0055-CPC-ACI-4.0.0.00.CPC-THM - PT-0008 - A1 - EN - 2 Refractory Installation Procedure

By:Dzifa Kodjokuma,KOD39371,21/08/2018
НАЗВАНИЕ ПРОЕКТА: ПРОЕКТ ПО СТРОИТЕЛЬСТВУ АМУРСКОГО

ГАЗОПЕРЕРАБАТЫВАЮЩЕГО ЗАВОДА
НЕЛИЦЕНЗИОННЫЕ УСТАНОВКИ
PROJECT TITLE: AMURSKY GAS PROCESSING PLANT
PROJECT NON LICENSED UNITS
НОМЕР КОНТРАКТА / AGPZ-900/0055
CONTRACT NUMBER
НАЗВАНИЕ ДОКУМЕНТА: ПРОЦЕДУРА УСТАНОВКИ ОГНЕУПОР
DOCUMENT TITLE: REFRACTORY INSTALLATION PROCEDURE
НОМЕР ДОКУМЕНТА /
0055-CPC-ACI-4.0.0.00.CPC-THM.PT-0008
DOCUMENT NUMBER:
КЛАСС ДОКУМЕНТА /
2
DOCUMENT CLASS
ПОДРЯДЧИК / CONTRACTOR:
CPECC
ПОСТАВЩИК / SUPPLIER: ACCEDE IMPIANTI ITALIA
ЗАКАЗ НА ПОКУПКУ / PURCHASE ORDER (PO): P2AM-4-0501
НОМЕР ДОКУМЕНТА ПОСТАВЩИКА / SUPPLIER

DOCUMENT NUMBER: 1544-00-0-Q-PT-0008
НОМЕР РЕДАКЦИИ ПОСТАВЩИКА / SUPPLIER 1
DOCUMENT REVISION:
ДАННЫЙ ДОКУМЕНТ ЯВЛЯЕТСЯ КОНТРОЛИРУЕМЫМ.

НЕ ВНОСИТЬ НЕУТВЕРЖДЕННЫХ ИЗМЕНЕНИЙ
THIS IS A CONTROLLED DOCUMENT. NO UN-AUTHORISED MODIFICATIONS
ДАННЫЙ ДОКУМЕНТ ВЫПОЛНЕН НА ДВУХ ЯЗЫКАХ.

УБЕДИТЕСЬ, ЧТО ИЗМЕНЕНИЯ ВНЕСЕНЫ В ОБЕ ВЕРСИИ
THIS DOCUMENT IS DUAL LANGUAGE. ENSURE BOTH VERSIONS ARE MODIFIED.
A1 23-JUL-2018 IFR AM GDP FV
РЕДАКЦИЯ
РЕД / СТАТУС / МИП
ПОДРЯДЧИКОМ ПОДГ. ПРОВ. / УТВ / УТВ /
УТВ /
ДАТА / DATE STATUS
УТВ /
REV
/ CONTRACTOR
/ BY
CHK
APP
APP
APP
CODE
EM APP
REV
ГЕН.
РЕДАКЦИИ ДОКУМЕНТ УТВЕРЖДЕН ПРОЕКТОМ CPECC УТВ ПОДРЯДЧИК
/
УТВ / GEN
REVISIONS
PROJECT APPROVALS
APPROVAL
CONTRACTOR
APPROVAL
Page 1 of 14
Номер Контракта / Contract Number :

AGPZ-900/0055
ПРОЦЕДУРА УСТАНОВКИ ОГНЕУПОР

Номер документа / Document Number:
REFRACTORY INSTALLATION PROCEDURE
0055-CPC-ACI-4.0.0.00.CPC-THM.PT-
0008
ПРОЕКТ ПО СТРОИТЕЛЬСТВУ АМУРСКОГО ГАЗОПЕРЕРАБАТЫВАЮЩЕГО

ЗАВОДА Редакция / Revision:
НЕЛИЦЕНЗИОННЫЕ УСТАНОВКИ A1
Page: 2 of 14
AMURSKY GAS PROCESSING PLANT PROJECT
NON LICENSED UNITS
ПЕРЕЧЕНЬ РЕДАКЦИЙ / REVISION DESCRIPTION SHEET
РЕДАКЦИЯ
ПОДРЯДЧИКОМ. ПАРАГ.
РЕД. ОПИСАНИЕ РЕДАКЦИЙ
/ CONTRACTOR
PARA.
REV.
REVISION DESCRIPTION
REV.
A1 ISSUED FOR REVIEW
ПЕРЕЧЕНЬ УТОЧНЕНИЕ / HOLDS LIST
РЕДАКЦИЯ
ПОДРЯДЧИКОМ. ОПИСАНИЕ УТОЧНЕНИЕ

РЕД. ПАРАГ.
/ CONTRACTOR
HOLDS DESCRIPTION
REV.
PARA.
REV.
ВОСПРОИЗВОДСТВО, РАСПРОСТРАНЕНИЕ И ИСПОЛЬЗОВАНИЕ ДАННОГО ДОКУМЕНТА, А ТАКЖЕ ПРИВЯЗКА ЕГО СОДЕРЖАНИЯ К ДРУГИМ БЕЗ ПИСЬМЕННОГО РАЗРЕШЕНИЯ \ АВТОРИЗАЦИИ ЗАПРЕЩЕНО. НАРУШИТЕЛИ БУДУТ НЕСТИ ФИНАНСОВУЮ ОТВЕТСТВЕННОСТЬ ЗА УБЫТКИ. ВСЕ ПРАВА
ЗАЩИЩЕНЫ В СЛУЧАЕ ПРЕДОСТАВЛЕНИЯ ПАТЕНТА,
ПРАВА НА ПРОМЫШЛЕННЫЙ ОБРАЗЕЦ ИЛИ ПРОМЫШЛЕННОГО ОБРАЗЦА ПРЕДМЕТА ШИРОКОГО ПОТРЕБЛЕНИЯ.
THE REPRODUCTION, DISTRIBUTION AND UTILIZATION OF THIS DOCUMENT AS WELL AS THE COMMUNICATION OF ITS CONTENTS TO OTHERS WITHOUT EXPRESS
AUTHORIZATION IS PROHIBITED. OFFENDERS WILL BE HELD LIABLE FOR PAYMENT OF DAMAGES. ALL RIGHTS RESERVED IN THE EVENT OF THE GRANT OF PATENT,
UTILITY MODEL OR DESIGN.
ДИЗАЙН ИЛИ ЕГО ЧАСТЬ, СОДЕРЖАЩИЕСЯ В ДАННОМ ДОКУМЕНТЕ, РАЗРАБОТАНА ДЛЯ ГАЗПРОМА И ЕГО ПРОЕКТА И ОСТАЕТСЯ В СОБСТВЕННОСТИ ГАЗПРОМА. ВСЯ ПРОИЗВОДСТВЕННАЯ ИНФОРМАЦИЯ CPECC ИЛИ РИД, ИСПОЛЬЗУЕМОЕ В СОЗДАНИИ ИНФОРМАЦИИ О КОНСТРУКЦИИ,
СОДЕРЖАЩЕЙСЯ В НАСТОЯЩЕМ СОГЛАШЕНИИ, ОСТАЕТСЯ СОБСТВЕННОСТЬЮ CPECC.
THE DESIGN OR PART THEREOF CONTAINED IN THIS DOCUMENT WAS DEVELOPED FOR GAZPROM FOR THE PROJECT AND REMAINS PROPERTY OF GAZPROM.
ALL CPECC PROPRIETARY INFORMATION OR UNDERLYING INTELLECTUAL PROPERTY UTILIZED IN THE CREATION OF THE DESIGN INFORMATION CONTAINED HEREIN SHALL REMAIN THE PROPERTY OF CPECC.

ПРОЦЕДУРА УСТАНОВКИ ОГНЕУПОР AGPZ-900/0055

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СТРАНИЦА ПОДПИСЕЙ: SIGNATURE PAGE:
Утверждено генеральным ИМЯ, ФАМИЛИЯ / FIRST NAME, LAST NAME Approved by General
подрядчиком: ПОДПИСЬ / SIGNATURE Contractor:
(Должность) (Position)
Утверждаю CPECC ИМЯ, ФАМИЛИЯ / FIRST NAME, LAST NAME Approved CPECC:
(Должность) ПОДПИСЬ / SIGNATURE (Position)
Менеджер по ИМЯ, ФАМИЛИЯ / FIRST NAME, LAST NAME Approved by
инженерному ПОДПИСЬ / SIGNATURE Engineering
проектированию - МИП: Manager-EM
Утверждаю: ИМЯ, ФАМИЛИЯ / FIRST NAME, LAST NAME Approved:
(Должность) ПОДПИСЬ / SIGNATURE (Position)
F. VALENTINO
(PM)
Проверено/Рассмотрено:
ИМЯ, ФАМИЛИЯ / FIRST NAME, LAST NAME
Checked/Reviewed:
(Должность) ПОДПИСЬ / SIGNATURE

(Position)
G. DELPIZZO
(ENG MGR)
Разработано: ИМЯ, ФАМИЛИЯ / FIRST NAME, LAST NAME

Author:
(Должность) ПОДПИСЬ / SIGNATURE

(Position)
A.MOREANU
(QA/QC)
ВОСПРОИЗВОДСТВО, РАСПРОСТРАНЕНИЕ И ИСПОЛЬЗОВАНИЕ ДАННОГО ДОКУМЕНТА, А ТАКЖЕ ПРИВЯЗКА ЕГО СОДЕРЖАНИЯ К ДРУГИМ БЕЗ ПИСЬМЕННОГО РАЗРЕШЕНИЯ \ АВТОРИЗАЦИИ ЗАПРЕЩЕНО. НАРУШИТЕЛИ БУДУТ НЕСТИ ФИНАНСОВУЮ ОТВЕТСТВЕННОСТЬ ЗА
УБЫТКИ. ВСЕ ПРАВА ЗАЩИЩЕНЫ В СЛУЧАЕ ПРЕДОСТАВЛЕНИЯ ПАТЕНТА,
ДИЗАЙН ИЛИ ЕГО ЧАСТЬ, СОДЕРЖАЩИЕСЯ В ДАННОМ ДОКУМЕНТЕ, РАЗРАБОТАНА ДЛЯ ГАЗПРОМА И ЕГО ПРОЕКТА И ОСТАЕТСЯ В СОБСТВЕННОСТИ ГАЗПРОМА. ВСЯ ПРОИЗВОДСТВЕННАЯ ИНФОРМАЦИЯ CPECC ИЛИ РИД, ИСПОЛЬЗУЕМОЕ В СОЗДАНИИ ИНФОРМАЦИИ О
КОНСТРУКЦИИ, СОДЕРЖАЩЕЙСЯ В НАСТОЯЩЕМ СОГЛАШЕНИИ, ОСТАЕТСЯ СОБСТВЕННОСТЬЮ CPECC.


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Содержание
Table of Contents
Contents
1 GENERAL .......................................................................................................................... 6
1.1 SCOPE AND REFERENCES ............................................................................................... 6
1.2 REFRACTORY DRAWINGS............................................................................................... 6
1.3 MATERIAL..................................................................................................................... 6
1.4 SUPPLY CONDITION AND STORAGE................................................................................ 6
1.5 SAFETY.......................................................................................................................... 7
2 PRE-INSTALLATION ........................................................................................................... 7
1.1 INTRODUCTION............................................................................................................. 7
2.2 REFRACTORY ANCHORS................................................................................................. 8
2.3 WATER.......................................................................................................................... 8
2.4 MIXING PROCEDURE ..................................................................................................... 8
3 TESTING............................................................................................................................ 9
1.1 ANCHORS...................................................................................................................... 9
3.2 CONCRETE..................................................................................................................... 9
4 WORKSHOP REFRACTORY INSTALLATION ........................................................................ 11
4.1 GENERAL..................................................................................................................... 11
4.2 RADIANT WALL PANELS (for type 30) ........................................................................... 12
4.3 RADIANT WALL (for type 70)........................................................................................ 12
4.4 RADIANT ARCH ........................................................................................................... 12
4.5 RADIANT FLOOR.......................................................................................................... 12
4.6 END TUBE SHEETS ....................................................................................................... 13
4.7 CONVECTION SECTION ................................................................................................ 13
4.8 HEADER BOXES ........................................................................................................... 13
4.9 STACK ......................................................................................................................... 13

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4.10 DOORS........................................................................................................................ 14
5 SITE REFRACTORY INSTALLATION .................................................................................... 14
5.2 RADIANT WALL (Type 30 Heaters only) ........................................................................ 14
5.3 BURNER MUFFLES ....................................................................................................... 14

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1 GENERAL
Include ASTM referenced below

Include reference to dryout procedure. Full
setails of shop dryout and site dryout
required in this separate document
1.1 SCOPE AND REFERENCES
This Refractory procedure cover engineering of insulating-refractory lining materials insulation for Type
“30” and type”70” Regeneration Gas Fired Heaters, provided by Accede Impianti Italia Project for
Amursky Gas Processing Plant
Reissue with refractory installer detail
This procedure will be later revised in accordance to specific / dedicated suggestion provided by
refractory supplier.
In addition to what is indicated here below, reference shall be made to prescriptions from API 560 latest
edition.
Before proceeding with the activities of installation of each type of insulating and or refractory lining, the
skill of involved operators shall be assured.
1.2 REFRACTORY DRAWINGS

In accordance with which
standard? API 936? API
976
To be issued
-Procedure to also be in
compliance with GOST R
53682
1.3 MATERIAL
Refractory materials supplied for this supply are the following:
Ceramic fiber blankets: Service Temperature 1260 °C d. 128 kg/m3
Bulk: CF Wool
Insulating Concrete: Very Low Weight Cast
Insulating Concrete: Low Weight Cast
Insulating Concrete: Medium Weight Cast
Ceramic Rope: Dia.5mm
Material data sheets and production test shall be performed by selected supplier in accordance to the
related inspection test plan, to be attached after finishing insulation application work.
1.4 SUPPLY CONDITION AND STORAGE
The insulating castable will be supplied in paper bags, premixed and on pallets shrink wrapped.
Ceramic fiber blankets will be supplied inside of paper boxes, on pallets shrink wrapped.
All refractory supplied materials shall be stored under covered and ventilated areas, with ambient
temperature (min.15ºC/max.30ºC) and humidity not higher of 70%.
The conventional shelf life of castable is usually one year, starting from the production date,
depending to the storage conditions, after dispersing it will be necessary to proceed to requalification
of material.
expiring? If material is beyond its shelf
life, new replacement material is expected


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The ceramic fiber blanket and ropes do not have any expiration date, but it is recommended to
storage these materials with the same caution in which the castable is stored.
Since these products react with water, the following recommendation shall be carried out:
a) Do not store pallets, loaded with refractory materials, where they are exposed to rain, snow
or where can be wetted in any other way
b) Always keep refractory materials on pallets away from wet areas. Do not place pallets
containing refractory materials in stale water.
c) Do not store pallets containing refractory materials in conditions where humidity is higher
than normal ambient conditions.
d) If bags that contain refractory materials are covered with polythene sheeting, etc., ensure
sufficient ventilation to prevent condense.

condensation
e) Do not use partially reacted concrete
f) Maximum two pallets of concrete will be placed above each other. Do not place pallets
contents ceramic fiber blanket above each other type of pallets.
1.5 SAFETY
General the regulations have included in this procedure to:
• Inform about the features and the specific risks of the place in which the staff has to work;
•
Take all the necessary precautions for the executions of the work in safety condition, especially
those expected by the activity related to CFBs and refractories;
•
Utilize a staff and suitable means for the execution of the work, considering the specific risks;
•
Adopt all the necessary protective means, using them correctly (install scaffolding, dust and
nose protection, glovers etc.)
•
All the hand tools will have to be placed in order to avoid their falling, during the works in raised
places and when they are not used kept in suitable sheaths.
2 PRE-INSTALLATION
2.1 INTRODUCTION
The purpose of this procedure is to outline the sequence and the methods to be applied for the correct
installation of refractory and ceramic fiber blankets on different parts of heater, before/after their
assembling.
It is recommended to provide skilled workers and supervision during workshop installation, whole period
of erection and at end dry-out. After installation has been completed and furnace assembled, a careful
inspection shall be carried out into heater to check the correctness of the work.
2.2 PANEL TEST
Panel Test is a Sample Test to be prepared prior to start the installation.
Before starting, test panel/s shall be prepared. Test panel/s shall be carried out by lining with refractory
steel panel/s 600 x 600 mm.

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One panel for each type of refractory material shall be prepared.
Eventually the acceptance tests will be evaluated (if any) in accordance with Chapter 3.
2.3 REFRACTORY ANCHORS
According to approved refractory drawings, selected and welded anchors, and installation refractory
activities shall be carried out after welding of anchors and bracket has been completed, controlled,
tested and steel surfaces cleaned.
For installation of Ceramic fiber blankets and castable arc stud welding anchors by gun.
For castable installation welded anchors type ”V” and “Y” could be used.
Welds Wels have to be according AWS D.1.1.
Attention: Non weld areas are indicated in refractory drawings.
2.4 WATER
a) Water temperature
Minimum water temperature will be 10°C and maximum 25°C: if temperature is not within these limits
adequate actions to cool or warm shall be taken.
The temperature and water/humidity percentage are suggested, suitable for casting preparing, from
refractory concrete material producers. Check water percentage necessary for the consistence mix.
The method in accordance with ASTM C 860 "ball in hand", this check must be done every day and
for all installation period when there are different weather condition and humidity.
b) Water quality
Water used will be drinkable water or containing a maximum of 50 ppm (50 mg/lt) of chlorides.
c) Water quantity
Concrete manufacturer specifies on the bags of the material or in the technical information sheet of
the product the best quantity of water. The quantity of added water gives the maximum structural
resistance and, therefore, it would be used as indicated.
The preliminary test, “ball in hand”, should define the proper quality of water not only for reaching the
best mechanical proprieties, but also to obtain the complete best filling of material during casting.
2.5 MIXING PROCEDURE
All equipment for mixing and handling must be thoroughly cleaned before use. Contaminants can
accelerate or retard the setting rate, resulting in difficulty in placing the material and a reduction in
quality.
Mixing water may also contain contaminants, therefore drinking quality or the cleanest possible water
must always be used.
Mixers (horizontal) with a positive blending action are recommended.

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Start putting castable into the mixer, then proceed adding the necessary quantity of water, as indicated
in issued manufacturer technical data sheet.
It’s important to calculate the exact quantity of water, using an appropriate measure and considering
the exact quantity of castable contained by the mixer.
Mix the castable and water for a period, necessary to obtain a good mixing.
3 TESTING
3.1 ANCHORS
Anchor welding shall be checked by bending and hammering test with hammer of 500 gr. About 5% of
the total number of anchors should be tested for a square meter.
3.2 CONCRETE
a) „BALL IN HANDS“ TEST
All mixture consistency will be verified with “Ball in hand” test in conformity with ASTM C860. Add
sufficient water to allow the castable to hold together in a ball when “bounced” in the palm of the hand.
• Too wet it will slump through the fingers
• Too dry the ball will break up into a crumbly mass
• This “bouncing” in the hand should impart a slight glistening to the surface of the ball of concrete,
but there should be no appreciable transfer of water and cement to the palm.
b) TEST SAMPLES
Following test type shall be carried out by lining erection Company as minimum requirements:
• Density ND Cold Crushing strength (CCS) at 815ºC as per ASTM C 133
• Bulk density (at 110ºC) as per ASTM C 134
• Permanently Linear Change (PLC) at 815ºC as per ASTM C 133
Tests to be done during installation shall be carried out for each different type of refractory material,
date and shift.
For each sample of the two first tests, 3 cubes 50x50x50mm shall be prepared and all sample cubes
shall be marked and reported.
For the PLC test, one bar 50x50x250mm shall be prepared and all sample bars shall be marked and
reported.
Preparation samples for testing: dry 18 hours in module, after that remove samples from modules
ambient air-dry additional 18 hours. Put samples in oven and dry at 110ºC for additional 12 hours. Heat
specimens according ASTM C865 to 815ºC, hold at max temperature for 5 hours, cool at max. rate of
105ºC per hour. After the oven drying procedure, density shall be reported in kg/m3.
c) HAMMER TEST


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Installed castable linings, after air dray out, shall be checked giving it light tap with a hammer of 500 gr.
For dual layer linings, the hammer tests shall be conducted on each layer after curing. Linings shall be
struck with machinist’s ball peen hammer over the entire surface using a grid pattern approximating the
following: for arch areas - 600 mm, for sidewall and floor areas - 900 mm centers. During Hammer test
sound need to be continuity equal, that have acoustic satisfactory results.
d) METHOD OF ACCEPTANCE
The test results of castable will be acceptable if compared to the data sheet of material with respect to
table acceptance.
specimen
LIMITS OF RANGE OF ACCEPTABLE RESULTS
SPECIFIED PROPERTIES AVERAGE OF SPECIMANTS INDIVIDUAL SPECIMENT
minimum maximum minimum maximum
a. Density
90% 110%
80% 120%
b. Strength
80% None
50% None
c. Linear Change
None 120%
None 150%
Records shall be taken during the preparation of samples. All tests will be carried out in accordance of
approved Refractory Inspection test plan; other test performed on samples shall be at client charge.
Voids greater than 150 x 150 mm or any soft or dry fill areas that may reduce the effective lining
thickness by more than 1/4 of the original thickness are not acceptable.
e) REPAIR PROCEDURE
- Inspection and testing requirements and acceptance/rejection criteria. Lining soundness or
“hammer test” shall be done to check any voids, soft areas and cracks.
- Defects to be repaired
Voids greater than 150x150mm, any soft or dry fill areas that may reduce the effective lining
against the nominal required thickness (-0 / + ½” ). Areas containing cracks wider than 1.5mm,
or areas showing random cracking of about 1.5mm width and spaced closer than 300mm.
- Repair of defective areas
Single layer lining or "back-up" of multi-layer linings showing defective areas found after curing,
shall be chiseled out and reapplied.
Multi-layer lining. Defective areas found in the "facing" after curing shall be removed to the
insulating "back-up" material, and the "facing" concrete reapplied as long as retained anchors
and backup are damage/defect free.
- Repair method
right angle
Remove the concrete defective area at small angle to the shell and at least around three
anchors. The periphery of any repair shall be located midway between studs.

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Cut-out should be cleared of all loose concrete, and adjacent material must be wetted before new
concrete is applied.
This activity should be carried out by qualified staff, that is able to recommend solutions and to explain
possible reparations of the refractory concrete and/or brick / shape.
f) CURING
Curing is important to avoid insulating casting hardening for 48 hours after installation, evaporation of
water is essential to binder to develop the whole mechanical resistance. The curing process should
start immediately after initial setting, when the lining surface has set hard enough to permit impinging
spray water to washing out the surface cement.
For multi-layer lining, the surface of the first layer must be dry in order to prevent the absorption of water
from upper layer. All time joint between two layers will be staggered according refractory drawing
details.
diffrentiate between
Curing could be executed covering the casting with wet bags or with polythene sheets.
shop dryout and
final site dryout
g) DRY-OUT
Dry-out is important to bring refractory lining to a suitable condition for the working phase of plant. The
process shall eliminate water coming from two sources: one is water added to make the pouring of
castable and the other is chemically combined with setting mortar.
To perform correctly dry-out activities folow strictly instruction from dry-out diagram.
h) SAFETY
General these regulations has to:
· Inform about the features and the specific risks of the place in which the staff has to work;
· Take all the necessary precautions for the executions of the work in safety condition,especially those
expeted by the activity related to CFBs and refractories;
· Utilize a staff and suitable means for the execution of the work, considering the specific risks;
· Adopt all the necessary protective means, using them correctly (instal scaffolding, dust and nose
protection,glovers etc.
· All the hand tools will have to be placed in order to avoid their falling, during the works in raised
places and when they are not used kept in suitable sheaths.
4 WORKSHOP REFRACTORY INSTALLATION
4.1 GENERAL
All refractory installation work shall be divided in:
Workshop Ceramic fiber blanket and Refractory installation
Site installation final Ceramic fiber

(see section 5)

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4.2 RADIANT WALL PANELS (for type 30)
shell
Fix Radiant wall panel in horizontal stabile position. Control all installed anchors, clean shall plate
surface and paint 3mm wet of Antiacid Paint. After dry paint, start with installation of Ceramic fiber
blankets, One after the other, always overlapping.and staggering them. Layers have to be installed in
vertical (related to final position) direction from Top to Bottom.
Attention: Last layer shall be installed with surplus for overlapping; left, right and top side will be
temporary closed back in package.
After finishing installation of CFB it is important to protect installed CFB from damages, dust and rain
with plastic sheets, best solution would be immediate packing in protected package according to
Transport drawings.
4.3 RADIANT WALL (for type 70)
Fix Assembled Radiant in vertical stabile position. Control all installed anchors, clean shall plate surface
and paint 3mm wet of Antiacid Paint. After dry paint, start with installation of Ceramic fiber blankets,
One after the other, always overlapping.and staggering them. Layers have to be installed in vertical
(related to final position) direction from Top to Bottom.
In case it is no possible carry out this operation in vertical position, the same can be carried out in
horizontal position taking care to distribute properly the blankets, without any damage to the anchors
and to the alongside previous installed blankets.
4.4 RADIANT ARCH
All Radiant Arch panels fixed on horizontal position. Control all installed anchors, clean shall plate
surface and paint 3mm wet of Antiacid Paint. After dry paint, start with installation of Ceramic fiber
blankets, One after the other, always overlapping.and staggering them. Layers have to be installed in
vertical (related to final position) direction from Top to Bottom.
Attention: Last layer shall be installed with surplus for overlapping; left, right and top side will be
temporary closed back in package.
4.5 RADIANT FLOOR
Pay attention that the proper space for Burner Muffle and floor peepholes have been properly prepared
and protected to avoid leakage of castable in said areas so as not to obstruct the clear installation of
Burner Muffle and floor peepholes.
Clean floor surface from dust and rubbish. Install all around Floor CF blankets for refractory expansion,
make formwork for shattering floor surface according to refractory drawing. Cast first layer, first floor
areas, than second floor areas, etc.
define first/second floor

shuttering
area

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When refractory is finished curing, start casting second layer of refractory using staggered system.
Clean Floor and close Access door.
4.6 END TUBE SHEETS
Refractory lining in End tube sheet in horizontal position.
4.7 CONVECTION SECTION
Lower convection module:
Rotate module with installed End tube sheets (reinforce Convection box.), so the lining surface will be
in horizontal position. Suitable formworks shall be provided internally, fixed formwork to install anchors
and lining refractory on first layer.
When first layer of refractory lining is duly hardened, formworks will be reinstalled in new form for
corbellings and cast refractory. Control position of corbeling according to coil position on End tube
sheet.
Lining refractory thickness 50 mm on connections to Header boxes at the end.
Cast section of refractory having dimension not more 1 x 1 m. Pay attention to staggering of joints
between the layers also in vertical direction.

add note about how joints are finished.Clarify if
butted refractory/refractory OR gap in specifican
locations for expansion.
Attention:
-Give details of how/when expansion joints are
finished: i.e. open OR filled with c.f rope
For all refractory installation rough and porous refractory surface is correct, surface trowel only with
wood plank.
Upper Convection module (Type 30 Heaters Only)
Rotate Upper Convection module upside down, that breeching in horizontal position. Carefully block
the breeching in order to avoid any movements during refractory installation. Proceed with installation
of the refractory material using the same staggered system already described for radiant and lower
convection module. Assure gap for insert CFB on connection area between two convection modules.
4.8 HEADER BOXES
For all Header boxes panels is required Low Weight Cast to be installed in horizontal position.
4.9 STACK
The installation of the refractory material has to be done with the sections of stack in horizontal position,
and on by rolling them, if the geometric shape of the piece allows, as necessary to cover the whole
surface to be lined by casting. Prepare the formwork following the shape of the piece.
Follow the same suggestions given above (for the other parts of the heater like damper and instrument
connection) about the staggering of zones to be lined.


0008

Page: 14 of 14
NON LICENSED UNITS
If the section to be lined is circular, formwork shall extend for an angle not larger than 120 degrees.To
be checked taking into account the diameters.
Installation of castable inside type 70 Heaters stacks could be carried out in vertical position due to
short internal diameter. Matter has to be studied and suggested by refractory supplier.
Casting sections with dimensions not more than 1m x 1m.
add note about how joints are finished.Clarify if

butted refractory/refractory OR gap in specifican
locations for expansion.
-Give details of how/when expansion joints are
finished: i.e. open OR filled with c.f rope
4.10 DOORS
Floor access door, Breeching access door and Inspection Convection door should be lined by castable
and positioned after curing or at site ( to be decided).
Observation doors and Explosion doors in radiant, Tube removal doors in arch shall be lined by using
meanwhile , Explosion door , convection Lancing door and stack Access door cast with CF blankets.
For all items make the following steps and

sequence clear:
Install material; inspect installation; prepare
for shipment (shop dryout for castable
5 SITE REFRACTORY INSTALLATION
material); pack after final inspection
5.1 RADIANT WALL (Type 30 Heaters only)
Carefuly erect radiant wall panels,do not damage installed CFBs.
After finishing erection all Radaint wall panels, control dimension and verticality, tighten bolts, install
internal scaffolding.
Between installed CFBs we have gap of 60 mm (if necessary with wood press and assure this gap) for
internal seal welding vertical connection two radiant panels.
After seal welding connection, clean and re-touch up of Antiacid Paint. After drying installed paint start
install CFBs.
5.2 BURNER MUFFLES
Clean floor surface from dust and rubbish.
Install burner muffle blocks and connect with mortar. Install Burners.
Around burner muffle blocks install CF blanket according Burner’s drawings for expansion.
Include (or reference separate document) section

giving details or of shop storage, shipping storage
and site storage. Durations should be repeated here.
Accede must identify and coordinate the installation
of material with deliverable to avoid expiry of material

0055-CPC-ACI-4.0.0.00.CPC-THM - PT-0008 - A1 - EN - 2 Refractory Installation Procedure

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By:Dzifa Kodjokuma,KOD39371,21/08/2018

НАЗВАНИЕ ПРОЕКТА: ПРОЕКТ ПО СТРОИТЕЛЬСТВУ АМУРСКОГО

PROJECT TITLE: AMURSKY GAS PROCESSING PLANT

PROJECT NON LICENSED UNITS

НОМЕР КОНТРАКТА / AGPZ-900/0055

НАЗВАНИЕ ДОКУМЕНТА: ПРОЦЕДУРА УСТАНОВКИ ОГНЕУПОР

DOCUMENT TITLE: REFRACTORY INSTALLATION PROCEDURE

ПОСТАВЩИК / SUPPLIER: ACCEDE IMPIANTI ITALIA

ЗАКАЗ НА ПОКУПКУ / PURCHASE ORDER (PO): P2AM-4-0501

НОМЕР ДОКУМЕНТА ПОСТАВЩИКА / SUPPLIER

НОМЕР РЕДАКЦИИ ПОСТАВЩИКА / SUPPLIER 1

ДАННЫЙ ДОКУМЕНТ ЯВЛЯЕТСЯ КОНТРОЛИРУЕМЫМ.

ДАННЫЙ ДОКУМЕНТ ВЫПОЛНЕН НА ДВУХ ЯЗЫКАХ.

A1 23-JUL-2018 IFR AM GDP FV

Номер Контракта / Contract Number :

ПРОЦЕДУРА УСТАНОВКИ ОГНЕУПОР

ПРОЕКТ ПО СТРОИТЕЛЬСТВУ АМУРСКОГО ГАЗОПЕРЕРАБАТЫВАЮЩЕГО

AMURSKY GAS PROCESSING PLANT PROJECT

NON LICENSED UNITS

ПЕРЕЧЕНЬ РЕДАКЦИЙ / REVISION DESCRIPTION SHEET

A1 ISSUED FOR REVIEW

ПЕРЕЧЕНЬ УТОЧНЕНИЕ / HOLDS LIST

ПОДРЯДЧИКОМ. ОПИСАНИЕ УТОЧНЕНИЕ

UTILITY MODEL OR DESIGN.

Номер Контракта / Contract Number :

Номер документа / Document Number:

ПРОЕКТ ПО СТРОИТЕЛЬСТВУ АМУРСКОГО ГАЗОПЕРЕРАБАТЫВАЮЩЕГО

AMURSKY GAS PROCESSING PLANT PROJECT

NON LICENSED UNITS

СТРАНИЦА ПОДПИСЕЙ: SIGNATURE PAGE:

подрядчиком: ПОДПИСЬ / SIGNATURE Contractor:

(Должность) ПОДПИСЬ / SIGNATURE (Position)

Менеджер по ИМЯ, ФАМИЛИЯ / FIRST NAME, LAST NAME Approved by

инженерному ПОДПИСЬ / SIGNATURE Engineering

проектированию - МИП: Manager-EM

Утверждаю: ИМЯ, ФАМИЛИЯ / FIRST NAME, LAST NAME Approved:

(Должность) ПОДПИСЬ / SIGNATURE (Position)

(Должность) ПОДПИСЬ / SIGNATURE

Разработано: ИМЯ, ФАМИЛИЯ / FIRST NAME, LAST NAME

(Должность) ПОДПИСЬ / SIGNATURE

UTILITY MODEL OR DESIGN.

Номер Контракта / Contract Number :

Номер документа / Document Number:

ПРОЕКТ ПО СТРОИТЕЛЬСТВУ АМУРСКОГО ГАЗОПЕРЕРАБАТЫВАЮЩЕГО

AMURSKY GAS PROCESSING PLANT PROJECT

NON LICENSED UNITS

1.1 SCOPE AND REFERENCES ............................................................................................... 6

1.2 REFRACTORY DRAWINGS............................................................................................... 6

1.4 SUPPLY CONDITION AND STORAGE................................................................................ 6

2.2 REFRACTORY ANCHORS................................................................................................. 8

2.4 MIXING PROCEDURE ..................................................................................................... 8

4 WORKSHOP REFRACTORY INSTALLATION ........................................................................ 11

4.2 RADIANT WALL PANELS (for type 30) ........................................................................... 12

4.3 RADIANT WALL (for type 70)........................................................................................ 12

4.4 RADIANT ARCH ........................................................................................................... 12

4.5 RADIANT FLOOR.......................................................................................................... 12

4.6 END TUBE SHEETS ....................................................................................................... 13

4.7 CONVECTION SECTION ................................................................................................ 13

4.8 HEADER BOXES ........................................................................................................... 13

4.9 STACK ......................................................................................................................... 13

UTILITY MODEL OR DESIGN.

Номер Контракта / Contract Number :

ПРОЦЕДУРА УСТАНОВКИ ОГНЕУПОР