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IRM-PU-4786-G

Installation of Monolithic Refractory Linings in Vessels and Lines

Application: Onshore

This document is the confidential property of Chevron U.S.A. Inc. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of Chevron U.S.A. Inc. Neither the whole nor any part of this document may be reproduced, stored in any retrieval system, or transmitted in any form or by any means (electronic, mechanical, reprographic, recording, or otherwise) without the prior written consent of Chevron U.S.A. Inc.

Rev. Date Description Author Technology Leader

E 5/2008 General Revision K. Young K. Young

F 11/2009 General Revision K. Young K. Young

G 08/2012 General Revision K. Young K. Young

Installation of Monolithic Refractory Linings in Vessels and Lines IRM-PU-4786-G


Contents 1.0 Scope............................................................................................................................................... 5

2.0 References ...................................................................................................................................... 5

2.1 Purchaser Documents......................................................................................................... 5 2.2 Industry Codes and Standards ........................................................................................... 6 2.3 Conflict Resolution .............................................................................................................. 6

3.0 Acronyms ........................................................................................................................................ 6

4.0 General Requirements ................................................................................................................... 7

4.1 Governing Documents ........................................................................................................ 7 4.2 Materials .............................................................................................................................. 7 4.3 Storage and Handling of Refractory Material ...................................................................... 9

5.0 Installation of Anchors and Other Metallic Components ........................................................... 9

5.1 Welder Qualification ............................................................................................................ 9 5.2 Surface Preparation .......................................................................................................... 10 5.3 Anchors ............................................................................................................................. 10 5.4 Metal Fiber Reinforcement – Installation .......................................................................... 10

6.0 Installation of Refractory Linings ............................................................................................... 11

6.1 General Requirements ...................................................................................................... 11 6.2 Weather Protection ........................................................................................................... 12 6.3 Surface Preparation .......................................................................................................... 12 6.4 Thickness Tolerances ....................................................................................................... 13 6.5 Cast Installation of Hydraulically Bonded Castable Linings .............................................. 13

7.0 Crew Prequalification .................................................................................................................. 14

7.1 General Requirements ...................................................................................................... 14 7.2 Gun-Installed Castables .................................................................................................... 15 7.3 Cast Castables .................................................................................................................. 15

8.0 Crew Inspection and Testing ...................................................................................................... 16

8.1 Crew Prequalification Inspection – Gunning ..................................................................... 16 8.2 Testing of Crew Prequalification Samples ........................................................................ 16 8.3 Anchor Inspection of Field Lining ...................................................................................... 16 8.4 Hold Points ........................................................................................................................ 17

9.0 Production Sampling ................................................................................................................... 17

9.1 General Requirements ...................................................................................................... 17 9.2 Field Curing of Production Samples ................................................................................. 18

10.0 Ambient Temperature Curing of Castable Linings ................................................................... 19

10.1 Curing Procedures for Hydraulically Bonded Castable Linings ........................................ 19 10.2 Inspection of Installed Linings ........................................................................................... 20



11.0 Controlled High Temperature Dryout ......................................................................................... 20

11.1 General ............................................................................................................................. 20 11.2 New Linings ....................................................................................................................... 21 11.3 Repaired Areas in Old or Previously Dried Linings ........................................................... 21 11.4 Additional Requirements for Dryout .................................................................................. 22

12.0 Repair of Defective Areas ........................................................................................................... 22



SUMMARY OF CHANGES 1. Revised technical content is indicated by change bars in the right margin.

2. Deleted, moved, and combined requirements, as well as editorial changes, are listed below.

Rev F Rev G Description Type of Change

Sect. 5.1 Sect. 4.3.1 Items 4 and 5 removed Delete

Sect. 6.3.1 Sect. 5.3.1 Items 3 and 4 combined Combined items

Sect. 8.3 Sect. 7.3 Item 2a removed Delete

Sect. 10.2.2 Sect. 9.2.2 Item 4 removed Delete

Sect. 10.2.2 Sect. 9.2.2 Table 2 removed Delete

Sect. 11.1 Sect. 10.1 Last sentence in Items 4 removed Delete

Sect. 12.4.1 Sect. 11.4.1 Item 3 removed Delete

Sect. 12.4.2 – Section removed Delete



1.0 Scope 1. This specification defines the minimum technical requirements for installing, curing,

inspecting, and testing monolithic refractory linings in vessels and piping installed by gunning or casting.

2. These linings are normally at least 2 inches thick.

3. This specification does not cover the following:

a. Installation of linings using vibration cast or self-leveling refractories (refer to IRM-PU-4788).

b. Installation of thin erosion-resistant linings or cyclone linings (refer to IRM-SU-4787).

c. Purchase of monolithic refractory materials (refer to IRM-SU-4785).

d. Installation of fired heater linings (refer to IRM-SU-4789).

2.0 References 1. The following documents are referenced herein and are considered part of this specification.

2. Unless otherwise specified in Section 2.1 or 2.2, use the latest edition of the referenced documents.

2.1 Purchaser Documents IRM-SU-4785 Purchasing Specification - Monolithic Refractories

IRM-SU-4787 Installation of Thin Erosion-Resistant Refractory Linings

IRM-PU-4788 Installation of Self-Leveling and Vibration-Cast Refractory Linings

GC-N1268 Monolithic Refractories Required Properties (Sheet 1) Monolithic Refractories Recommended Brands (Sheet 2)

GD-N1269 Installation Details for Monolithic Refractory Linings Thicker Than 1-Inch

GD-N1271 Sample Boxes for Refractory Materials Qualification Crew Prequalification and Production Sampling



2.2 Industry Codes and Standards American Petroleum Institute (API)

STD 936 Refractory Installation Quality Control—Inspection and Testing Monolithic Refractory Linings and Materials

ASME International (BPVC)

Boiler and Pressure Vessel Code (BPVC)

Section VIII, Division 1Rules for Construction of Pressure Vessels, (Paragraph UW-32 Cleaning of Surfaces to be Welded)

Section IX, Qualification Standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators (Paragraphs QW-181.2 Performance and QW-462.4 [b] Fillet Welds in Plate - Performance)

ASTM International

A276 Standard Specification for Stainless Steel Bars and Shapes

A479/A479M Standard Specification for Stainless Steel Bars and Shapes for Use in Boilers and Other Pressure Vessels

A743/A743M Standard Specification for Castings, Iron-Chromium, Iron-Chromium-Nickel, Corrosion Resistant, for General Application

A820 Standard Specification for Steel Fibers for Fiber-Reinforced Concrete

C309 Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete

The Society for Protective Coatings (SSPC)

SP-3 Power Tool Cleaning

SP-7 (NACE No. 4) Brush-Off Blast Cleaning

2.3 Conflict Resolution Any conflict between this specification and other instructions shall be submitted to Purchaser representative for resolution prior to the start of any work where the particular material or procedure in conflict will be used.

3.0 Acronyms MSDS—Material Safety Data Sheets



4.0 General Requirements

4.1 Governing Documents 1. The refractory manufacturer shall supply a compliance data sheet that lists property

guarantee values for refractory materials to be used.

a. The guarantee values shall meet or exceed the values listed in GC-N1268.

b. The compliance datasheet shall conform to API 936.

2. The refractory manufacturer’s installation instructions shall be part of this specification.

3. Prior to the start of work, refractory installation Supplier shall prepare and submit written installation procedures for acceptance by Purchaser.

4. The accepted procedures shall be part of this specification and, at a minimum, shall include the following:

a. Material safety data sheets (MSDSs) for all refractory materials to be used.

b. Installation procedures for each type of refractory material, including the following:

1.) Type of anchor.

2.) Amount of water for casting.

3.) Pre-damp water for gun mixes.

4.) Amount of metal fiber to be added.

5.) Mixing time.

6.) Tempering time, if applicable.

7.) Placement of equipment.

8.) Surface preparation.

c. Installation schedule for tracking each individual refractory installation.

d. Curing and dryout schedule.

e. Quality control plan.

5. Purchaser shall provide the refractory installation Supplier with project documents.

4.2 Materials

4.2.1 Refractory Material

1. Physical and chemical properties of the refractory material shall meet the values given on the compliance data sheet.



2. For testing purposes, physical and chemical properties of the refractory material shall meet or exceed manufacturer’s guarantee values.

3. Refractory material shall be prequalified in accordance with IRM-SU-4785.

4.2.2 Metallic Components

1. Installation Supplier shall select metallic components based on the maximum hotface temperature expected as shown in GD-N1269.

2. Anchors and studs of austenitic stainless steel shall be supplied in fully solution-annealed condition after the bending process, per ASTM A276, Condition A.

3. Anchors and other metallic components installed under this specification shall be tested to ensure compliance with the specification for alloy, style, and size.

4. Minimum sampling for ensuring compliance shall be 1 per 1000 anchors of each design.

4.2.3 Independent Anchors

1. Independent anchors for single- and multi-layer linings shall conform to GD-N1269.

2. Chain link and wire mesh anchoring systems shall not be used.

3. Tip caps shall be required for “vee” anchors.

4. Hooked anchors and steer horns shall not require caps.

5. Caps shall extend 0.5 inches (13 mm) down the tine and shall be composed of rubber or plastic 0.03 to 0.05 inches (30 to 50 mils) thick.

6. Length of the tines of the anchors shall differ by 0.5 inches (13 mm).

7. For linings 2 inches (51 mm) or less in thickness, the longest anchor tip shall be 0.5 inches (13 mm) from the hotface.

8. For lining layers greater than 2 inches (51 mm) in thickness, the longest anchor tip shall be 1 inch (25 mm) from the hotface.

9. Anchor material chemistry shall conform to ASTM A479.

10. Anchors for two-component linings shall be in accordance with GD-N1269.

11. Other independent anchoring systems for refractory linings may be proposed by refractory installation Suppliers and shall be subject to acceptance by Purchaser.

4.2.4 Metal Fiber Reinforcement

Metal fibers for applications with hotface temperatures below 1500° F (815.5 °C) shall be stainless steel Type 304 (ASTMA 743/A743M), and shall meet the following requirements:

1. Fibers shall be 0.020 inch (0.5 mm) diameter by 1 inch (25 mm) long, made by a “melt-extraction” process (ASTM A820/A820M Type III), or corrugated fibers manufactured from slit sheets (ASTM A820/A820M Type II).



2. Proposals to use other alloys or metal types shall be submitted to Purchaser’s representative for acceptance.

4.3 Storage and Handling of Refractory Material

4.3.1 Moisture Protection

1. Refractory material shall be protected from moisture during shipping, handling, and storage.

2. Refractory material shall be stored on an elevated ventilated platform protected by a weatherproof covering above and on all sides, and arranged so that water cannot come into contact with material or bags.

3. Refractory material shall not be stored outdoors.

4.3.2 Water Contaminated Materials

1. Bags of material showing evidence of water contamination shall be rejected prior to use, regardless of the date of the prequalification (or requalification) testing.

2. Individual containers of refractory material containing lumps resulting from moisture penetration shall be discarded.

4.3.3 Shelf Life

1. Refractory material not used within 4 months of prequalification testing shall be re-qualified before installation and shall meet the original material requirements specified for this application.

2. After retesting, the material shall be considered qualified for an additional 3 months, after which time it shall be qualified again and used within 3 months.

3. Requalification of material shall be allowed only until the material reaches manufacturer’s published shelf life. Material exceeding manufacturer’s shelf life shall be discarded.

4.3.4 Handling Requirements

Refractory material shall be handled carefully during storage and transfer to minimize damage to the pallet plastic wrap and individual containers.

5.0 Installation of Anchors and Other Metallic Components

5.1 Welder Qualification Welders shall be qualified in accordance with BPVC Section IX, Paragraphs QW-181.2 and QW-462.4(b).



5.2 Surface Preparation 1. Surface shall be prepared for anchor welding.

2. Loose rust, loose scale, and other foreign matter shall be removed from surfaces to which anchors are to be welded per BPVC Section VIII Paragraph UW-32.

3. Abrasive blasting to SSPC SP7 or NACE 4 standards, or power tool cleaning to SSPC SP3 standard shall be acceptable.

4. Oil and grease shall be removed by appropriate methods.

5.3 Anchors

5.3.1 General

1. Anchor pattern, orientation, and spacing for one- and two-component linings shall be as shown in GD-N1269.

2. During layout of anchor locations, center punch marks (showing where anchors are to be installed) shall be encircled in soap stone to make the marks easier to see. Grease pencils shall not be acceptable.

3. Vee anchors shall be welded per GD-N1269 (GD-N1269 lists recommended welding consumables and preheat requirements).

4. Stud welding of anchors shall not be allowed.

5.3.2 Anchor Welding Inspection Hold Point

1. Completion of anchor welding shall constitute an inspection hold point.

2. Refractory material shall not be installed without written notice of acceptance by the inspector of anchor installation.

5.4 Metal Fiber Reinforcement – Installation 1. When metal fibers are used, refractory installation Supplier shall ensure that fiber is

uniformly distributed in the refractory castable.

a. Fibers added in the field shall be added after the refractory has been placed in the mixer but before addition of water.

b. Fibers shall be introduced as a rain of individual fibers through a vibrating screen to prevent clumping of the fibers.

2. For gunned linings, fiber shall be added at a rate of 2 percent by weight of fiber for each batch of refractory material.

3. For cast linings, fiber shall be added at a rate of 3 percent by weight of fiber for each batch of refractory material.



6.0 Installation of Refractory Linings

6.1 General Requirements 1. The mix temperature shall follow manufacturer’s recommendations. If manufacturer’s

recommended mix temperature is not available, mix temperature shall be between 60°F (15°C) and 80°F (27°C).

a. The dry material temperature shall be adjusted to obtain recommended mix temperature. The temperature of the dry material shall usually range from 50°F to 90°F (10°C to 30°C).

b. The temperature of the water used for mixing shall be adjusted to obtain the desired mix temperature. The water temperature shall usually range from 40°F to 80°F (4°C to 27°C).

2. Water used for mixing refractory material shall be clean, potable, and shall include no more than 50 ppm chlorides.

3. Mix water Supplier shall supply a recent certificate of analysis.

4. For wetting of fibers in metal fiber-reinforced linings or to attain the required consistency for casting during hot weather, the maximum amount of water used in casting applications shall not exceed the water used in the materials prequalification test samples for the respective batch of castable material.

5. Refractory materials shall be mixed to the consistency required by manufacturer.

6. With the exception of metal fibers, no additives shall be added to the mix in the field.

7. Mixers, guns, conveyors, and other equipment and tools shall be thoroughly cleaned prior to use. The equipment shall be cleaned at each shift change and more often if needed.

8. Castable refractory material shall be installed by casting, vibration casting, pump casting, nozzle mix gunning, or wet gunning.

Note: Installation by vibration casting or pump casting is detailed in IRM-PU-4788.

a. “Gunning grade” products shall be used for gun application.

b. “Casting grades” shall be used for cast installations.

c. Handpacking shall only be used for small areas where the refractory cannot be cast or gunned.

9. In multi-layer linings, anchors for the facing layer shall be clean and free of backup refractory material before the installation of the next layer.

10. Refractory-lined equipment shall not be moved or rotated until the refractory has cured.

11. Equipment lined with hydraulic-bonded castable shall not be moved or rotated for a minimum of 24 hours after installation of the refractory material.



6.2 Weather Protection Hydraulically-bonded castables shall be installed and cured only when ambient temperatures at the installation area are between 50°F (10°C) and 90°F (32°C), unless precautions stated in Section 6.2.1 or 6.2.2 are taken.

6.2.1 Cold Weather

The following cold weather protection procedures shall be initiated when ambient temperatures are below or are expected to fall below 50°F (10°C) during the installation of hydraulically bonded castables:

1. Castables shall be stored at 50°F (10°C) to 90°F (32°C) for 48 hours prior to use.

2. When the shell or metal temperature is below 50°F (10°C), the interior and exterior of the area to be lined shall be insulated or heated prior to and while the refractory is being placed, and shall be maintained at 60°F (16°C) or above for at least the first 48 hours after placement.

a. Monolithic refractory linings shall not be allowed to freeze before they are dried out.

b. Live steam shall not be used for heating.

3. Warm water shall be used to raise the temperature of the mix above 60°F (16°C).

4. Refractory mixing, handling, and preparation areas shall be enclosed, heated, and weatherproofed.

6.2.2 Hot Weather The following hot weather protection procedures shall be initiated when the ambient temperature is above 90°F (32°C) during the installation of hydraulically bonded castables:

1. When the shell or metal temperature exceeds 90°F (32°C), the exterior of the area to be lined shall be cooled by water spray, shading, or both prior to and while the refractory material is being placed.

2. Cold or iced water shall be used to reduce the temperature of the mix to between 60°F (16°C) and 70°F (21°C) to prevent premature setting. No solid ice particles shall be present in the mix.

3. It shall also be possible to reduce the mix temperature by storing the dry refractory castables in an air conditioned area prior to use.

4. During hot weather installation, the material mixing and handling areas shall be shaded from the sun.

6.3 Surface Preparation 1. Prior to refractory installation, metal surfaces shall be free of rust, dirt, loose debris, grease,

and oil.



2. Before beginning refractory installation, the surface and work area shall be cleaned and prepped to ensure that the lining installation can proceed without danger of incorporating dirt, debris, or dehydrated material into the lining.

3. Refractory material placed over or against improperly cleaned surfaces shall be rejected.

4. Completion of cleaning prior to refractory installation shall constitute a hold point. Refractory material shall not be installed until Purchaser’s authorized inspector accepts the surface preparation.

6.4 Thickness Tolerances 1. For single-component gunned linings and for the hot face layer of multi-component linings,

the final installed thickness shall be the design thickness minus (−) zero inch, plus (+) 1/4 inch (6 mm).

2. Tolerances for the backup lining in a two-component system shall be minus (−) 1/4 inch (6 mm), plus (+) zero inch.

3. Tolerances for cast linings shall be plus or minus (±) 1/4 inch (6 mm) of the design thickness.

4. Offsets of matching cast pieces shall not exceed 1/16 inch (1.6 mm).

5. For gunned linings that incorporate metal shrouds, thickness tolerance shall be minus (−) 0 inch, plus (+) 1/4 inch (6 mm).

6.5 Cast Installation of Hydraulically Bonded Castable Linings

6.5.1 General Requirements

1. Water content used to mix castable refractory linings shall be kept at or near the levels used for samples preparation during material prequalification.

a. Installation Supplier’s prequalification panel preparation shall be used to determine the actual range of water content for each type of material at jobsite conditions.

b. Amount of water used to cast the material shall be within plus or minus (±) 5 percent of the amount used in the prequalification mock-up.

c. Castable manufacturer’s recommended water ratio shall not be exceeded.

2. For cast installations of hydraulically bonded refractory linings, a horizontal paddle-type mixer shall be used for mixing.

6.5.2 Forms

1. Forms shall be thoroughly cleaned and waterproofed prior to use.

2. Forms shall be sufficiently strong to support the wet castable and shall be essentially watertight.

3. Forms shall be left in place for a minimum of 24 hours after placement of the castable refractory.



6.5.3 Gunned Installation of Hydraulically Bonded Castable Linings

1. Pneumatic gun application shall start at the lowest elevation and proceed upward to minimize the inclusion of rebound material.

2. When possible, material shall be installed in “bands” 5 to 6 feet (152 to 183 cm) high.

3. Depth gauges of the proper size, shot boards, or both shall be used to ensure that the lining is installed at the correct thickness.

4. When interruptions of more than 30 minutes occur during the installation of a layer of castable, or at the discretion of the inspector, the castable shall be cut perpendicular to the hot face where it has been installed to full thickness and at a point midway between anchors. The edge shall be scored after cutting and thoroughly wetted before installation of the adjacent lining.

5. Gunning of refractory lining shall be on vertical walls or on the overhead.

a. No gunning shall be done in the down-hand position below 30 degrees from horizontal, the 4 o’clock, or the 8 o’clock position (see GD-N1269).

b. Bottom sections of horizontal piping and vessels shall be cast or rotated prior to gunning.

6. Rebound and loose material shall be removed from the surface of a completed band before proceeding with the next band.

a. Adjacent anchors shall be cleaned off continuously during installation, usually by the nozzleman’s assistant.

b. No rebound material shall be allowed to accumulate at any point where the lining has not already been installed.

c. Rebound material shall be removed and discarded to prevent its inclusion in the lining.

d. Reuse of rebound material shall be absolutely prohibited.

7. Minimum diameter of piping or vessel for gunning shall be 40 inches (102 cm) unless accepted by Purchaser.

7.0 Crew Prequalification Crew prequalification shall be Supplier’s responsibility.

7.1 General Requirements 1. Crew prequalification testing shall be undertaken at least one week prior to actual jobsite

refractory installation to allow time for curing and laboratory testing of prepared specimens.

2. For preparation of samples, the crew shall use the refractory installation Supplier’s written installation procedures accepted by Purchaser.



3. Refractory anchors, metal fibers, and the method of mixing and installation used for the test panels shall be the same as specified on project drawings for the actual refractory lining.

4. In the event of failure to pass qualification tests, the crew, procedure, or both shall be changed and retested.

a. For individual installers, retesting shall be by consent of Purchaser.

b. Only one retest shall be allowed.

7.2 Gun-Installed Castables 1. Supplier shall qualify each team for each material gunned, defined as one nozzleman plus the

gun operating team.

a. Nozzlemen shall be qualified by shooting one 2-foot by 2-foot (60-cm by 60-cm) panel of each material to be used.

b. Thickness of the panel shall match job requirements.

c. Each nozzleman shall pass this test prior to commencing work.

d. Test panels shall be done with actual jobsite equipment using the longest hose length that will be used for the job to equal the pressure drop on the actual job.

e. Panel shall be oriented in a 45-degree overhead position.

2. Refractory installer shall provide the test panel box with anchors as required.

a. Test panel box shall be constructed so that the back can be removed for refractory inspection without damaging the refractory.

b. Test panel box is defined in drawing GD-N1271.

3. Each sample shall be tagged with the following information:

a. Name of nozzleman

b. Name of gun operator

c. Material used

d. Batch and pallet number

e. Date and time prepared

7.3 Cast Castables 1. Personnel responsible for installing refractory by casting procedures shall be qualified by

preparing test panels, specimens, or both per the requirements of this section.

2. If the castable is to be cast, the sample panel box shall be prepared with the same refractory, anchors, and fiber additions as required by the installation.



3. Panels shall be constructed so that the backs can be removed without damaging the sample.

4. Each installer shall prepare a test panel that shall be tested and accepted before the installer is allowed to work on the project.

8.0 Crew Inspection and Testing

8.1 Crew Prequalification Inspection – Gunning 1. After the prequalification panels have been completed per Sections 7.2 and 7.3 and have

cured, the panel(s) shall be inspected to ensure the following:

a. Refractory has been installed around anchors properly.

b. There are no obvious laminations, voids, or junctions between separate batches.

c. Reinforcing fibers, when used, are randomly distributed throughout the lining.

d. Rebound has not been trapped in the lining (gunning).

2. Acceptance of the nozzleman and crew shall be based on the following:

a. Visual inspection of their installation method.

b. Destructive examination of panels.

c. Physical test results from samples as described in Section 8.2.

8.2 Testing of Crew Prequalification Samples 1. Testing shall be performed by a qualified laboratory accepted by Purchaser.

2. Testing shall be witnessed by an authorized agent of Purchaser.

3. Specimens cut from the prequalification panels shall be dried and tested per requirements in IRM-SU-4785, and shall be performed by a qualified laboratory accepted by Purchaser.

4. Testing shall be witnessed by an authorized agent of Purchaser. Unsatisfactory test results shall be cause for rejection.

8.3 Anchor Inspection of Field Lining 1. Inspector shall verify the qualification of welders in accordance with Section 5.1.

2. Anchors and other metallic components installed under this specification shall be tested to ensure compliance with specification for alloy, style, and size.

3. Minimum sampling shall be 1 per 1000 anchors of each design.

4. Installed anchors shall be subjected to 100-percent visual and hammer testing to ensure that they are fully welded and properly spaced.

5. Anchors shall also be checked for proper configuration.



6. Anchors displaying evidence of incomplete welding or undercutting shall be re-welded or replaced as directed by Purchaser’s inspector, at Supplier’s expense.

7. Particular care shall be taken to ensure that anchors are clean and set to the specified height.

8.4 Hold Points 1. The following shall constitute hold points:

a. Completion of anchor installation.

b. Cleaning of lining surface prior to refractory installation.

c. Crew prequalification.

2. Work shall not proceed until Purchaser’s authorized inspector accepts work at each hold point.

9.0 Production Sampling

9.1 General Requirements 1. Supplier shall collect production samples daily during the refractory installation.

2. For gunned installations, Supplier shall take one sample set per nozzleman, per shift, per material installed.

3. For cast installations, Supplier shall take one sample set per mixing station, per shift, per material installed.

4. Samples shall be collected so that the sample is representative of the installed lining.

5. If material is installed by gunning, the sample collection wire basket shall be hung on the wall adjacent to where the nozzleman is working.

a. Basket shall be 12 inches (30 cm) by 12 inches (30 cm) with a depth of either 4 inches (10 cm) or the lining thickness, whichever is greater.

b. Nozzleman shall fill the basket without changing the water content or pressure and without changing relative position of gunning on the wall.

Note: A typical sample box is shown in GD-N1271.

6. If materials are prepared for installation by mechanical mixing and casting, the sample shall be collected from a mixer load of material that is to be installed in the equipment.

a. If material thus prepared will be installed by ramming, the sample shall be placed into the individual specimen molds using the same equipment and technique as the actual installation.



b. For cast samples, a shoebox mold shall be used as shown in GD-N1271.

Note: See Section 9.2.2 for sample requirements.

7. Samples shall be cured in the same manner as the refractory lining.

8. Refractory installation Supplier shall be responsible for supplying required molds, baskets, and sample boxes for testing.

9. A log shall be maintained by refractory installation Supplier detailing locations where samples were taken, pertinent information regarding sample preparation, and the operating parameters at the time of sample collection such as the following:

a. Material used

b. Batch and pallet number

c. Ambient temperature

d. Water content

e. Mixing time

f. Names of preparers

10. A map of the installation shall show areas installed, and shall indicate individuals and shifts responsible for each installation.

9.2 Field Curing of Production Samples

9.2.1 General Requirements

1. Production samples shall be allowed to cure under the ambient conditions of the installation area for 24 hours.

2. Exposed surfaces shall be completely coated with a curing compound that conforms to the requirements of ASTM C 309 within one hour of installation.

3. After the onsite ambient air cure, the production samples shall be forwarded to an accepted laboratory for testing.

9.2.2 Testing of Production Samples

1. Required testing, number of test specimens per sample, and sizes of specimens for each type of refractory shall be per Table 1 (material types are defined in GC-N1268).



Table 1: Monolithic Refractory Required Testing and Number of Test Specimens, for One Sample Set

MATERIAL Types Per GC-N1268

Test Specimens Dimensions, inch Dimensions, mm

A, B, C, D 2 for erosion test 1 for linear change 3 for density and compressive strength

4-1/2 x 4-1/2 x 1 plate 2 x 2 x 9 bar 2 x 2 x 2 cube

114 x 114 x 25 50 x 50 x 114 50 x 50 x 50

C 1 for porosity (when specified) 1 workability for plastic materials

2 x 2 x 9 bar 50 x 50 x 114

E, F, G, H, I 1 for linear change 3 for density and compressive strength

2 x 2 x 9 bar 2 x 2 x 2 cube

50 x 50 x 114 50 x 50 x 50

A, B, C, D 2 for erosion test 1 for linear change 3 for density and compressive strength

4-1/2 x 4-1/2 x 1 plate 2 x 2 x 9 bar 2 x 2 x 2 cube

114 x 114 x 25 50 x 50 x 114 50 x 50 x 50

2. Testing procedures for refractory materials cut from panels or from cubes, bars, and plates shall be per the requirements of IRM-SU-4785.

3. The data obtained shall meet or exceed the values listed on manufacturer’s compliance data sheet.

4. If a production sample fails to display the required physical properties, then a retest shall be performed on a second sample taken from the same area represented by the failed sample. Failure of a retest sample shall be cause for rejection of the installed lining.

10.0 Ambient Temperature Curing of Castable Linings

10.1 Curing Procedures for Hydraulically Bonded Castable Linings 1. The lining surface shall be coated with a colored membrane curing compound that meets the

requirements of ASTM C 309 within one hour of refractory placement.

a. Brand name and description of curing compound shall be submitted to Purchaser representative for acceptance prior to refractory installation.

b. Wax-based sealers shall not be permitted.

2. For a minimum of 24 hours after placement, the refractory lining and surface to be lined shall be maintained at a temperature greater than 50°F (10°C).

3. When feasible, refractory temperature shall be maintained at greater than 80°F (27°C).

4. Installed refractory linings shall not be allowed to freeze before they are dried out.

5. Ends of castable-lined pipe shall be sealed with an impermeable membrane, such as polyethylene sheeting.



10.2 Inspection of Installed Linings 1. Purchaser’s authorized inspector shall witness all phases of the refractory installation and

testing.

2. After ambient curing, the following shall occur:

a. Inspector shall perform a visual examination and hammer sounding over 100 percent of the surface of the cured refractory linings after the linings have set for 24 hours.

b. Hammer soundings shall be made by striking the surface on 1-foot maximum centers with a 12-ounce ball peen or similar hammer.

c. Voids, rebound pockets, or otherwise defective areas larger than 6 square inches (152 square millimeters), greater than 1/2 inch (12.7 millimeters) deep, or both shall be repaired in accordance with 12.0 of this specification as directed by Purchaser’s inspector.

d. For all installation techniques, inspection of construction “joints” shall be performed to ensure proper installation of new material against old or freshly set material.

11.0 Controlled High Temperature Dryout Previously dried linings shall not be put in service at heat-up rates exceeding 100°F (60°C) per hour.

11.1 General 1. Dryout of monolithic refractory linings shall begin within 2 weeks of the refractory

installation.

2. Refractory manufacturer’s recommended dryout procedure shall be followed.

3. If these requirements conflict with what is possible onsite, resolution shall be by mutual agreement among castable manufacturer, refractory installation Supplier, and Purchaser representative.

4. Prior to dryout of refractory, the refractory installation Supplier shall submit detailed procedures that describe the following for thermocouples:

a. Number and location.

b. Installation method.

c. Those used for ramp-up and ramp-down temperature rates.

d. Those used for controlling hold times and temperatures.



11.2 New Linings 1. Before dryout begins, refractory installation Supplier shall install sufficient temperature

measuring devices to monitor gas temperature throughout the lined area to be dried, particularly near the burner areas and at the gas exit of the lined areas.

2. Thermocouples shall also be provided on the steel casing as directed by the on-site inspector.

a. Duplicate thermocouples shall be installed at each critical location.

b. Thermocouple junctions shall be on the refractory lining and steel casing surfaces.

3. The dryout schedule in the refractory installation Supplier’s written installation procedures accepted by Purchaser shall be followed.

4. Heat up rate specified in the dryout schedule shall not exceed 100°F (60°C) per hour.

5. If a multi-component lining is used, the dryout schedule for each component shall be determined as follows:

a. Based on the slower of the two schedules.

b. Considering the insulating effect of the hotface layer on the backup layer.

6. Cold-wall refractory-lined components shall be dried by the application of heat from the inside only.

7. Proper air circulation for the removal of moisture shall be provided during the dryout process.

8. When steaming during dryout is witnessed, no increase in temperature shall be made until steaming subsides.

11.3 Repaired Areas in Old or Previously Dried Linings 1. Patched areas in old or previously dried out linings no larger than 5 square feet

(1.5 square meters) shall be put into service after initial cure without dryout.

2. Patched areas larger than 5 square feet (1.5 square meters) but less than 30 square feet (9 square meters) shall be dried out after initial cure by limiting the heat-up rate to no more than 50°F (30°C) per hour until the gas temperature in the vicinity of the repair reaches 600°F (310°C).

a. This temperature shall be held for 1 hour for each inch of lining thickness, after which time normal heat up can continue.

b. Local heating shall be used as an alternative.

3. Major refractory replacement involving areas larger than 30 square feet (9 square meters) or areas exceeding 20 percent of the total lining installation shall be cured and dried according to the procedures for a new lining.



11.4 Additional Requirements for Dryout

11.4.1 Hydrotesting or Flushing

1. Hydrostatic testing or flushing of castable-lined vessels and piping shall require acceptance of the Purchaser representative.

2. For equipment that has been hydrostatically tested since dryout, the lining shall be dried according to Section 11.2.

11.4.2 Hammer and Visual Inspection – After Dryout

1. After high temperature dryout has been completed, inspector shall repeat hammer and visual testing procedures in accordance with Section 10.2.

2. Surface spalls greater than 6 inches (150 mm) in area, 1/2 inch (12.7 mm) deep, or both, and cracks larger than 1/16 inch (1.6 mm) wide shall require repair.

3. Repairs shall be performed in accordance with Section 12.0.

12.0 Repair of Defective Areas Areas requiring repairs shall be brought to the attention of the project engineer or project manager, who shall have final decision of repairs required.

1. For single-layer linings or the backup layer of multi-layer linings, the defective areas shall be chiseled out completely to the shell and shall be reapplied per GD-N1269.

2. For dual-layer linings, the defective areas found in the facing layer shall be removed to the insulating backup material and the facing castable lining reinstalled.

a. GD-N1269 shall be referenced for minimum required replacement area and edge preparation.

b. For repair of two-component linings, the working lining repair shall be greater than 3 inches (76 mm) larger in diameter all around than the insulating layer so that repair joints are not aligned.