the laboratory and tested.

From this sample the following samples shall be cut for testing:

3 Cold Crushing Cubes: 50x50x50mm for erosion resistant and extreme duty refractory.

1 Permanent Linear Change bar 250x50x50mm for erosion resistant material.


7.3 Prequalification for hand-packing into hex mesh

Each applicator shall hand-pack a test panel of hex mesh, 300x300xproduction thickness, which shall be attached to a removal backing of steel, wood or plastic and placed in the vertical position.

At the same time, each applicator shall prepare two erosion plates for laboratory testing.

After 24 hours air curing, or corresponding to the Manufacturer’s requirements, the panel shall be removed from its backing and examined for voids and dry in-fill.

Satisfactory visual examination and test results will serve to qualify the applicator.

8 Material Storage and Handling

8.1 Prior to placement, all refractory shall be protected from water and moisture.


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8.2 Materials shall be stored off the ground and covered with tarps to protect against water or moisture damage.

8.3 The Refractory Manufacturer’s precautions, as specified on the MSDS sheets, must be strictly followed.

9 Surface Preparation, Hot Side

9.1 All metallic surfaces shall be clean, dry, and free from oil, grease, weld slag, and mill scale prior to installation of refractory.

9.2 Prior to the application of refractory, all metallic surfaces shall be grit-blasted in accordance with SSPC SP 6, “Commercial Blast Clean” and coated with the appropriate vapor barrier, i.e. high temperature coating.

9.3 Surfaces that were previously coated with a vapor barrier or that are heavily corroded shall be brush blasted in accordance with SSPC SP 7, “Brush Blasting” and re-coated with the appropriate vapor barrier prior to the application of refractory.

10 Installation

10.1 General

10.1.1 Application of hydraulic-setting refractory shall be by gunning, casting, or vibration casting.

10.1.2 Test panels must be made prior to the application of castable refractory. The testing procedures are to be performed in accordance with the requirements of paragraph 12.

10.1.3 Surfaces to be lined shall be inspected prior to refractory installation. Lining shall not be applied without prior approval of Company’s authorized Refractory Inspector.

10.1.4 Linings shall not be applied when the temperature of the backing surface exceeds 32°C.

10.1.5 Linings must be protected from heat-induced accelerated setting by maintaining the temperature of the backing surface, a maximum of 32°C for a minimum of 24 hours after installation.

10.1.6 In order to achieve the temperature limitations specified in paragraphs 10.1.4 and 10.1.5, the backing surface may be shaded from direct sunlight, the refractory lining


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may be applied indoors, or apply refractory lining at night with proper illumination. Cooling by use of water spraying is prohibited.

10.1.7 Linings shall not be applied in freezing weather unless all materials are kept above 10°C during the lining application and for a period 24 hours after the lining application.

10.1.8 Linings shall be applied in a manner that will ensure minimal shrinkage. All cracks are subject to repairs.

10.1.9 The water used to mix refractory shall comply with the following:

1) The pH shall be within a range of 5.8-8.6.

2) The quality of the water shall be within the following limits:

Total Impurity Level < 1000 ppm

Calcium < 300 ppm

Magnesium < 300 ppm

Chlorine < 200 ppm

Iron < 500 ppm

Sulfur < 200 ppm

10.1.10 Admixtures shall not be used.

10.1.11 The water ratios as specified by the Refractory Manufacturer shall be used.

10.1.12 The temperature of the water and refractory shall be controlled so that the mixed refractory is between 10°C and 32°C.

10.1.13 Additives to linings shall not be used unless approved by Company Representative.

10.1.14 Piping and equipment shall be adequately supported to prevent distortion during lining.

10.1.15 Threaded attachments on equipment shall be protected from the lining during application. Protection shall not interfere with the application of the lining.

10.1.16 Equipment nozzle extensions shall be coated with grease to prevent refractory from bonding to them.


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10.1.17 All openings in equipment shall be closed by means of tapered hardwood plugs or sheet metal sleeves that are long enough to extend beyond the final thickness of the lining. These plugs or sleeves shall be coated with grease, shall be snugly fitted into openings, and shall not be removed until the refractory has set.

10.1.18 Refractory that shows signs of having set (lumps or hardness throughout) prior to installation shall be rejected. All refractory shall be placed within the Refractory Manufacturer’s recommended time limits. Refractory that is not used within specified time limit shall be discarded.

10.1.19 If refractory is installed in piping or vessel sections prior to their being connected by welding a minimum gap of 100 mm at the ends of each section shall be left unlined until the sections have been welded.

10.1.20 The second layer in double-layer linings shall not be applied until the first layer has been cured for a minimum of 24 hours. Immediately prior to applying the second layer, the first layer must be thoroughly wetted with water of a quality as outlined in 10.1.9.

10.1.21 Linings of each type of refractory shall be installed to the full thickness in a single application and shall not be built up in layers. If it is necessary to apply lining in sections to achieve full thickness in single application, edge forms shall be beveled 10° to provide for keying of adjoining sections. Appropriate provisions shall be made for construction joints.

10.2 Welding

10.2.1 All refractory anchor welding shall be in accordance with the requirements of ASME SEC IX, QW-190 as appropriate for fillet welds or QW-192 for stud welding, together with the requirements of JERES-W-010.

10.2.2 All refractory anchors, stud supports, vapor stops, and edging bars for the support of castable refractory materials on pressure vessels and pressure piping are to be welded using the shielded metal arc welding (SMAW) or gas tungsten arc welding (GTAW) processes only and the weld shall be all around. For anchors, stud welding is an acceptable alternative.

10.2.3 The Equipment Manufacturer shall submit Welding Procedure Specifications and Performance Qualification Records to the Company Inspector for review and approval prior to welding.


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10.2.4 The Equipment Manufacturer shall prepare and have available the detailed anchor welding procedure(s) that is to be used. This procedure(s) shall include results of the welding procedure qualification tests.

10.2.5 For anchors welded by SMAW or GTAW, the procedure qualification test shall include tension tests to failure on three anchors that have been welded according to the procedure on materials that will be used for production welds. One welded anchor shall be bent through 90° and shall show no evidence of failure in the weld.

10.2.6 Refractory anchorage, including anchors, studs, supports and similar items shall not be welded within 12.5 mm of circumferential and longitudinal seams of pressure vessels and piping. Anchors of edging bars type shall not be welded less than 50 mm parallel to circumferential or longitudinal seams of pressure vessels and piping.

10.2.7 If equipment is to be post weld heat treated, all welding for anchors, studs, supports, and similar items shall be made prior to heat treatment.

10.3 Installation of Anchors and Supports

10.3.1 Anchors and T studs shall be installed in accordance with JERSD-N-0003.

10.3.2 Details of nozzle and manway openings in refractory lined pressure vessels and piping shall be in accordance with JERSD-N-0007.

10.3.3 Hexsteel shall be installed in accordance with JERSD-N-0002.

10.4 Mixing Refractory in Pneumatic Applications

10.4.1 Mixing of refractory materials shall be done in a paddle type mixer.

10.4.2 Only full contents of refractory bags or drums shall be placed in the mixer. Fractional parts of a bag or drum shall not be used.

10.4.3 Dry gunning application method shall be used. Wet gunning application requires approval of Company Representative.

10.4.4 When fiber reinforcement is used, the fibers shall be added to the mixer through a wire mesh screen approximately 12 mm openings to obtain proper fiber distribution.

10.4.5 The refractory shall be used within 15 minutes of mixing.

10.5 Pneumatically Applied Refractory


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10.5.1 Only qualified personnel who are thoroughly experienced with pneumatic application of refractory lining shall be employed for this work.

10.5.2 Minimum air pressure, consistent with adequate compaction of the refractory, shall be used. The air pressure is to be determined by test prior to application.

10.5.3 Gun nozzles are to be sized to enable the “nozzleman” to maintain effective control of the application and to allow maneuverability in confined spaces.

10.5.4 The “nozzleman” shall shoot at right angles to the surface that is being lined.

10.5.5 The water supply and air pressure must remain constant during application.

10.5.6 All rebound material ahead of the “nozzleman” shall be removed to prevent inclusion in the lining.

10.5.7 Under no circumstances shall rebound material be reused.

10.5.8 For a specific band all rebound and loose material shall be removed from the surface before application of the next band is started. No rebound material shall be allowed to accumulate at any point where the lining has already been applied.

10.5.9 In vertical vessels and piping, the lining shall be applied circumferentially in narrow bands. Application is to start at the bottom and is to proceed upwards. The full final thickness shall be permitted to develop in each band before the next band is applied. In no case shall a thickness be applied that is less than the thickness that is specified to allow the applied lining to develop into initial set. The required thickness shall not be built up in layers.

10.5.10 In large vessels and piping, where the height of the bands needed to provide effective bonding would be too small to be practical, multiple crews or sectionalizing may be used.

10.5.11 The top of each band shall be cut back to the shell with a steel trowel. The cut shall be made at right angles to the shell, at a location where the full thickness of the refractory has been applied. All refractory above this location shall be removed and discarded. The bottom of each successive band shall be securely bonded to the top of the preceding band before the latter has developed an initial set.

10.5.12 The same general procedures shall be used for horizontal equipment with the exception that horizontal equipment can be rotated for either casting or gunning in the flat position.


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10.5.13 The lining shall be screeded to the final required thickness after placement and any deficiencies shall be immediately corrected. Smoothing, trowelling, and floating are not permitted.

10.5.14 When application is interrupted before completion of the entire lining, any refractory that is applied at a thickness less than the full thickness shall be removed by cutting back to the shell with a steel trowel. The cut shall be beveled into the adjacent lining by approximately 10° and all material above the line shall be discarded.

10.5.15 During a period of interruption in application, the curing of the lining that has already been applied may be completed.

10.5.16 Immediately prior to resuming application, the exposed surface of lining to which a bond must be made shall be thoroughly wetted with water of a quality as outlined in 10.1.9.

10.6 Mixing Refractory in Casting Applications

10.6.1 Mixing of refractory materials shall be done in a paddle type mixer.

10.6.2 Only full contents of refractory bags or drums shall be placed in the mixer. Fractional parts of a bag or drum shall not be used.

10.6.3 When fiber reinforcement is used, the fibers shall, in order to obtain proper fiber distribution, be added to the mixer through a wire mesh screen with approximately 12 mm openings.

10.6.4 The quantity of refractory material that is mixed in one mixing shall not be greater than the quantity that can be placed prior to initial set or 15 minutes after addition of water, whichever is shorter. Materials not used within this time shall be discarded. Precautions shall be made to prevent the separation of aggregates and cement prior to placement.

10.6.5 The amount of water that is used shall be the minimum amount that will give the proper consistency for placement. This amount is not to exceed the refractory manufacturer’s specified amount.

10.6.6 The “ball in hand” test described in ASTM C860 shall be used to determine the correct consistency.

10.7 Application of Cast Refractory


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10.7.1 Only qualified personnel who are thoroughly experienced with cast application of refractory lining shall be employed for this work.

10.7.2 Forms shall be rigidly constructed and sufficiently tight to prevent excessive leakage. The surface that are in contact with the lining shall be uniform, reasonably smooth, and suitably coated to prevent bonding of refractory to the forms. Forms shall be designed to facilitate their removal without damage to the refractory.

10.7.3 Refractory shall be applied in a manner that will minimize section segregation.

10.7.4 Refractory shall be compacted by spading or vibrating. Compacting shall be done with care to avoid segregation of materials, damage to previously applied portions of the lining, or damage to the equipment.

10.7.5 Work shall not be terminated until a panel or section is complete. When work is resumed, the contact surface of the lining that is in place shall be thoroughly cleaned, roughened, and wetted with water of a quality as outlined in 10.1.9. Any excess water shall be removed.

10.7.6 Curing shall be carried out whenever the application is interrupted.

10.8 Application of Vibration Casting

10.8.1 The refractory materials to be used shall be manufactured specifically for vibration casting and shall be fine grain and evenly distributed.

10.8.2 Additives used to promote flow shall be used in strict accordance with the Refractory Manufacturer’s instructions.

10.8.3 Forms used shall be made of steel sheet and shall be rigidly constructed.

11 Curing and Dry Out

11.1 General

11.1.1 All new linings shall be cured and dried out in accordance with the Refractory Manufacturer’s recommendations.

11.1.2 During dry out, the equipment must be properly supported to prevent damage to the lining and equipment.

11.2 Curing


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11.2.1 Castables shall be cured after an initial set of 1 to 3 hours. All exposed lining shall be cured by means of a fine water spray or by the application of a membrane-curing compound. If a water spray is used, the surface shall be kept damp for a minimum of 24 hours.

11.2.2 If forms were used during placement, these forms shall remain in place for a minimum of 24 hours.

11.2.3 During the curing period, the temperature of the shell and refractory material shall be maintained between 4°C and 32°C.

11.2.4 Lined equipment shall not be moved during curing.

11.3 Dry out

11.3.1 Adequately calibrated temperature measuring devices shall be installed to monitor the temperature. When dry out is by auxiliary burners, temperature monitoring must be provided on the gas outlet and burner areas.

11.3.2 The maximum dryout temperature must be controlled so as not to reduce the mechanical properties or chemical composition of the materials of the lined equipment.

11.3.3 When dry out is done in a furnace, the temperature measuring devices shall be installed on the refractory side and on the external surfaces of equipment to indicate differentials between metal and refractory temperatures.

11.3.4 Unless otherwise specified by the Refractory Manufacturer, the minimum holding times during dry out shall be 1 hour per 25 mm of refractory thickness.

12 Production Sampling and Testing

12.1 General

12.1.1 All testing shall be done in accordance with but is not limited to the applicable ASTM and ISO standards referenced in this specification.

12.1.2 Production tests shall be conducted during refractory application as specified in this standard. As a minimum at least one set of samples per piece of equipment shall be tested. Test results of as-installed samples must be submitted and approved by the Company Representative prior to shipment of the lined equipment.


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12.1.3 Installer shall provide at least one set of samples for each equipment, apart from that which are sent to the testing laboratory, which shall remain at the job site for possible future testing.

12.1.4 The test result of the as-installed samples shall not exceed the Table 2, Appendix B, JERES-N-100 specified value by more than 10% below the value of compression and 10% above the value of erosion. Test value for density shall be within 81 kg/m3 of the value specified in Table 2, Appendix B, JERES-N-100. No deviation is permitted for linear change. Test values falling outside the limits shall be cause for rejection. In the event of disagreement over the quality of the installed lining, additional samples may be sent for testing or core samples shall be taken as per paragraph 12.4.5. For FCC unit application, refer to JERES-N-150.

12.1.5 The Refractory Installer shall keep an accurate log of installation so that location of refractory that is represented by the production samples can be determined in case it becomes necessary to remove the refractory.

12.1.6 Any refractory that is found to be defective due to presence of voids, honeycombing, insufficient curing, or construction damage shall be totally removed to the full thickness of the layer and shall be relined to comply with this standard.

12.2 As-installed Samples

12.2.1 Gunite application

One panel measuring a minimum of 400x400x100mm shall be gunned in the vertical position per nozzelman per shift.

Panel shall be constructed of steel, wood or plastic, or as an alternative, a wire mesh basket made of approximately 13mm mesh openings placed on the vessel wall during application and immediately removed.

All loose refractory or rebound entrapment where the basket was placed shall be removed.

The following samples shall be cut from the above panel for testing:

3 Cold Crushing Cubes: 50x50x50mm for heat insulating, erosion resistant and extreme duty refractory.

1 Permanent Linear Change bars 250x50x50mm for heat insulating and erosion resistant material.


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12.2.2 Vibrocast and freeflow applications

For each section or spool piece to be lined, a sample box measuring at least 250x250x100mm will be placed on the equipment being lined and vibrated in a similar method.

From this sample box the following samples pieces shall be cut for testing:

3 Cold Crushing Cubes: 50x50x50mm for erosion resistant and extreme duty refractory.

1 Permanent Linear Change bar 250x50x50mm for erosion resistant material.


12.2.3 Hand-packing applications (for all type of materials)

A set of samples shall be prepared per shift/mixing crew and shall be cast directly into the test sample moulds.

3 Cold Crushing Cubes: 50x50x50mm.

2 Erosion plates: 114x114x25mm.

For hand casting of erosion resistant or extreme duty materials refer to JERES-N-150.

12.3 Samples drying and firing

Remove the specimens from the mould (or cut from block as necessary) after 24 hours or as per Manufacturer recommendation, and dry for 18 hours at 105°C.

Heat the specimens as per ASTM C865 to 815°C and hold for 5 hours.

Cool down at a maximum rate of 150°C per hour.

12.4 Laboratory Testing

12.4.1 All testing shall be conducted by a fully qualified independent testing laboratory.

12.4.2 Compressive strength testing:

Testing shall conform to ASTM C133 and the following:


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− Loading head of test machine shall have a spherical/floating loading head;

− Cardboard shims or similar (75x75x1.5-3mm thick) shall be placed between head of test machine and the specimens. Use new shims for each test.

12.4.3 Permanent linear change:

At room temperature, measure the length (230mm direction) of bars after having dried to 105°C. Take five measurements: The four corners and center points and report as an average of five.

After heating at 815°C, perform the above measurement again, at the same location and report the percentage average linear change.

12.4.4 Erosion tests

Testing shall conform to ASTM C704. New silicon carbide grit shall be used for each test.

12.4.5 To resolve questions concerning the as-installed quality, cylindrical core samples measuring 75mm diameter shall be taken from the lining. These core samples shall then be cut to give parallel faces and obtain cubes of 50mm diameter which shall be tested for compressive strength.

13 Inspection and Repair

13.1 All inspection shall be carried out in accordance with Company Inspection Requirement JERITP-N-328110 and the requirements of this standard.

13.1 For cyclones, slide valves and other critical surfaces, defective areas are not permitted regardless of size.

13.2 At the completion of curing and drying, the lining shall be randomly checked for voids or damaged areas. The check shall be conducted by lightly tapping with hammer and audibly noting the presence of voids and insufficient hardness. A hammer having a weight not more than 300g shall be struck on the surface of the lining at 300 to 500mm interval. This interval should be closer for thin-wall erosion resistant linings using heavy duty erosion type of material, particularly in hexmesh anchorage. Hammer testing shall not replace refractory sample testing.

13.3 Hammer testing of the lining shall take place after a minimum of 24 hours air curing and/or when the refractory material has taken its final set. Further hammer testing


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shall also take place after heat-curing (if applicable). Erosion resistant, heat insulating refractory material cannot be hammer tested until heat cured at 370°C.

13.4 If the refractory is questionable or defective the size of the defect shall be investigated and sample test results shall be consulted before the decision is made on removal of the refractory. Visual examination and hammer testing shall be repeated after the refractory is replaced, cured and dried out.

13.5 The method of repair, curing and retesting shall be in accordance with the original installation procedure. Any part of a single layer lining, except hexmesh or S-bar linings, which is defective, shall be removed for the full thickness of the refractory material. The minimum area removed shall be approximately one square foot. The surface shall be cleaned of all refuse and pre-wet prior to refractory replacement. Refractory that is under repair shall have exposed surfaces of the joint thoroughly wetted with water of a quality as outlined in 10.1.9 prior to placement of refractory. Jubail Export Refinery Inspector shall determine the extent of the repair.

13.6 Refractory lining cracks with a width of 3 mm (1/8”) and larger and a depth of more than 20% of refractory thickness shall be repaired.

13.7 Cracks exceeding the parameters of paragraph 13.6, loose and or hollow sounding areas, delaminations, soft or dry fill areas, should be removed back to the shell exposing a minimum of three anchors. Repairs should comply with paragraph 13.5.above and paragraph 8.2.1, JERES-N-130. All repairs shall be made using the original refractory material and installation technique.

13.8 Cast applications performed using internal framework may show surface voids or air bubbles. This is due to air expulsion during the casting. The following dimensions of surface voids are considered acceptable:

− Up to 12mm wide and 6mm deep;

− Up to 20mm wide and 3mm deep.

13.9 Void in excess of the above tolerances, shall be cleaned out , drilled with a masonry bit and filled-in with high erosion resistant or extreme duty material. It shall be

allowed to air-cure and then ground flush. Voids in excess of 70% of the lining thickness, shall be chipped off and repaired according to paragraph 13.7.

13.10 Any step joint along the gas flow between refractory applications, spool piece sections, change of direction etc. in excess of 3mm shall be ground flush.


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13.11 Thickness tolerance shall be as follows:

At pipe end in vessel :

− Gunned linings -0mm/+3mm

− Cast (vibro/freeflow) -3mm/+3mm

Within pipe or vessels sections:

− Gunned linings -0mm/+12mm

− Cast (vibro/freeflow) linings -3mm/+6mm for straight sections

− Cast (vibro/freeflow) linings -10mm/+10mm for curved sections

13.12 For erosion resistant and extreme duty erosion resistant materials refer to JERES-N-150.

13.13 If un-satisfactory as-installed test results are obtained and/or subsequent core samples are also un-satisfactory, the area or lined section represented by the sample and identified in the sample location sheet shall be removed. For this reason it is suggested that the Installing Contractor keeps a second series of samples.

13.14 When specified or required by the Company Representative, in addition to or as an alternative to the requirements of previous paragraph 13.13, radiographs of the installed lining may be made but a detailed procedure should be submitted to the Company Representative for approval.

13.15 Inspection of Anchors and Supports

13.15.1 The strength of each anchor and stud attachment shall be checked with a hammer blow.

13.15.2 All refractory anchors and their attachment welds shall be visually inspected for complete fusion around the base of the anchor and at the “T” stud plate. Any anchor that is not straight or that shows incomplete fusion shall be subjected to a bend test as described in paragraphs 13.15.3 and 13.15.4.

13.15.3 A total of 5% of all anchor welds shall be subjected to a bend test. If any of these samples shows cracks or failure at the weld, they shall be rejected. Succeeding and


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preceding anchors in the same course shall be bend tested until five consecutive welds in each direction are found to be acceptable.

13.15.4 Bend testing shall be accomplished through use of a method that will bend the anchor through approximately 30° and back to the normal position.

13.15.5 Additional refractory anchors, where needed, shall be installed in accordance with JERSD-N-0009.

13.15.6 Checklist for Refractory Installation

Figure 1, Appendix A is a checklist of activities that shall be used by the Refractory Installer for the installation of castable refractory.


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Appendix A Figure 1 – Refractory Installation Checklist

A. Prior To Installation Materials Weather Protection Vibrators ( ) Verify the types of ( ) Verify that materials ( ) Number of vibrators materials supplied, are properly stored ( ) Type data sheets and] ( ) Verify that equipment ( ) Attachment method mixing instructions to be lined is prepared ( ) Operating condition ( ) Verify availability of for inclement weather ( ) Backup MSDS sheets conditions Documents Equipment - Mixers Curing Compound Applicators ( ) Verify approved ( ) Verify number and type ( ) Type and size detail drawings are adequate ( ) Cleanliness ( ) Back up mixer is available ( ) Number Inspection ( ) Location relative to work ( ) Working conditions ( ) Cleanliness ( ) Inspect surface Air Compressors preparation Gunnite Rig ( ) Size ( ) Inspect anchor ( ) Number of Rigs ( ) Operating Condition layout and welding ( ) Type ( ) Contingencies ( ) Review welding ( ) Operating Condition procedures ( ) Cleanliness Sample Molds ( ) Sufficient Hose ( ) Cubes ( ) Nozzle type ( ) Gunnited

B. Installation Condition Surface Preparation Casting and Vibration Casting ( ) Ambient and Anchorage ( ) Vibrator frequency ( ) Weather protection ( ) Surface preparation ( ) Movement of material meets spec ( ) Time between mixing Forming ( ) Welding procedures and placement ( ) Strength ( ) Anchor welds. Bend ( ) Mixing per checklist ( ) Form release tests, cracks ( ) Forms per checklist ( ) Position of forms ( ) Squaring of old refractory ( ) Curing compound applied for proper thickness ( ) Anchor layout ( ) Total casting time ( ) Sealed ( ) Hammer testing ( ) Water content ( ) Bracing ( ) Vibration arrangement ( ) Secured Gunniting ( ) Batch size ( ) Competence of operator ( ) Anchor loss Mixing ( ) Pre-qualification of ( ) Water source gun operator Production Sampling ( ) Storage container ( ) Material feed rate ( ) Proper molds and size ( ) Introduction of metallic ( ) Sampling ( ) Frequency of samples fiber reinforcement ( ) Rebound ( ) Sampling procedure ( ) Percentage of metallic ( ) Curing compound matches installation fibers application procedure ( ) Cleanliness ( ) Maintenance of gun ( ) Curing ( ) Method of adding water ( ) Gunning technique ( ) Handling ( ) Water quality ( ) Air pressure ( ) Water temperature ( ) Thickness Dryout ( ) Mixing time ( ) Cut back ( ) Firing equipment ( ) Mix temperature ( ) Construction joints ( ) Burner locations ( ) Water percentage ( ) Prewet relative to refractory ( ) Dryout schedule Inspection after Dryout Inspection after Curing ( ) Thermocouple locations ( ) Cracking ( ) Cracking ( ) Recording equipment ( ) hammer testingnats ( ) Construction joints ( ) Hammer testing

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