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NIOEC-SP-45-14(0)

 
 

DOCUMENT CODE

 

NO. OF PAGES: 8

PLAN/PRJ/SUB

UNIT

PHASE

DISCIPLANE

DOCUMENT TYPE

SERIAL NO.

REV. NO.

DATE

NIOEC

000

EG

ME

SP

4514

A0

JULY, 2005

NATIONAL IRANIAN OIL REFINING & DISTRIBUTION COMPANY NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY NIOEC SPECIFICATION

NATIONAL IRANIAN OIL REFINING & DISTRIBUTION COMPANY

NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY

NATIONAL IRANIAN OIL REFINING & DISTRIBUTION COMPANY NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY NIOEC SPECIFICATION

NIOEC SPECIFICATION FOR

PROCEDURE FOR REFRACTORY LINING

FIRST EDITION JULY, 2005

THIS SPECIFICATION IS THE PROPERTY OF NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY. IT IS CONFIDENTIAL AND ALL RIGHTS RESERVED TO THE OWNER. NEITHER WHOLE NOR ANY PART OF THIS DOCUMENT MAY BE DISCLOSED TO ANY THIRD PARTY, REPRODUCTED, STORED IN ANY RETRIEVAL SYSTEM OR TRANSMITTED IN ANY FORM OR BY ANY MEANS WITHOUT THE PRIOR WRITTEN CONSENT OF THE NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY

JULY, 2005

NIOEC-SP-45-14(0)

JULY, 2005 NIOEC-SP-45-14(0)

JULY, 2005

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REVISION INDEX

REV. REV. REV. REV. 1 2 3 4 5 1 2 3 4 5 1 2
REV.
REV.
REV.
REV.
1
2
3 4
5
1
2
3
4 5
1
2
3
4
5
1
2 3
4 5
PAGE
PAGE
PAGE
PAGE
1
26
51
76
2
27
52
77
3
28
53
78
4
29
54
79
5
30
55
80
6
31
56
81
7
32
57
82
8
33
58
83
9
34
59
84
10
35
60
85
11
36
61
86
12
37
62
87
13
38
63
88
14
39
64
89
15
40
65
90
16
41
66
91
17
42
67
92
18
43
68
93
19
44
69
94
20
45
70
95
21
46
71
96
22
47
72
97
23
48
73
98
24
49
74
99
25
50
75
100
NOTES:
1)
THIS SHEET IS A RECORD OF ALL REVISIONS TO THIS SPECIFICATION.
2)
REMARKS RELATED TO EACH REVISION SHOW A BRIEF DESCRIPTION. THESE REMARKS SHALL BE
INTERPRETED IN CONJUNCTION WITH THE REVISED TEXT MARKED BY REVISION NUMBERS.
3)
WHEN
APPROVED
EACH
REVISION
SHALL
BE
CONSIDERED
AS A PART OF THE ORIGINAL
4)
DOCUMENT.
NUMBER OF PAGES EXCLUDES THIS SHEET AND THE COVER SHEET.
5
4
3
2
1
0
JULY 2005
M.R.F./A.K.
M.H. ZAKER
M.R. FARZAM
M.A.A. SAJEDI
REV.
DATE
PREPARED
CHECKED
APPROVED
AUTHORIZED

JULY, 2005

NIOEC-SP-45-14(0)

CONTENTS:

PAGE NO.

  • 0. INTRODUCTION

......................................................................................................................

2

  • 1. SCOPE.........................................................................................................................................2 REFERENCES

  • 2. ...........................................................................................................................

2

  • 2.1. Equivalent to IPS Standard

...............................................................................................

3

UNITS

  • 3. ..........................................................................................................................................

3

  • 4. DEFINITIONS & TERMINOLOGY

.......................................................................................

3

  • 5. ADDENDUM TO IPS STANDARD (IPS-C-TP-352)

.............................................................

4

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NIOEC-SP-45-14(0)

  • 0. INTRODUCTION

To satisfy the requirements of this NIOEC Specification, relevant sections of Iranian Petroleum Standard IPS-C-TP-352 about refractory lining with the modifications as specified herein after shall be strictly followed. Articles 1 through 4 of this document replace entirely the related articles in the referenced IPS Standard.

  • 1. SCOPE

    • - This procedure pertains to materials, application, curing inspection and thermal drying of refractory linings for fired heaters, boilers, incinerators, vessels and the evaluation through

compressive strength tests of insulating refractories which are field installed.

  • - This Specification includes requirements for preparation of material for use, application,

drying or curing, transportation, installation, repair of lining and inspection of lined parts.

  • - It applies to equipment fabricated in metal or concrete and in both bonded and loose linings.

  • - Requirement for design and fabrication of the equipment, the state of preparation necessary for the surface to be lined and thickness of lining shall be according to NIOEC-SP-45-07

  • 2. REFERENCES

Throughout this Specification the following dated and undated standards/codes are referred to. These referenced documents shall, to the extent specified herein, form a part of this Specification. For undated references, the latest edition of the referenced document (including any supplements and amendments) applies. For dated references, the edition cited applies. The applicability of changes in dated references that occur after the cited date, shall mutually be agreed upon by NIOEC and the Vendor/Contractor.

ASTM (AMERICAN STANDARDS FOR TESTING AND MATERIALS)

C-71

"Standard Terminology Relating to Refractories"

C-93

"Test Methods for Cold Crushing Strength and Modulus of Rupture of Insulating Fire Brick"

C-133

“Test Methods for cold crushing strength and modulus of rapture of insulating firebrick”.

C-268

"Preparing and Curing refractory Concrete Test Sample"

C-309

“Liquid membrane forming compounds for curing concrete”.

C-860

“Practices for determining and measuring consistency of refractory concretes”.

C-862

“Practice for preparing refractory concrete specimens by casting”.

C-865

“Practice for firing refractory concrete specimens”.

IPS (IRANIAN PETROLEUM STANDARDS)

IPS-E-TP-350

“Engineering Standard for Lining”

IPS-C-TP-352

“Construction Standard for Lining”

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IPS-C-TP-101

“Construction Standard for surface preparation”

NIOEC-SP (NIOEC SPECIFICATIONS)

NIOEC-SP-00-10

NIOEC-SP-45-07

NIOEC-SP-80-02

“NIOEC Specification for units” “NIOEC Specification for Refractory Linings” “NIOEC Specification for Painting”

SIS

(SWEDISH STANDARD)

SIS 05 59 00

"Rust Levels of Steel Structure and Quality Levels for Preparation of Steel Surface for Rust Protecting Paints"

  • 2.1. Equivalent to IPS Standard Substitute the following IPS Standards as referred to throughout IPS-C-TP-352 to relevant NIOEC's Specifications as follows: IPS Standard

Relevant NIOEC Specification

IPS-E-TP-350

NIOEC-SP-45-07

IPS-C-TP-352

NIOEC-SP-45-14

IPS-C-TP-101

NIOEC-SP-80-02

  • 3. UNITS

International System of units (SI) shall be used in accordance with NIOEC-SP-00-10, Unless otherwise specified.

  • 4. DEFINITIONS & TERMINOLOGY

    • 4.1 “Employer” means: “National Iranian Oil Engineering & Construction Company”. (NIOEC)

    • 4.2 “Purchaser” means: “National Iranian Oil Engineering & Construction Company”. When quoted in this Specification as part of a direct purchase order by NIOEC and “Contractor” where this Specification is part of Contract Documents.

    • 4.3 “Vendor” means: The manufacturer's from which the equipment is to be purchased.

    • 4.4 “Contractor” means: The party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation of a facility.

    • 4.5 “Inspector” means: The inspector or engineer employed by the Purchaser and acting as the Purchaser's representative, the inspector's or engineer's respective assistants properly authorized and limited to the particular duties assigned to them, or the Purchaser acting as the inspector.

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4.6 “Refractory” means: Non-metallic materials with chemical and physical properties applicable for structures and system components exposed to environments above 538°C (1000°F), ASTM-C-71.

  • 5. ADDENDUM TO IPS STANDARD (IPS-C-TP-352) This addendum revises the below listed articles of the referenced standard as follows:

17.1 General (Modification)

Add the following articles at the end of paragraph

  • 17.1.7 Experience of Personnel

Only personnel who are thoroughly familiar and experienced in application of refractory shall be employed in application of linings. Supervisors and foremen should have acted in a supervisory category on at least two previous jobs. Skilled tradesmen such as bricklayers and nozzle operators should have had at least one year's previous experience of such work on jobs of a similar nature.

  • 17.1.8 Steel anchors shall be furnished by the Vendor and installed by the Contractor unless

otherwise specified.

  • 17.1.9 Prior to application of refractory, inspect all support anchors to make sure that anchors

are attached securely to metal surfaces. If visual inspection warrents, test anchor by sharply striking the ends of the anchor with a light hammer. Properly fused welds give a ringing sound; defective welds give a dull, flat sound. Any anchor indicated to be unsatisfactorily welded shall be replaced and retested.

17.1.10 See NIOEC-SP-45-07 for details of types of anchors.

17.2.1.2 Mixing (Modification)

Add the following article at the end of paragraph

17.2.1.2.9 Check pneumatic gun to assure that refractory wheels are included.

17.2.2 Preparation of Surface to be lined (Modification)

Add the following sentences at the end of paragraph:

  • - Prepare the surface for the lining by thoroughly cleaning to remove all rust loose mill scale or other foreign materials. All temporary field attachments shall be removed. Surface to be lined shall be thoroughly sand blasted (Sa 2) with sharp, abrasive sand or wire brushed to remove all unbounded scale, slag, rust, and other materials. All sand blasting dust shall be removed before applying lining material. (see NIOEC-SP-80-02)

  • - Do not wash with water.

  • - The tube supports and other exposed structural items within the limits of the lining shall be wrapped with several layers of tarred or deadening felt to prevent the concrete from bonding to them.

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  • - Observation access and similar openings shall be fitted with sheet metal or wooden forms slightly tapered and of such dimensions that they extend beyond the finished surface of the concrete, and shall fit snugly into the openings. They shall be lightly coated with tar or heavy grease to prevent bonding and shall not be removed until the concrete has developed its final set.

  • - After these steps have been completed, the surface shall be inspected for cleanliness.

  • - All refractory shall be applied as per the Vendor’s detail application procedures approved by the Purchaser.

17.3 Application Methods 17.3.3.1.4 Casting Process (Modification)

Add the following paragraphs at the end of article:

  • - Immediately prior to resuming lining application, the exposed surfaces of the refractory, to which a bond will be made, shall be thoroughly wetted.

  • - When application is interrupted or concrete is discontinued, the concrete shall be cut back to the steel platework with a steel trowel. This cut shall be made at locations where the full thickness has already been applied. All material above the cut shall be discarded.

  • - Other cements, lime, etc. shall not be added to any mixture. Tools used in mixing and applying the refractory shall be kept clean and free of such substances.

  • - When the work is done during hot sunny weather the materials shall be stored in a shaded place until ready for use.

  • - Care should be taken at time of ordering to ensure that recommended shelf life is not likely to be exceeded before application.

17.3.3.2 Refractory gunning method (Modification)

Add the following paragraphs at the end of article:

  • t) All refractory materials shall be thoroughly dry mixed in a paddle or ribbon type mixer before loading into gun chamber. Mixing on a concrete floor is not permitted. Since the tendency to wash out the binder and segregation of particles will occur. There is also the danger of contamination by foreign particles.

  • u) To reduce rebound and dust and increase the quality of the castable lining due to reduction of stratification and increased uniformity. Refractory should be predampened uniformly with just enough water added to the mixer to reduce dusting to a satisfactory level. Water at this point should be introduced by means of a fine spray to insure uniformity.

  • v) Mixer blades should be cleaned frequently during a day’s operation by striking blades with a hammer to remove built up refractory. This waste should be removed from mixer and discarded. Under no circumstances should this material be loaded into gun.

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  • w) Water for mixing the refractory shall be cool, free of impurities and from a chemical stand point good enough to drink. The water temperature shall not be less than 5ºC.

17.3.3.3 Finishing of Castable Refractories (Addition)

Add the following articles:

17.3.3.3.1 The finished surface shall be reasonably smooth. This can be accomplished by screeding excess material from the surface. However, excessive troweling of the concrete shall be avoided. Screeding shall follow directly after application and any deficiencies in thickness found during screeding shall be immediately corrected by applying additional material, to prevent any laminations occurring in the lining.

17.3.3.3.2 In places where the refractory is subject to abrasions, such as where soot blowers are used in fired heaters and in incinerator stacks, an abrasion resistant wash shall be used to protect the surface of the refractory

17.4. Curing and Drying (Modification)

Add the following articles at the end of paragraph

17.4.8 Freshly gunned hydraulic setting refractory linings may be cured with a fine water spray using an atomizing (fog) nozzle for 24 hours after material has taken its initial set (which generally occurs in about four hours) ,or when heat of hydration is first noted . If curing is done in an ambient temperature below 15ºC (60ºF), curing time in excess of 24 hours is required.

17.4.9 Use of a liquid membrane forming curing compound is preferred .The liquid membrane forming compound used shall be pigmented and shall meet the requirements of ASTM-C-309, Type .2. Except that the loss of water shall not exceed 0.04 grams per sq.cm. The pigmented curing compound shall be applied to the refractory surface as soon as practicable after the disappearance of the sheen due to surface water. The curing compound shall be applied to the refractory surfaces with a fine mist spray until it is no longer absorbed.

  • 17.4.10 After applying curing membrane, the lining shall be air dried for at least 24 hours by

circulation of warm air.

  • 17.4.11 Curing with wet sacks spread on the surface of the lining shall not be permitted under

any circumstances.

  • 17.4.12 Care shall be taken to prevent entrance of rain.

  • 17.4.13 After the water curing, the lining shall be allowed to dry under ordinary atmospheric

conditions for as long as possible but not less than 72 hours.

  • 17.4.14 When first placed in service, the temperature of the equipment shall be raised slowly

to gradually expel excess moisture.

17.8 Inspection and Test Methods

17.8.1(Modification)

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NIOEC-SP-45-14(0)

Add the following paragraphs at the end of article

  • - The Purchaser’s inspector shall make certain that the procedures outlined herein are followed.

  • - Continuous observation shall be made by the Purchaser’s inspector, he shall check the thickness of applied refractory with the use of a depth gauge immediately after refractory has been applied, but under no circumstances after material has taken it’s initial set. See attached sketch of depth gauge.

17.8.2.5 (Modification)

The whole paragraph shall be modified as follows Samples shall be prepared and compression tested in 114 mm × 114 mm × 65mm test

samples, in accordance with ASTM C133, C860, C862, C865.

  • 17.8.4 Sampling (Addition)

    • 17.8.4.1 In addition to the pre-application tests outlined in article 17.8.2 of this Standard; representative samples shall be taken of the mix during application.

    • 17.8.4.2 A minimum of one test sample shall be taken cured for 24 hours and tested as follows:

      • a) The first batch of refractory applied by each crew each day.

      • b) One for each stack lining.

      • c) As further required by NIOEC’s appointed inspector.

17.9 Minimum Compressive Strengths (Addition)

17.91 Refractory concrete tested in accordance with Specification NIOEC-SP-45-07 shall develop a minimum compressive strength of 110 bar (1600psi) for material whose density after drying at 104°C(220°F) for 18 hours is about 1360-1520Kg/m3 (85-

95lbs/ft3).

  • 17.9.2 Should failure to meet minimum compressive strength occur in materials already

placed, further test specimens may be taken by coring to confirm condition of placed

material.

  • 17.9.3 Lining placed for which cored samples have failed shall be removed and replaced.

  • 17.9.4 Prior to thermal drying, test all refractory linings by striking with a ball peen hammer

300-500gm (10 to 16-oz) at approximately 30 cm. intervals. Any voids or dry filled places will produce a dull sound. Such areas shall be chiseled out completely to steel, and laterally to sound refractory material. The minimum area removed shall be sufficient to expose at least three (3) anchors. The sides of the cut shall be tapered back towards the vessel wall forming a keyed hole to form a stronger patch. Method of repair, curing and retesting shall be in accordance with the original procedure for installation. Cracks of any size are not acceptable at this stage.

  • 17.9.5 After thermal dry-out per paragraph 10.0 a thorough visual examination shall be made

of all refractory surfaces. Small networks of cracks 1.5mm (1/16”) in width & 19mm

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NIOEC-SP-45-14(0)

(3/4”) deep are considered normal. Areas showing larger cracks shall be considered for repair.

17.10 Thermal Dry-Out(Addition)

The Vendor shall submit thermal dry-out procedure for NIOEC's review and comment. Detailed application procedures shall be approved by the Purchaser.