refractory procedure

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REFRACTORY APPLICATION PROCEDURE Da te:09-Ju n-12

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REFRACTORY APPLICATION PROCEDURE FOR

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DESCON ENG INEE RING REFRACTORY APPLICATION PROCE D URE

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TABLE OF CONTENTS

1.0 SCOPE & GENERAL COMMENTS

2.0PRE-INSTALLATION REQUIREMENTS FOR THE INSTALLING CONTRACTOR

3.0REFRACTORY MATERIALS AND STORAGE

4.0GENERAL REQUIREMENTS

5.0 APPLICATORS'S QUALIFICATION

6.0APPLICATION OF POURED REFRACTORIES (CASTING)

7.0 TOLERANCES

8.0 CURING OF CASTABLE REFRACTORIES

9.0SAMPLING AND TESTING DURING INSTALLATION

10.0 INSPECTION

11.0 REPAIRS TO REFRACTORY LINING

DESCO N ENGINEERING REFRACTORY APPLICATION PROCEDURE

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1. S COPE AND GENERAL COMMENTS

1 .1This procedure shall be used in accordance with GASCO General Specifkation

DGS-6531-020_0_001 0.

1.2 AMBHertel shall perform all refractory installation work

1 .3All units shall be in S.l (metrk)

1.4 The purpose of this Procedure is to define the requirements for refractory Materials, handllng, installation, dryjng, curing, testing, inspection and repair work if any.

1.5 The refractory installation contractor AMBHertel is responsible for providing a finished refractory lining to the specified density, thickness, and uniform composition that will perform in service to the ability proven in previous use and test data.

1.6 The general guidelines of this procedure are mm1mum care and quality requirements. The installation contractor is expected to utilize his expertise in refractory installation, if and where conditions require, to exceed these minimums or take additional steps to insure a satisfactory, serviceable lining is provided.

1 .7 The contractor shall be responsible for the maintenance of records of the refractory used (by manufacturer's batch number and date) and, when required, for the arrangements of independent lab tests and recording of the results.

2.0 PRE-INSTALLATION REQUIREMENTS FOR THE INSTALLING CONTRACTOR

2.1 AMBHertel shall check all materials upon receipt at the site of installation for damage such as broken bags, moisture infiltration, etc., to assure the refractory containers (bags, drums, etc.) as marked are material specified on the arrangement drawing, and that the refractory is the specific mix for the intend method of applkation (Casting).

2.2 Prior to starting refractory installation, Descon shall verify that 5% random bend test of the anchors has been performed and recorded.

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2.3 When castable tie back has been installed by a party other than the AMBHertel, AMBHertel shall assure by hammer or bend test, that the tieback is suitabl y welded to the shell before starting work.

2.4 Bagged refractory shall have the batch date checked prior to mixing to confirm that the material has not passed the manufacturer 's recommended shelf life.

2.5 Castables which show signs of having set (lumps or hardness throughout) prior to mixing shall be rejected, regardless of shelf life expiration date.

3.0 REFRACTORY MATERIAL AND STORAGE

The material MANUFACTOR'S instructions for storage, handling, and shipment of materials shall be met. Shipment of refractory should be scheduled to ensure that it is installed within its specified shelf life. Material which has been longest in storage shall be used first.

Refractory materials hall be stored with protection from extreme weather conditions and exposure to sun. In winter, plastic mouldable refractory materials may freeze and must be thawed before use. This is done by removing only the outside packaging, not the foil, and storing in a warm place. Thawing may take several days; the material is ready when it can easily be formed by hand.

All hydraulic setting refractory materials shall be protected from moisture absorption during shi pment and storage. Air-tight, moisture-tight polyethylene bags shall be used when specified by the CONTRACOR.

Refractory that shows signs of having set, ie. Hard or unbreakable lumps in the dry mixture prior to installation shall be rejected and be removed from the job site. Fractional part from previous jobs as well as damaged bags shall also be removed from the job site.

Refractory materials, except dated castable refractory materials, shall be protected to withstand ocean transit and extended periods of storage at the jobsite for a minimum period of 18 months. Materials shall be protected to safeguard against all adverse environments, such as humidity, moisture, rain, dust, dirt, sand, mud, salt air, salt spray, and sea water.

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4.0 GENERAL REQUIREMENTS

4.1 The recommended procedures from a manufacturer of a proprietary material for water rates, mixing, placing and curing shall be followed unless:

3.1.1 Site conditions dictate some modifications to obtain the desires results.

3.1.2 The installations contractor has demonstrated through previous experience that his recommended changes will produce a superior in place product.

3.1.3 Deviations in the manufacturer's recommended procedures shall be submitted to client in writing. Acceptance of the contractor's recommended changes by client do not relieve the contractor of his responsibility and liability for the completed lining.

4.2 Clean Water used for mixing or preparation of the refractory components Wetting of surfaces to be lined and for water spray during curing shall be potable and shall have low chloride content (50 ppm maximum)

5.0 APPLICATOR'S Qualification

1. Each team of mixer operations and APPLICATORS shall prepare either a standard shape (230 X 114 X 64 mm minimum dimensions) of a box specimen (280 X 180 X 75 mm minimum dimensions) in a hardwood box.

2. The box should contain the same anchor system (type and spacing) as to be using in the actual installation.

3. The specimen shall be placed by hand in approximately 25 mm thick layers, subsequently poked to achieve accurate filling and good workmanship.

4. Vibrators shall not be used with castables having a bulk density of less than 1750 kg/ m3.

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

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APPLICATOR'S test samples shall be stored to set and dry.

6.0 APPLICATION OF POURED REFRACTOY (CASTING)

6.1 Preparation

a. (astable refractory are normally supplied in moisture proof bags and are mixed with water on site and poured in place. The amount of water to be added depends on the type of the castable and the consistency required during installation. The minimum amount of castable to be mixed shall be one bag and larger mixes shall be made using a whole number of bags. No partial bag should be used.

b. Where the steelcasing does not completely surround the refractory surface, forms are necessary. Forms should have a relatively rigid, stable, smooth surface, be water resistant, and be greased or coated with concrete mould release agent.

c. Forms shall be kept in place for the curing period to provide support and retain moisture within the castable. Their design shall allow removal without damage to the refractory. Forms shall be sealed when jointed to prevent loss of water

or material.

d. The preferred mixer for poured castable is a paddle type mixer (mortar mixer )

to separate unwanted matter such as paper.

e. Temperature of mix shall be maintained between 5C-30C.

f. During mixing, the consistency shall be checked by the "Ball-in-hand" method in accordance with ASTM C860

g. Ferrules to be fixed in the tube sheet before the starting the castable works.

h. After fixing the ferrules shuttering should be done for casting.

6.2 Installation

a. The lining shall be applied in narrow areas, starting at the bottom and working upward.

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b. Each batch of the mixer shall be cast over the full thickness and evenly distributed.

c. Once application has started it shall proceed without intervals until the entire scheduled lining has been completed.

d. If an unavoidable interruption occurs, the wet ending of the lining shall be cut back at an angle to the surface to provide a slight "keyed" effect when the final material is cast. All material ahead of the cut shall be discarded.

e. Care should be taken that no castable materials should protrude inside the tube sheet or ferrules. If it happens, then the same to be cleaned.

f. When casting horizontal areas without molds, the finished surface shall be levelled off with a scraper or screed only; slurry shall not appear after finishing the surface.

g. As the work progresses, the refractory shall be checked for final thickness and any deficiencies shall be corrected immediately. A screened finish is all that is required; smoothing, floating or trowelling shall be avoided.

7 TOLERANCES

6.1Thickness

1. The refractory castable thickness shall be within +12mm,-O measured from the steel plate.

8 CURING OF CASTABLES REFRACTORIES

The purpose of curing a castable refractory is to prevent the loss of water through evaporation needed by the refractory binder to develop its strongest hydraulic bond.

1. Surface temperatures must be maintained between 10- 30C for 36 hours during curing. If ambient temperatures above 30C are anticipated during the cure, AMBHertelshall provide the cooling method by spraying the water on the surface to maintain the temperature.

2. Surface temperatures shall be measured and recorded every 4 hours.

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3. Direct sunlight is not permitted on any refractory within 36 hours of installation.

4. The castable must be allowed to partially set up before start of spraying to prevent washing out the binder.

5. Frequency of spraying is determined by factors such as ambient

temperature, humidity, air circulation, etc. In genera,l

the surface must not

be allowed to dry during the first 24hours after refractory placement.

6. After the 24hour cure period, an additional 24hours of air drying is mandatory before handling or application of any heat to the refractory.

7. In excessively hot weather, the forms, steel sections, and refractory face may be sprayed with cold water to cool the refractory.

9 SAMPLING AND TESTING DURING INSTALLATION

1. At randomly selected times during each shift, the APPLICATOR shall prepare a number of samples (panels) using the same refractory materials being installed.

2. The minimum number of samples shown in Table A2-2 of DGS- 6531-

020_0_0010

3. Preparation of the samples shall be witnessed by the CONTRACTOR.

Depending on the type of refractory material, samples shall be either

(Figure A2-1) DGS-6531-020_0_0010:

Standard shape : 230 X 114 X 64 mm (see Note below)

Box: 280 X 280 X 75 mm, for ramming and poured castables;

Panels materials.

: 500 X 500 X 114 mm, for gunned refractory

NOTE: Filling shall be done with dimension of 114 mm upright.

Each sample shall be clearly marked with APPLICATOR'S code numbers for that Day/shift/crew and for sequence of production. Each code shall be unique, and traceable to the locations where refractory has been applied by that crew during that shift.

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4. The APPLICATOR is responsible to ensure that the samples are regularly delivered for testing to the test laboratory. Test specimens shall be cut from the samples at the laboratory, after being prepared, cured and air dried at the work site.

5. For each sample, the following properties shall be tested:

Bulk Density

Water Content (1 per shift)*

Cold Crushing Strength;

*for information purposes only, not subject to acceptance criteria. The acceptance criteria for these tests shall be as stated in Table A2-3.

If the test values do not meet the specification, new samples from the same panel or, if necessary, from the related lining section, shall be retested for:

Bulk Density

Cold Crushing Strength

If the retest results do not meet the specification, the lining section related to the tested samples shall be rejected.

10 INSPECTION

10.1 Visual

1. After air drying, the lining shall be inspected for cracks.

2.Random surface cracking up to 2 mm wide, not more than Y2 the full refractory thickness in depth, and not exceeding an average spacing of 300 mm is acceptable.

3.Areas containing cracks wider than 2 mm or any criss-cross (intersecting) cracks are considered defective and shall be repaired.

4. Visua,l

dimensional, and quality inspection of expansion joints shall be made.


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10.2 Hammer Testing

1. The type of inspection is generally referred to as a Hammer test. It involves the practice of striking the lining over its entire area with a ball point machinist hammer having a recommended weight of 450grams.

2. Hammer testing will indicate whether or not a lining is homogeneous. An experienced ear will determine, in more detail, faults which might cause a lining to collapse such as voids eliminations etc.

11. REPAIRS TO REFRACTORY LINING

1. If inspection reveals defective areas as previously defined greater than 150 mm x 150 mm, the full thickness of the defective concrete layer must be removed for a

minimum area that include 3-4 anchors.

2. Care must be taken in the removal of the faulty material that the surrounding sound lining is not damaged

3. The removal of the refractory concrete should progress at a small angle to the shell and the periphery of any repair be located mid-way, between anchors.

4. The area being repaired should be cleaned of all loose concrete and debris and the adjacent sound material thoroughly wetted before any new concrete is installed.

5. Only the same concrete as originally employed should be used for replacement and wherever possible, especially in large areas the same installation method as was originally used.

refractory procedure

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