eg-4789c - installation of fired heater...

Chevron Specification IRM-EG-4789-C

INSTALLATION OF FIRED HEATER REFRACTORIES

January 2001 of 26

SPECIFICATION IRM-EG-4789-CINSTALLATION OF FIRED HEATER REFRACTORIES



of 26 January 2001

CONTENTS

1.0 SCOPE.........................................................................................................................................4

2.0 GENERAL REQUIREMENTS..................................................................................................4

PART 1 - MATERIALS OTHER THAN REFRACTORY CERAMIC FIBER FOR FIREDHEATERS .............................................................................................................................................5

3.0 MATERIALS ..............................................................................................................................5

3.1 Castable Refractory Material.........................................................................................................53.2 Insulating Firebrick (IFB)..............................................................................................................63.3 Brick and Shapes (other than IFB).................................................................................................63.4 Mortar ..........................................................................................................................................63.5 Metallic Components.....................................................................................................................63.6 Block Insulation ............................................................................................................................8

4.0 STORAGE AND HANDLING OF REFRACTORY MATERIAL...........................................8

4.1 Moisture Protection.......................................................................................................................84.2 Water Contaminated Materials ......................................................................................................94.3 Shelf Life......................................................................................................................................94.4 Handling Requirements .................................................................................................................9

5.0 INSTALLATION OF ANCHORS AND OTHER METALLIC COMPONENTS...................9

5.1 Welder Qualification .....................................................................................................................95.2 Surface Preparation.......................................................................................................................95.3 Vee Anchors for Castable Linings .................................................................................................95.4 Installation Requirements - Metal Fiber Reinforcement ................................................................105.5 Installation Requirements - Anchorage System for IFB Lining......................................................105.6 Anchor Welding Hold Point.........................................................................................................10

6.0 INSTALLATION OF CASTABLE LININGS IN FIRED HEATERS ...................................10

6.1 General Requirements .................................................................................................................106.2 Weather Protection......................................................................................................................116.3 Surface Preparation.....................................................................................................................126.4 Thickness Tolerances ..................................................................................................................136.5 Cast Installation of Hydraulically Bonded Castable Linings .........................................................136.6 Gunned Installation of Hydraulically Bonded Castable Linings.....................................................14

7.0 INSTALLATION OF INSULATING FIREBRICK AND FIRECLAY BRICK....................14

7.1 Insulating Firebrick .....................................................................................................................147.2 Installation of Fireclay Brick .......................................................................................................15



January 2001 of 26

8.0 AMBIENT TEMPERATURE CURING AND HIGH TEMPERATURE DRYOUT OFCASTABLE LININGS.........................................................................................................................16

8.1 Ambient Temperature Curing ......................................................................................................168.2 Controlled High Temperature Dryout ..........................................................................................16

9.0 CREW PREQUALIFICATION ...............................................................................................17

9.1 General Requirements .................................................................................................................179.2 Castable Refractory Installation Crew .........................................................................................17

10.0 PRODUCTION SAMPLING....................................................................................................18

11.0 INSPECTION AND TESTING ................................................................................................19

11.1 Hold Points .................................................................................................................................1911.2 Crew Prequalification Inspection .................................................................................................1911.3 Anchor Inspection .......................................................................................................................2011.4 Inspection of Installed Castable Linings .......................................................................................2011.5 Testing........................................................................................................................................2111.6 Inspection of Firebrick and Special Shape Lining Installations .....................................................21

12.0 REPAIRS...................................................................................................................................22

12.1 Castable Refractory Linings ........................................................................................................22

PART 2 - REFRACTORY CERAMIC FIBER LININGS FOR FIRED HEATERS ............................23

20.0 GENERAL REQUIREMENTS................................................................................................23

21.0 MATERIALS ............................................................................................................................23

21.1 Anchors ......................................................................................................................................2321.2 Vapor Barrier Coating.................................................................................................................2421.3 RCF Products .............................................................................................................................24

22.0 STORAGE AND HANDLING OF RCF LINING MATERIALS...........................................25

23.0 ANCHOR INSTALLATION....................................................................................................25

24.0 VAPOR BARRIER INSTALLATION.....................................................................................26

25.0 RCF INSTALLATION .............................................................................................................26

30.0 ATTACHMENTS .....................................................................................................................26



of 26 January 2001

1.0 SCOPE

This specification covers the installation requirements for refractory material in fired heaters andboilers. These materials include:

• Castable, hydraulic setting refractory

• Insulating Firebrick (IFB)

• Firebrick and special shapes

• Refractory Ceramic Fiber (RCF)

2.0 GENERAL REQUIREMENTS

2.1 Standards and Codes

The following standards and specifications, latest editions, are part of this specification:

American Petroleum Refractory Installation Quality Control Guidelines — InspectionInstitute (API) RP 936 and Testing Monolithic Refractory Linings and MaterialsSSPC SP-3 "Power Tool Cleaning" orSSPC SP-7 "Brush Blasting" (NACE #4)ASME VIII Paragraph UW-32 "Surface Preparation for Welding"ASME IX Paragraph QW-181.2 and QW-462.4(b) "Welder Qualification"ASTM C-155 "Classification of Insulating Firebrick"ASTM C-909 "Dimensions of a Modular Series of Refractory Brick and

Shapes"ASTM C-133 "Concrete Aggregates"

2.1.1 Procedures

2.1.2 Governing Documents

2.1.3 Refractory lining materials, testing, installation and inspection shall comply withthe requirements of API 936 except where modified by either Chevron StandardSpecifications or Chevron Project Specifications and Drawings.

2.2 The refractory manufacturer's installation instructions are part of this specification. Anyconflict between this specification and other instructions shall be submitted to theCompany representative for resolution prior to the start of any work where the particularmaterial or procedure in conflict will be used.



January 2001 of 26

2.3 Prior to the start of any work, the installation Contractor shall prepare and submit writteninstallation procedures for approval. The approved procedures are part of thisspecification. The procedures as a minimum shall include:

• Materials Safety Data Sheets (MSDS) for all refractory materials to be used

• Installation procedures for each type of refractory material, including type of anchor tobe used, amount of water (also predamp water for gun mixes), amount of metal fiberto be added, mixing time, tempering time if applicable, placement of equipment

• Installation schedule for tracking each individual refractory installation.

• Curing and dryout schedule

• Brand name of curing compound to be applied to castable surface

• Type of mortar to be used for brick, type and thickness of mortar joints, bonding ofbrick walls

• Quality control plan

2.4 The Company will provide the installation Contractor with Project Documents.

PART 1 - MATERIALS OTHER THAN REFRACTORY CERAMIC FIBER FOR FIREDHEATERS

This part of the specification covers refractory materials other than RCF and installation methods usedwith these other materials. Inspection and testing of castables and certain types of brick (used in firedheaters) are also included.

3.0 MATERIALS

3.1 Castable Refractory Material

3.1.1 Standard Drawing GB-N1268 shows various types of monolithic refractories thatare acceptable. The physical and chemical properties of the refractory materialshall, as a minimum, meet the values of GB-N1268.

3.1.2 All refractory material shall be prequalified in accordance with IRM-EG-4785.

3.1.3 L-H-V-type castables shall not be used for these applications.



of 26 January 2001

3.2 Insulating Firebrick (IFB)

3.2.1 Only commercial IFB with a 2300°F or higher temperature rating shall be used.Refer to ASTM Specification C 155-70.

3.2.2 The manufacturer's quality control data for the IFB selected shall be supplied tothe Company's representative for review. If there are concerns about one or morephysical properties, the Company will send a small representative sample to anindependent laboratory for reheat and compressive strength testing (preferably,before shipment to the jobsite).

3.2.3 Dimensions of the IFB shall meet the requirements of ASTM C 909-81.Dimensional tolerances shall be ± 1/16 inch.

3.3 Brick and Shapes (other than IFB)

3.3.1 Only super-duty firebrick shall be used in the construction of bridge and dividerwalls.

3.3.2 Dimensions of firebrick used in the construction of walls shall meet therequirements of ASTM C 909-81. Dimensional tolerances shall be ± 1/16 inch onall dimensions. Brick not meeting these requirements will be rejected at thejobsite.

3.3.3 Dimensions of special shapes shall meet the following requirements:

1. ± 1/16-inch tolerance on dimensions < 36 inches.2. ± 1/8-inch tolerance on dimensions > 36 inches.

3.4 Mortar

Air-set mortars shall have adequate refractory properties and be chemically compatiblewith the brick being laid.

3.5 Metallic Components

3.5.1 General Requirements

3.5.1.1 The installation Contractor shall select metallic components on the basisof 1) the maximum long-term exposure temperature to which any part ofthe component will be exposed and 2) sulfur content of the fuel, as shownin Tables 1A and 1B of GD-N1262. These tables also cover metallurgyrequirements for RCF anchorage.

3.5.1.2 Anchors and studs of austenitic stainless steel shall be supplied in thefully solution-annealed condition.



January 2001 of 26

3.5.2 Independent Anchors for Castable Linings

3.5.2.1 Acceptable independent anchors for single and two-component castablelinings are shown in Detail 1 of GD-N1269.

3.5.2.2 For thick, single-component linings, the independent anchor height shallbe approximately 75% of the lining thickness. In all cases, refractorycover over the anchor tip shall be 1 inch minimum. In other words, for a4-inch thick lining, the anchor height should be approximately 3 inches.

3.5.2.3 Anchors for two-component linings shall be in accordance with Detail 2of GD-N1269.

3.5.2.4 Other independent anchoring systems for refractory linings may beproposed by fired heater suppliers and refractory installation Contractorsand are subject to approval by the Company.

3.5.3 Anchorage Systems for IFB Linings

3.5.3.1 If the anchorage system will be designed by the installation Contractor,the type of anchors, hangers and/or anchorage systems used to hold IFBlinings (both walls and arches) in place shall be clearly detailed onproject drawings and approved by the Company before the job is started.

3.5.3.2 Locations and/or exact spacings for individual anchors shall be clearlydefined on project drawings.

3.5.4 Support Shelves

Complete details on structural members used as support shelves for IFB and otherlinings shall be shown on the project drawings and approved by the Companybefore the job is started. The details shall include:

• Type of metal

• Dimensions

• Spacing

• Attachment method

• Slits for thermal expansion, if required.



of 26 January 2001

3.5.5 Metal Fiber Reinforcement

3.5.5.1 Metal fibers shall be used to reinforce linings in areas where mechanicalabuse or thermal shock is a design consideration.

3.5.5.2 Metal fibers shall be stainless steel Type 302 or 304 and shall meet thefollowing requirements:

• Gunned Refractory Installation. Fibers shall be 0.020-inchdiameter by 1 inch long, made by a "melt-extraction" process, withchemical requirements per ASTM A 743/A 743M.

• Proposals to use other alloys or metal types shall be submitted to theCompany representative for approval.

3.6 Block Insulation

3.6.1 Block insulation shall be used as back-up material (to IFB or other refractory)only in fired heaters and furnaces where sulfur content of the fuel is relatively low(< 0.2%).

3.6.2 Block insulation shall be rated by ASTM procedures for a minimum temperatureof 1800°F, well above anticipated hot face temperatures.

4.0 STORAGE AND HANDLING OF REFRACTORY MATERIAL

4.1 Moisture Protection

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

4.1.2 Refractory material shall be stored indoors on dry concrete slabs unless approvedotherwise by Company.

4.1.3 If refractory material must be stored out of doors, the material shall be set onconcrete slabs or compacted shell, stone, or other hard durable surfaces which aresloped to ensure water drainage away from the storage area.

4.1.4 Refractory material shall not be stored outdoors on grass, soil, or any softuncompacted surfaces or in an area where water has, or may collect or stand.



January 2001 of 26

4.1.5 If refractory material is stored outdoors, the factory shrinkwraps shall be leftundamaged and, in addition, the pallets shall be covered completely with waterresistant tarpaulins free from holes, tears, or other defects which may prevent thecovers from protecting the pallets from moisture. The tarpaulins shall be stretchedor sloped to prevent water from standing or collecting on top or around the bottomof the storage area.

4.2 Water Contaminated Materials

4.2.1 Any material or pallets of material showing evidence of water contamination shallbe rejected prior to use, regardless of the date of the prequalification (orrequalification) testing.

4.2.2 Any individual container of refractory material containing lumps resulting frommoisture penetration shall be discarded.

4.3 Shelf Life

Refractory material not used within six months of prequalification testing shall berequalified before installation in accordance with the requirements of Section 3.0 ofSpecification IRM-EG-4785, Purchasing Specification - Monolithic Refractories.

4.4 Handling Requirements

All refractory material shall be handled carefully during storage and transfer to minimizedamage to the pallet shrinkwraps and individual containers.

5.0 INSTALLATION OF ANCHORS AND OTHER METALLIC COMPONENTS

5.1 Welder Qualification

Welders shall be qualified in accordance with ASME IX Section QW-181.2 andQW-462.4(b).

5.2 Surface Preparation

The surface shall be prepared per Standard Drawing GD-N1269.

5.3 Vee Anchors for Castable Linings

5.3.1 Vee anchor pattern, orientation, and spacing of anchors for one- and two-component linings shall be as shown on Detail 4 of GD-N1269.

5.3.2 During layout of anchor locations, the center punch marks (showing whereanchors are to be installed) shall be encircled in crayon beyond the affected area tomake the marks easier to see.



of 26 January 2001

5.3.3 Anchors shall be welded per Detail 5 of Standard Drawing GD-N1269. Table 2on the drawing lists recommended consumables and preheat requirements. SeeSection 11.0 for inspection requirements.

5.4 Installation Requirements - Metal Fiber Reinforcement

5.4.1 Castable linings in the convection section of fired heaters and process furnacesshall contain metal fibers.

5.4.2 When metal fibers are used, the fiber shall be uniformly distributed in therefractory castable. Fibers added in the field shall be added after the refractory hasbeen placed in the mixer but before the addition of water. Fibers shall beintroduced as a rain of individual fibers through a vibrating screen to preventclumping of the fibers. Wire mesh for the screen box should have ½-inch (square)nominal openings.

5.4.3 For insulating and semi-insulating castables (the types used in fired heaters), 5pounds of stainless steel fiber shall be used per 100 pounds of dry castable.

5.5 Installation Requirements - Anchorage System for IFB Lining

5.5.1 The design of IFB walls and arches and anchorage systems for these installationsshall be clearly shown on project drawings. The IFB anchor shall not be attached(or welded) directly to the shell.

5.5.2 Angle clips, nuts, or other shell attachments (anchor connectors to hold the coldend of the IFB anchor) shall be carefully positioned and welded to the shell as perproject drawings.

5.6 Anchor Welding Hold Point

Welded anchor and/or anchor connector installation constitutes a hold point. Therefractory cannot be installed without prior inspection of these components.

6.0 INSTALLATION OF CASTABLE LININGS IN FIRED HEATERS

6.1 General Requirements

6.1.1 Hydraulically bonded castables shall be installed and cured only when ambienttemperatures at the installation area are between 50°F and 95°F.

6.1.2 All water used for mixing refractory material shall be clean, potable, and have nomore than 200 ppm chloride, and shall be within the specified temperature range(50°F and 95°F).



January 2001 of 26

6.1.3 To compensate for wetting of fibers in metal fiber reinforced linings or to attainthe required consistency for casting during hot weather, the maximum amount ofwater used in casting applications shall not exceed 1.03 times the water used in thematerials prequalification test samples for the respective batch of castablematerial.

6.1.4 Additives (other than metal fiber in some cases) shall not be added to the castablein the field.

6.1.5 Mixers, guns, conveyors and all other equipment and tools shall be thoroughlycleaned prior to use. The equipment shall be cleaned at each shift change and moreoften if needed.

6.1.6 Castable refractory material shall be applied by casting, handpacking, orpneumatic gun application. "Gunning grade" products shall be used for gunapplication. "Casting grades" shall be used for cast installations.

6.1.7 For cast or gunned refractory applications, shell nozzle necks shall be cast orhandpacked first to within 1 inch of the inside of the shell to which they areattached. The remaining 1 inch shall be cast or gunned monolithically with theshell.

6.1.8 Refractory anchors and surfaces on which refractory material will be applied shallbe checked for cleanliness and for compliance with other requirements of thisspecification prior to refractory installation.

6.1.9 In multi-layer linings, anchors for the hot face layer shall be clean and free of allback-up refractory material before application of the hot face layer.

6.1.10 Refractory-lined equipment shall not be moved or rotated until the refractory hastaken an initial set. Equipment lined with hydraulic bonded castable shall not bemoved for a minimum of 24 hours.

6.2 Weather Protection

6.2.1 Hydraulically bonded castables shall be installed and cured only when ambienttemperatures at the installation area are between 50°F and 95°F unless theprecautions stated in Paragraphs 6.2.2 and 6.2.3 are taken.



of 26 January 2001

6.2.2 Cold Weather. When hydraulically bonded castables are being installed, thefollowing cold weather protection procedures shall be initiated when ambienttemperatures are below or expected to fall below 50°F:

6.2.2.1 Castables shall be stored at 50°F to 90°F for 48 hours prior to use.

6.2.2.2 When the shell or metal temperature is below 50°F, the interior andexterior of the area to be lined shall be insulated or heated prior to andwhile the refractory is being placed, and shall be maintained at 60°F orabove for at least the first 48 hours after placement. The proceduresgiven in Section 7.4.2 of this specification need to be carefully followedif linings are allowed to freeze. Live steam shall not be used for heating.

6.2.2.3 Warm water may be used to raise the temperature of the mix above60°F.

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

6.2.3 Hot Weather. When hydraulically bonded castables are being installed, thefollowing hot weather protection procedures shall be initiated when the ambienttemperature is above 95°F:

6.2.3.1 When the shell or metal temperature exceeds 95°F, the exterior of thearea to be lined shall be cooled by water spray and/or shading prior toand while the refractory material is being placed.

6.2.3.2 Cold or iced water shall be used to reduce the temperature of the mix tobetween 60°F and 70°F to prevent premature setting. No solid iceparticles shall be present in the mix.

6.2.3.3 The mix temperature may also be reduced by storing the dry refractorycastables in an air conditioned area prior to use.

6.2.3.4 During hot weather application, the material mixing and handling areasshall be shaded from the sun.

6.3 Surface Preparation

6.3.1 All surfaces not cleaned per Section 5.2 shall be cleaned to meet SSPC SP-7 orNACE #4 standards for abrasive blasting or SSPC SP-3 for power tool cleaning.New metal surfaces that are free of rust, dirt, grease, or oil are acceptable for mostlinings covered under this specification.



January 2001 of 26

6.3.2 Before beginning any part of refractory installation, the surface and work areashall be cleaned and prepped to ensure that the lining installation can proceed in anorderly and workmanlike manner without danger of incorporating dirt, debris ordehydrated material into the lining. Refractory material placed over or againstimproperly cleaned surfaces will be rejected.

6.3.3 Completion of cleaning prior to refractory application constitutes a hold point.Refractory material shall not be installed prior to written sign-off by the inspector.

6.4 Thickness Tolerances

6.4.1 For single-component gunned linings and for the hot face layer of multi-componentlinings, the final installed thickness shall be the designed thickness - zero inch, +1/4 inch.

6.4.2 Tolerances for the back-up lining in a two-component system shall be -1/4 inch, +zero inch.

6.4.3 Tolerances for cast linings (e.g., floor) shall be + 1/4 inch of the design thickness.

6.4.4 For gunned linings which incorporate metal shrouds, thickness tolerance shall be -zero inch, + 1/4 inch.

6.4.5 For boilers, the proper distance between the boiler tubes and the refractory hotface shall be maintained to assure the proper heat flux ratio.

6.5 Cast Installation of Hydraulically Bonded Castable Linings

6.5.1 The water content used to mix castable refractory linings shall be kept at or nearthe levels used for sample preparation during material prequalification. Theinstallation Contractor's prequalification panel preparation shall be used todetermine the range of water content for each type of material. At no time is thecastable manufacturer's recommended water ratio to be exceeded.

6.5.2 A paddle-type mixer shall be used.

6.5.3 The size of individual mix batches shall be controlled such that the total durationbetween mixing of castable with water and placement does not exceed 20 minutes.Mixing time shall not exceed 6 minutes.

6.5.4 An internal vibrator shall be used to facilitate compaction of wet-mixed castable,when feasible.



of 26 January 2001

6.6 Gunned Installation of Hydraulically Bonded Castable Linings

6.6.1 Nozzle-mix guns shall be used with maximum predampening in a paddle mixer.Permission to use wet-mix guns must be obtained in writing from the Company'srepresentative.

6.6.2 When gunning insulating castables, application (hose) pressure shall be adjustedsuch that excessive compaction of lightweight aggregates does not occur.

6.6.3 Pneumatic gun application shall start at the lowest elevation and proceed upwardto minimize the inclusion of rebound material. When possible, apply the materialin "bands" that are 5 to 6 feet high.

6.6.4 Depth gages of the proper size and/or shot boards shall be used to ensure that thecastable is applied to the correct thickness.

6.6.5 When interruptions of more than 30 minutes' duration occur in the application of alayer of castable, or at the discretion of the inspector, the castable shall be cutperpendicular to the hot face where it has been applied to full thickness and at apoint midway between anchors. The edge shall be scored after cutting andthoroughly wetted before application of the adjacent lining.

6.6.6 Gunning of castable refractory shall be on vertical walls or overhead. No gunningshall be done in the downhand position below 45 degrees from the horizontal. SeeDetail 6 of GD-N1269.

6.6.7 All rebound and loose material shall be removed from the surface of a completedband before proceeding with the next band. Adjacent anchors shall be cleaned offcontinuously during application. No rebound material shall be allowed toaccumulate at any point where the lining has not already been applied. All reboundmaterial shall be removed and discarded to prevent its inclusion in the lining.Reuse of rebound material is absolutely prohibited.

6.6.8 Gunned refractory linings shall be installed full thickness in individual sections notexceeding 35 square feet to avoid lining laminations.

7.0 INSTALLATION OF INSULATING FIREBRICK AND FIRECLAY BRICK

7.1 Insulating Firebrick

The installation Contractor shall ensure that qualified journeymen brickmasons will installthe brick and/or shapes.

7.1.1 IFB walls and arches shall be installed in accordance with the project drawings.

7.1.2 IFB walls shall be properly anchored and shall be straight and level.



January 2001 of 26

7.1.3 Dipped mortar joints shall be used. The joints shall be less than 1/16 inch thickand normally about 1/32 inch thick.

7.1.4 Expansion joints shall be carefully formed and of the proper width.

7.1.5 Horizontal expansion joints on high walls shall be provided in front of andimmediately below each (structural member) support shelf.

7.1.6 Excess mortar shall not be used to level an individual row of IFB.

7.1.7 All IFB cuts shall be made with a masonry saw and a bonded silicon carbideblade.

7.1.8 Hook anchors shall be inserted carefully into IFB such that the brick is notcracked or damaged.

7.1.9 If block insulation is used as a back-up layer, IFB shall be pressed tightly againstthe block thereby minimizing air gaps and voids. Insulating cement shall be usedto fill large gaps between blocks and/or small, broken areas in the block insulation.

7.1.10 If insulating castable is used as a back-up layer, a small space shall be providedaround the hook anchor within the castable layer such that the IFB wall is free toexpand and contract slightly.

7.1.11 For installations with castable used as back-up insulation, no more than six brickcourses shall be laid before castable is installed into the space between brick andcasing.

7.2 Installation of Fireclay Brick

7.2.1 Floors. Fireclay brick (regular firebrick) shall be laid flat (2 ½ inches thick) ontop of the insulation castable that lines the floor of the heater. High duty firebrickshall be used. These firebrick shall be laid without mortar. A small perimeter gapshall be left between these floor brick and the walls for thermal expansion and thegap shall be filled with 6-lb. ceramic fiber blanket.

7.2.2 Divider or bridge walls shall be erected in accordance with the project drawings.Requirements for these walls follow:

7.2.2.1 Divider walls shall be straight (plumb) and level.

7.2.2.2 Troweled mortar joints shall be used. These joints shall be between 1/32inch and 1/16 inch thick.

7.2.2.3 Approved methods of bonding (e.g., alternate header and stretchercourses) shall be used for the thicker (lower) parts of the wall.



of 26 January 2001

7.2.2.4 Excess mortar shall not be used to level an individual row of brick.

7.2.2.5 Brick having one or more dimensions outside of the ± 1/16 inch toleranceshall be rejected. The thickness dimension is most critical.

7.2.2.6 Large 9-inch straight bricks shall be used to break joints.

7.2.2.7 Workable (vertical) expansion joints shall be provided as per drawings.

8.0 AMBIENT TEMPERATURE CURING AND HIGH TEMPERATURE DRYOUT OFCASTABLE LININGS

8.1 Ambient Temperature Curing

8.1.1 Curing of semi-insulating and insulating castables (types use in fired heaters) shallbe accomplished by application of a colored membrane curing compound appliedto the castable surface within one hour of placement. Brand name and descriptionof curing compound shall be submitted for approval to the Company'srepresentative. Wax-based sealers are not permitted.

8.1.2 In lieu of curing compound, a fine water spray may be used. The surface shall bekept damp for a minimum of 24 hours after application. Spraying atapproximately 2-hour intervals is required. Water spraying shall not start until thelining has taken its initial set.

8.1.3 For a minimum of 24 hours after placement, the refractory lining and surface to belined shall be maintained between 50°F and 90°F. When feasible, refractorytemperature shall be maintained between 80°F and 90°F. Suitable means forheating or cooling shall be provided, if necessary. Live steam however, shall notbe used for heating.

8.1.4 Installed refractory linings shall not be allowed to freeze during placement or thecuring period. A minimum of 48 hours at temperatures >60°F is required forcuring if the lining is to be allowed to freeze before dryout.

8.2 Controlled High Temperature Dryout

This operation will normally be done at the refinery or other plant during startup of theheater.

8.2.1 Heat-up rates not exceeding 100°F/hour should be used with castable or plasticinstallations.

8.2.2 No limit on heat-up rates for ceramic fiber are imposed.



January 2001 of 26

9.0 CREW PREQUALIFICATION

Crew prequalification is the installation Contractor's responsibility.

9.1 General Requirements

9.1.1 Crew prequalification testing shall be undertaken at least one week prior to actualjobsite refractory installation to allow time for curing and laboratory testing ofprepared specimens.

9.1.2 For preparation of samples, the crew shall use the installation Contractor's writteninstallation procedures that were approved by the Company.

9.1.3 Refractory anchors, metal fibers, and the method of mixing and application usedfor the test panels shall be the same as specified on project drawings for the actualrefractory lining.

9.1.4 In the event of failure to pass this testing procedure, the crew and/or procedureshall be changed and retested. For individual applicators, retesting shall only be byconsent of Chevron. Only one retest will be allowed.

9.2 Castable Refractory Installation Crew

9.2.1 Cast or Handpacked Castables

9.2.1.1 All personnel who will install refractory by casting or handpackingprocedures shall be qualified by preparing test panels and/or specimensper the requirements of this section.

9.2.1.2 If the castable is to be cast or handpacked, the sample panel box shall beprepared with the same refractory, anchors, and fiber additions asrequired by the installation. If the installation requires a thickhandpacked lining, then the minimum test panel size shall be 18 inchessquare. The panels shall be constructed so that the backs may beremoved without damaging the sample.

9.2.1.3 Each installer shall prepare a test panel which will be tested andapproved before the worker is allowed to work on the project.

9.2.1.4 If the installation requires a thick, monolithic lining, then the specimensshall be cut from the panels and tested as per the requirements of gunnedsamples in Section 9.2.2.



of 26 January 2001

9.2.2 Gun Applied Castables

9.2.2.1 All nozzlemen shall be qualified by shooting one (1) 3-foot by 3-footpanel of each material to be used. The thickness of the panel is to matchjob requirements. Each nozzleman must pass this test prior tocommencing work. The test panel shall be done with actual jobsiteequipment at the highest elevation to be gunned on the job. The panelshall be oriented in a 45-degree overhead position.

9.2.2.2 The installation Contractor shall provide the test panel box with anchorsas required. The test panel box shall be constructed so that the back maybe removed for refractory inspection without damaging the refractory.See Detail 1 of Standard Drawing GD-N1271.

9.2.2.3 Each sample shall be tagged with the following information: Name ofnozzleman, name of gun operator, material used, batch and palletnumber, date and time prepared.

10.0 PRODUCTION SAMPLING

10.1 Contractor shall collect production samples daily during the refractory installation.

10.2 For gunned installations of Type D, E, F, G, H and I refractory, one (1) set of samples pernozzleman, per shift, per material used shall be taken.

10.3 For cast or handpacked installations of Types D, E, F, G, H and I refractory, one (1) set ofsamples per mixing station, per shift shall be taken.

10.4 The samples shall be collected in such a manner that the sample is representative of theinstalled lining.

10.5 If the materials are prepared for installation by mechanical mixing and casting, then thesample shall be collected from a mixer load of material that is to be installed in theequipment. If the material thus prepared will be installed by handpacking, hammering, orramming, then the sample shall be placed into the individual specimen molds using thesame equipment and technique as the actual installation. For cast or handpacked samplesa shoebox mold should be used as shown in Detail 5B of GD-N1271. See Section 11.5.4for Sample Requirements.

10.6 If the material is installed by gunning, then the sample collection box shall be hung on thewall adjacent to where the nozzleman is working. The nozzleman will then fill the boxwithout changing the water content or pressure and without changing relative position fromwhich he was gunning on the wall. A typical sample box is shown in Detail 4 of StandardDrawing GD-N1271.



January 2001 of 26

10.7 The installation Contractor is responsible for supplying all required molds and sampleboxes for testing.

10.8 A log shall be maintained by the installation Contractor detailing the location from whichthe samples were taken. A map of the installation shall show which areas were installed,by individuals and by shift.

10.9 The log shall detail all pertinent information regarding sample preparation and theoperating parameters at the time of sample collection, such as material used, batch andpallet number, ambient temperature, water content, mixing time, names of preparers, etc.

10.10 Field Curing of Production Samples

10.10.1 The production samples shall be allowed to cure under the ambient conditions ofthe installation area for 24 hours. Curing compound should be used.

10.10.2 After the onsite ambient air cure, the production samples shall be forwarded to theapproved laboratory for testing.

11.0 INSPECTION AND TESTING

The provisions of this section are the Company's responsibility.

11.1 Hold Points

The following items shall constitute hold points, and work shall not proceed until theCompany's authorized inspector approves the work.• Anchor installation• Cleanliness of lining surface prior to refractory installation• Crew prequalification

11.2 Crew Prequalification Inspection

11.2.1 After the prequalification panels have been completed per Sections 8.2 and 8.3 andhave set a sufficient amount of time (>12 hours) the panel(s) shall be inspected toensure:

1. Refractory has been installed around anchors properly.

2. There are no obvious laminations or junctions between separate batches.

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

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



of 26 January 2001

11.2.2 Approval of the nozzleman and crew shall be based on: 1) visual inspection oftheir installation method, 2) destructive examination of the panels, and 3) physicaltest results from samples per Section 11.5.3.

11.3 Anchor Inspection

11.3.1 Inspector shall verify that welders are qualified in accordance with Section 5.1.

11.3.2 All anchors and other metallic components installed under this specification shallbe tested to ensure compliance with specification for alloy, style, and size.Minimum sampling shall be 1 per 1000 anchors of each design.

11.3.3 All installed anchors shall be subjected to 100% visual and hammer testing toensure they are fully welded and properly spaced. Anchors shall also be checkedfor proper configuration. Anchors displaying evidence of incomplete welding orundercutting shall be rewelded or replaced as directed by Company's inspector atthe Contractor's expense.

11.3.4 Particular care shall be taken to ensure that all anchors are set to the specifiedheight, and that they are clean.

11.4 Inspection of Installed Castable Linings

11.4.1 The owner's authorized inspector shall witness all phases of the refractoryinstallation and testing and shall check frequently that the lining thickness is withintolerance.

11.4.2 Hammer and Visual Inspection - After Ambient Curing

11.4.2.1 The inspector shall perform a visual examination and hammer soundingover 100% of the surface of the cured refractory linings after the liningshave set for 24 hours. Hammer soundings shall be effected by strikingthe surface on 1-foot maximum centers with a 12-ounce ball peen orsimilar hammer.

11.4.2.2 Any voids, rebound pockets, or otherwise defective areas larger than 6square inches and/or greater than 1/4 of the lining depth shall berepaired in accordance with Section 12.0 of this specification, asdirected by the Company's inspector.

11.4.2.3 For all installation techniques, inspection of construction "joints" shallbe performed to ensure proper installation of new material against old,or freshly set material.



January 2001 of 26

11.5 Testing

11.5.1 Testing shall be performed by a qualified laboratory approved by the Company.

11.5.2 All testing shall be witnessed by an authorized agent of the Company.

11.5.3 Testing of crew prequalification samples.

11.5.3.1 The specimens cut from the prequalification panels shall be dried andtested per the requirements of Section 3.0 of IRM-EG-4785.Unsatisfactory test results are cause for rejection.

11.5.4 Testing of production samples.

11.5.4.1 Testing procedures for refractory materials cut from panels, or fromcubes, bars, and plates shall be per the requirements of Section 3.0 ofIRM-EG-4785.

11.5.4.2 The following properties shall be tested and reported:

1. Density (three 2" x 2" x 2" cubes per sample)2. Permanent linear change (one 2" x 2" x 9" bar per sample)3. Cold crushing strength (three 2" x 2" x 2" cubes per sample)

11.5.4.3 Acceptance/rejection criteria for production samples shall be based onthe prequalification requirements as shown in Standard Drawing GB-N1268.

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

11.6 Inspection of Firebrick and Special Shape Lining Installations

11.6.1 During installation, the Company's inspector and/or project engineer shall checkon the following important items:

11.6.1.1 Brick walls shall be straight, level and properly anchored.

11.6.1.2 All anchors shall be installed and the anchor system must comply withthe design drawings.

11.6.1.3 Individual rows of firebrick (and/or IFB) shall be level.

11.6.1.4 Brick shall be kept clean (and free of dust) to facilitate bonding with themortar.



of 26 January 2001

11.6.1.5 Mortar shall be chemically compatible with the brick being laid.

11.6.1.6 Thickness of mortar joints shall be held between 1/32 inch and 1/16inch.

11.6.1.7 Expansion joints shall be installed per the design drawing. They mustbe kept clean (free of debris) to allow thermal expansion movement ofthe wall (or other component).

11.6.1.8 When packed expansion joints are called for, the joints shall be filledwith suitable "packing" material per design drawing.

11.6.1.9 Proper shapes or brick shall be used for bullnose applications.

11.6.1.10 Flue gas stop baffles shall be installed around burner blocks (in walls)and at other locations as shown on the design drawing.

11.6.1.11 All individual rings in cylindrical linings shall be properly keyed.

11.6.1.12 The interior (hot face) surfaces of cylindrical linings shall be smoothand uniform. Interior dimensions of the brickwork shall be maintainedwithin prescribed tolerances. Minor variations in roundness of thecasing shall be compensated for in the thickness of the back-up layer(refractory or block insulation).

11.6.2 Final inspection shall check:

1. Tightness of the lining

2. Dimensions

3. Expansion joints

12.0 REPAIRS

All areas requiring repairs shall be brought to the attention of the project engineer or projectmanager. He shall have the final decision as to the extent of repairs.

12.1 Castable Refractory Linings

12.1.1 For one-component linings, or the back-up layer of multi-layer linings, thedefective areas shall be chiseled out completely to the shell or duct wall, and shallbe reapplied per Detail 7 of GD-N1269.

12.1.2 For two-component linings, the defective areas found in the hot face layer shall beremoved to the insulating back-up material, and the hot face layer reapplied. Referto Detail 7 of GD-N1269 for minimum required replacement area and edgepreparation



January 2001 of 26

PART 2 - REFRACTORY CERAMIC FIBER LININGS FOR FIRED HEATERS

This part of the specification covers the requirements for materials and installation of refractory ceramicfiber (RCF) linings in fired heaters.

20.0 GENERAL REQUIREMENTS

20.1 The Company will provide the following information:

• Locations within fired heater to be lined with RCF• Normal operating temperature• Maximum operating temperature• Maximum allowable shell temperature• Assumed ambient temperature• Gas velocities throughout fired heater• Type of fuel and furnace atmosphere• Any limits on RCF thickness due to furnace geometry

20.2 The installation Contractor shall provide:

• Proposed lining system method(s) and materials• RCF thickness, K factors, heat loss calculations• Written installation procedures

21.0 MATERIALS

21.1 Anchors

21.1.1 The anchor material for fired heaters burning "clean fuel" shall be chosen inaccordance with the temperature limits in Table 1A of GD-N1262. "Clean fuel" isdefined as fuel containing less than 0.5% sulfur. "Temperature" is defined as themaximum long-term exposure temperature (adjusted to reflect the gradient throughthe lining) of any part of the anchor.

21.1.2 The anchor material for fired heaters burning "dirty fuel" shall be chosen inaccordance with the temperature limits in Table 1B of GD-N1262. "Dirty fuel" isdefined as fuel containing more than 0.5% sulfur. "Temperature" is defined as themaximum long-term exposure temperature (adjusted to reflect the gradient throughthe lining) of any part of the anchor.

21.1.3 All Type 304, Type 310, RA 330, and Inconel 601 anchors shall be supplied inthe fully bright solution-annealed condition.

21.1.4 The anchor supplier shall verify the material chemistry by submitting mill testreports for all materials. Also random chemistry checks shall be made on aminimum of 3 of every 1000 of each type of anchor hardware.



of 26 January 2001

21.2 Vapor Barrier Coating

Vapor barrier coating shall be Stalastic (manufactured by Witco Corporation) or anapproved equal. Either grade of Stalastic (trowelable, 61031 or sprayable, 61036) isacceptable.

21.3 RCF Products

21.3.1 Manufacturer's data must show that the RCF to be used will shrink less than 3%at the fired heater's maximum operating temperature. Alternatively, the maximumuse temperature of the RCF shall be set 300°F lower than the manufacturer'smaximum recommended use temperature.

21.3.2 Module systems and blanket/board systems can be proposed for any hot facetemperature as long as the requirements of 21.3.1 are met. Layered blanketsystems are limited to 2000°F maximum hot face temperature in addition to thelimits of 21.3.1.

21.3.3 RCF products are limited to the following maximum gas velocities:

• Blanket: 30 ft/sec

• Modules: 60 ft/sec

• Boards and other vacuum formed shapes: 80 ft/sec

21.3.4 RCF products must have the following minimum densities:

• Layered blanket systems: 8 lb/ft3 for the top two one-inch layers (closest to thehot face), 6 lb/ft3 for one-inch thick back-up layers.

• Blanket/board systems: 10 lb/ft3 for the top 1-1/2 inch board layer, 8 lb/ft3 forany back-up blanket layers.

• Module systems: Modules shall be made from blanket with a minimum densityof 8 lb/ft3. The minimum density of the compressed module shall be 9.3 lb/ft3.

21.3.5 Maximum size of RCF materials shall be:

• Modules: 12 inches x 12 inches x thickness, unless a larger size is approvedby the Company

• Blankets: 24 inches wide x 1 inch thick unless otherwise approved

• Boards: 18 inches x 18 inches x 1-1/2 for ceilings and 18 inches x 18 inches x1-1/2 inches or 24 inches x 24 inches x 1-1/2 inches for walls.



January 2001 of 26

21.3.6 RCF rigidizers shall not be used. Sprayable RCF shall not be used unless it isspecified for repairs or veneering.

21.3.7 Only RCF mortars and cements that are recommended by the RCF manufacturershall be used.

22.0 STORAGE AND HANDLING OF RCF LINING MATERIALS

22.1 All RCF products shall be kept dry and protected from mechanical damage during thecourse of the job.

22.2 The Manufacturer's limits on shelf life of the vapor barrier coating shall be followed.

23.0 ANCHOR INSTALLATION

23.1 Module anchoring systems must be able to be preattached to the shell before moduleinstallation. No systems requiring "blind" welding shall be used.

23.2 The installation Contractor shall install the anchors in accordance with Standard DrawingGD-N1262 or GD-N1263, whichever applies.

23.3 Welder Qualification Testing

Stud welding equipment must be properly adjusted to obtain a full fillet weld around theentire stud base. At least three trial stud welds shall be made using the anchor material forthe job and a plate the same thickness as the furnace shell. These welds shall be bendtested by hitting them with a light hammer and bending them 15 degrees from vertical andback. An additional three trial welds shall be made each time welding is started, includingat the beginning of the day, after a shift change, and after a break for any other reason. Ifany welds crack, they fail the test, and an additional three welds must pass afteradjustments to the stud welding equipment are made.

23.4 Production Weld Testing

The actual production anchor welds shall be 100% hammer tested, as follows: A stud shallbe considered to have a good weld if, when the stud is hit with a light hammer it producesa ringing sound similar to that obtained when the furnace shell is struck. Any studs thatdon't produce such a sound, and any studs that bend or loosen upon hitting, shall beremoved and replaced. Care shall be used during hammer testing so that studs are notdamaged.



of 26 January 2001

24.0 VAPOR BARRIER INSTALLATION

The vapor barrier shall be installed to all surfaces beneath the RCF.

25.0 RCF INSTALLATION

The RCF material shall be installed in accordance with Standard Drawings GD-N1262 andGD-N1263, whichever applies.

30.0 ATTACHMENTS

The following attachments are part of this Specification:

GD-N1262 Details for Installation of Module Lining and Veneering for Refractory CeramicFiber Linings in Fired Heaters

GD-N1263 Details for Installation of Layered Blanket and Blanket/Board for RefractoryCeramic Fiber Linings in Fired Heaters

GB-N1268 Refractory Material Requirements

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

GD-N1271 Sample Boxes for Materials Qualification, Crew Prequalification, andProduction Sampling