BPCL Mahul Job S-05771 Doc. M51202-HE-05 Rev.

0
Capacity revamp of HGU-2 1 / 13

General specification for

refractory lining of HTER pressure shell
and connecting transfer lines
(Item no. 133-F-302)

Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be
used by or disclosed to third parties without written approval of Haldor Topsøe A/S.

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Contents

1 Scope 3
2 General 3
3 Design 3
3.1 Lining design 3
3.2 Installation procedures 3
3.3 Thermal conductivity correction 4
3.4 Gunning 4
3.5 Anchor system 4
3.6 Lining of stuffing box cone 4
3.7 Transfer line parts dry connection 4
3.8 Outline of refractory lining 4
4 Operating and design conditions 5
5 Refractory lining materials, anchors and accessories 5
5.1 High alumina firebrick (for support of cone) 5
5.2 High alumina castable (Hot face) 6
5.4 Insulating castable 6
5.5 Ceramic fibres 7
5.6 Refractory anchors 7
6 Quality control, material supply 7
7 Installation 8
7.1 General 8
7.2 Refractory installer qualifications 8
7.3 Instructions and recommendations concerning samples 8
7.4 Installation of refractory material 8
7.5 Surface preparation 8
7.6 Execution of refractory installation 9
7.7 Equipment lined in workshop prior to installation 9
8 Installation quality assurance 9
8.1 Quality control plan 9
8.2 Testing requirements 10
8.3 Photos 10
8.4 Supervision personnel 10
8.5 Protocol 11
9 Dry-out 11
10 Documentation 11
10.1 Documentation in the design phase 11
10.2 Documentation required for the material supply 12
10.3 Documentation required for site installation 12
10.4 Final documentation 12
11 Packing and marking 12
12 References 13

Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be
used by or disclosed to third parties without written approval of Haldor Topsøe A/S.

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1 Scope
This specification covers the requirements for supply of materials and the installation of the
refractory lining in a Haldor Topsoe exchange reformer (HTER) vessel and in connecting transfer
lines.

2 General
The HTER is installed vertically with connecting transfer lines from the upstream reformer and
downstream waste heat boiler (WHB). All equipment is refractory lined, and the temperature of
the steel shell is thus appreciably lower than the temperature of the process gas.

Vendors may propose deviations in materials and procedures from those described in this
specification, and which they consider technically more suitable for the installation; however any
such changes must be agreed with Topsoe.

3 Design
Refer Topsoe document no. M51202-HE-04 for vessel dimensions, ID tolerances, and extent of
the refractory required.

Following points must be considered during design of refractory lining:

3.1 Lining design

It is a requirement that the refractory design for the HTER and transfer line is made by personnel
experienced in this type of unit, and the documentation shall as a minimum show the following
information for each part of the equipment:

Refractory type and thickness

Refractory construction details
Guaranteed datasheets of the applicable materials
Anchoring details
Installed weight of each type of refractory in each section of the equipment
Heat transfer calculations

3.2 Installation procedures

The vendor must give detail description of the refractory installation procedures. Installation
procedures shall be identified for each part as follows:

Vessel dimensions, special tolerances and means of achieving these

Surface preparation
Installation sequence
Mixing of refractory
Installation of refractory (including pre-qualification)
Sampling (quantities, location and re-test)
Sample handling, preparation and testing (including storage and curing)
Curing
Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be
used by or disclosed to third parties without written approval of Haldor Topsøe A/S.

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Dry-out
Preparation of qualification testing panels
Identification of critical activities and special procedures in that respect

3.3 Thermal conductivity corrections

Thermal conductivity values used in the heat transfer calculation must be suitably modified for
the gas composition. Thermal conductivities modification shall also be done for possible steam
condensate in lining near the metal shell.

3.4 Gunning
Where the vendor considers it necessary to install refractory castable by gunning or shot
creating, agreement must in each case be obtained from Topsoe.

3.5 Anchor system

A proposal for the anchoring system including anchor type, fixing of anchors and anchor pattern
are shown in Topsoe drawing no. M51202-HE-04. The refractory anchoring system comprises
two parts:

1. A part, which is welded to the inner surface pressure shell, of the same material as the
pressure shell. The refractory vendor designs and specifies this part. The vessel manufacturer
will supply and weld this part to the shell.

2. A loose part, which is to be mounted at site when the refractory installation takes place. A
screwed system is envisaged. The anchor material must be of a suitable heat and corrosion
resistant material such as Alloy 602 CA.

The design of anchors and any other refractory support must be made in such a way that no
welding to pressure bearing parts is required on site. We refer to our standard for anchoring,
Topsoe Standard no. 4-2725/E (Reference-1).

3.6 Lining of stuffing box cone

Special notice must be taken while designing the lining at the stuffing box cone as anchoring
cannot be made to the box which is covered in ceramic fibre to take up the differential expansion.
A lining made of large precast shapes with key and keyway or an extended anchoring in the
under lying refractory, could be accepted.

3.7 Transfer line parts dry connection

To connect the lined transfer lines, an expansion joint must be incorporated which can take up
the tolerances and the differential expansion. The expansion joint must be made staggered and
protect the backing strip. The fibre joint in the hot face must be compressed to 30% of original
thickness, or expandable felt must be used.

3.8 Outline of refractory lining

It shall be noted that the thicknesses of the refractory lining layers shown on the Topsoe
drawings are indicative only and these shall be confirmed by the refractory designer. However
the inside dimensions of the refractory lining must be maintained.

Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be
used by or disclosed to third parties without written approval of Haldor Topsøe A/S.

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The refractory thickness in the upstream transfer line shall be coordinated with the refractory
lining thicknesses of the HTER.

In the calculations of the lining design, special notice must be taken to avoid materials with higher
amount of silica at working temperatures above 800 C, and where risk of flowing process gas is
present.

Thermal expansion and relief joints shall be designed with due consideration to the risk of high
stresses on parts of the refractory lining, especially at the proposed heating-up rate. Expansion/
working joints with tolerances shall be specified by the vendor on the drawings.

Further the design shall be made so the risk of gas penetration is reduced to a minimum.

A membrane of oil or similar is to be applied between refractory layers to avoid water absorption.

4 Operating and design conditions

Following is information for refractory design basis

Refractory design temperature 955 C

Operating temperature (inlet/outlet) 905/601 C
Design pressure 29.5 kg/cm2 g
Refractory lined shell temperature ~ 130 C (max. 160 C)
Surface transmission coefficient Approx. 15 W/m2-K
Ambient temperature, min./max 12 / 40 C
Gas composition (weight %) H2 –50, CO –16, CO2 –6, H2O –25, miscel.

5 Refractory lining materials, anchors and accessories

Refractory materials shall not be procured against typical data sheets, but against guaranteed
material specifications. The manufacturer shall guarantee the critical properties in addition to any
properties that are normally part of their in-house quality control. Materials shall be delivered with
test certificates.

The vendor shall submit a full description of the materials, which he proposes to install. The
description shall include detailed information regarding classification temperatures, analyses, hot
and cold strengths and conductivity curves or tables.

All materials proposed for refractory lining, including material, size and spacing for refractory
anchors etc. shall be submitted to Topsoe for approval. The quantities of materials supplied shall
include necessary allowances for breakage during transport and for wastage on site.

5.1 High alumina firebrick (for inlet distributor)

The shaped material shall be characterized by high alumina content and thermal stability and
shall conform to the following:

Minimum temperature limit 1800 °C

Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be
used by or disclosed to third parties without written approval of Haldor Topsøe A/S.

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Analysis shall conform to Min. 99% Al2O3

Max. 0.2% SiO2
Max. 0.1% Fe2O3
Typical values:
Density app. 3,200 kg/m3
Apparent porosity max. 20 %
Cold crushing strength min. 60 MPa

5.2 High alumina castable (Hot face)

The material shall be characterised by high alumina content, high abrasion resistance, low silica
content, low iron content, low linear shrinkage, high thermal stability, and the material must
conform to the following:

Minimum temperature limit: 1600°C

Analysis shall conform to: min. 94% Al2O3
max. 1% SiO2
max. 0.1% Fe2O3
Typical values:
Thermal conductivity at 1000°C: max. 1.9 W/m-K
Density app. 2,600 kg/m3
Cold crushing strength (After firing at 110oC): min. 60 MPa
Permanent linear change (After firing at 1000°C): app. -0.1%

The material shall be installed by vibration in formwork or be supplied in connection with pre-cast
shapes in same material with key and keyway horizontally and vertically.

5.3 Impervious Layer

An impervious layer shall be installed between the inner castable lining and the insulating
castable refractory in order to prevent propagation of cracks from one component of the lining to
another.

The layer can be achieved by means of a heavy coat of non-soluble paint or oil (e.g. concrete
curing oil). Great care must be taken to choose a material which will have no adverse effects on
the process or the lining materials under operating conditions.

5.4 Insulating castable

The main insulating layer of the refractory lining is installed between the intermediate high
alumina bubble castable and the shell. The material shall be characterised by low thermal
conductivity, medium silica content, low linear shrinkage and high thermal stability.

As there is a possibility of condensation of water within this layer, the material shall be completely
insoluble in water. In cases where this part of the refractory lining is relatively thick, it is advisable
to divide it into two layers, thus reducing cracking due to shrinkage and differential temperatures
between the inner and outer surfaces. Casting joints shall be alternating in the insulating layers.

The insulating castable shall conform to the following:

Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be
used by or disclosed to third parties without written approval of Haldor Topsøe A/S.

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Minimum temperature limit: 1200°C

Analysis shall conform to: app. 60% Al2O3
app. 30% SiO2
max. 0.7% Fe2O3
Typical values:
Thermal conductivity at 600°C: max. 0.35 W/m-K
Bulk density app. 1,250kg/m3
Cold crushing strength (After firing at 110oC): min. 4 MPa
Permanent linear change (After firing at 1000°C): app. -0.2%

5.5 Ceramic fibres

Ceramic fibres for large expansion gaps:
Material: Aluminium silicate.
Classification temperature: 1400°C

Ceramic fibres for joints in hot face surfaces:

Material: High alumina fibres.
Classification temperature: 1600°C

5.6 Refractory anchors

The anchor parts (to be installed on bushings, welded to pressure shell), are to be supplied with
the refractory materials. All anchors of the same shape shall be made of the same material.

Recommendations for designs of anchors are given in our standard for metal anchors viz.
Topsoe Standard no. 4-2725/E.

6 Quality control, material supply

A quality control plan must be worked out for the refractory material supply covering all materials.
Where this is relevant, the quality control plan must as a minimum include the following issues:

- Chemical analysis verification.

- Grain size verification
- Visual inspection and acceptance criteria
- Dimensional control and acceptance criteria
- Testing
- Pre-firing certification
- Preassembly test for complicated pre-cast sections, if necessary
- The norms according to which the inspection must be made
- The acceptable quality level foreseen for individual inspections.

The quality control plan is subject to acceptance by Topsoe prior to commencement of any
project dedicated material production.

Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be
used by or disclosed to third parties without written approval of Haldor Topsøe A/S.

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7 Installation
7.1 General
The refractory installation contractor must provide a site organisation plan showing the roles and
responsibilities of the site management functions, i.e. site manager, shift supervisors, inspectors, site
safety officer, foremen, etc.

The refractory installation contractor must similarly provide a site safety plan and necessary
procedures. It is the responsibility of the refractory installation contractor to adhere to and
observe all local safety and working regulations, at all times.

7.2 Refractory installer qualifications

Each refractory installer has to have proven experience and must be able to judge when the
material is suitable for placement. Each refractory installer shall be pre-qualified for the work he
is intended to perform. The purpose of the qualification testing for gunning and casting is to
assess the ability of the installers to correctly install refractory into test panels, which simulate the
actual installations. Back-plates of the testing panels are to be removable for checking of voids.

7.3 Instructions and recommendations concerning samples

The refractory manufacturer instructions and recommendations shall not be violated without
written acceptance from Topsoe.

The contractor shall keep records to identify material installed during each shift, location, installation
team and the related production sampling test results. The contractor shall also record moisture
content, ambient and water temperatures, material certificates, and batch numbers.

During installation of the refractory lining material, numbered test samples are to be made for each
material used for each batch and each shift. These samples will be prepared inside the applicable
unit by using the same procedure as used for the actual installation. The samples will be left inside
the unit until cured. These test samples will be handed over to the client at the end of the installation
together with all other QA/QC documents. Records are to be kept by the contractor, which will enable
identification of the unit, and location of the material installed relating to an individual test sample.

Topsoe inspector can require additional test samples to be cast when greater amount of materials is
foreseen to be installed.

7.4 Installation of refractory material

Installation of refractory material shall not commence before:
- The installers have been successfully pre-qualified
- Installation procedures have been successfully pre-qualified
- Refractory installation drawings have been accepted by Topsoe for installation
- Quality plan has been accepted
- Refractory materials have been successfully pre-qualified.

7.5 Surface preparation

Surfaces to be refractory lined must be shot blasted free of rust and other foreign matters and
coated with a refractory friendly coating (e.g. Sigmatherm 540) in order to avoid corrosion during the
Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be
used by or disclosed to third parties without written approval of Haldor Topsøe A/S.

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installation of refractory. Shot blasting and temporary surface protection form part of the refractory
supplier's scope of work.

7.6 Execution of refractory installation

Before starting the refractory installation, the refractory contractor must have agreed upon the
planning of the execution of the refractory installation, specifying dates for start of the work,
planned milestones of the individual installation steps, and for the final completion.

The following shall as a minimum be taken into consideration:

- Availability of qualified refractory workers
- The space available for the work to be carried out
- Setting characteristics of the castables and mortars
- Capacity of material handling equipment
- Climatic conditions
- Working schedule (number of shifts per day and days per week).

7.7 Equipment lined in workshop prior to installation

In cases when equipment is lined in the workshop prior to installation, the supply shall include
materials for completion of refractory at site. Adequate surplus materials shall also be supplied
for repair of breakage that may occur during transport.

8 Installation quality assurance

8.1 Quality control plan
The contractor must develop a step-by-step quality plan showing all the installation activities,
such as:

Vessel take over requirements and certification

Witness points
Hold points
Approvals
Frequency of test coupon production and testing requirements
Final inspection and acceptance
Responsibilities
Acceptance criteria.

Where an activity is repeated several times and it is deemed impractical to list this activity in the
quality plan for each time it is performed, this activity can be recorded in separate forms.

The contractor must keep record of:

Inspection of the construction site

Pre-qualification tests
Material reception and storage at site
Material qualification tests
Daily summary, including material consumption
Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be
used by or disclosed to third parties without written approval of Haldor Topsøe A/S.

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Inspection of pressure shell

Water quality
Castable mixing
Casting / Gunning
Daily installation test cubes
Dry out chart
Non-conformance reports
Final acceptance.

Records, procedures and certificates must be available on site during installation. The daily
installation test cubes are to be kept safe by the contractor and handed over at the end of the
installation as part of the QA/QC package.

8.2 Testing requirements

For each material used, three (3) test cubes must be prepared and tested prior to installation.

The minimum requirement for testing of the test cubes prepared during installation is three (3)
(for each material used) by approximately 50% and 100% complete. All test cubes shall be tested
by an independent organisation.

In the event that any of the daily installation test cubes tested as part of the above testing
requirements fail to give results within the minimum / maximum acceptance limits agreed for the
installation, the material installed that day relative to the sample cubes will be considered defective
and unacceptable, and a non-conformity report shall be issued.

At this point the installation contractor must take immediate steps to replace the material or prove
that the material installed is of acceptable quality by taking core samples from the material
installed in the unit and arranging for testing of these samples. If the results of the core samples
fall within the minimum / maximum acceptance limits, the material will be deemed to be
acceptable.

Proving of the quality or removal of the defective material must be completed within one week after
receipt of the original test results, and either of these actions will be the only way to close out the
non-conformity report and allow acceptance of the refractory installation.

8.3 Photos
Photos of installation during erection are to be taken with intervals as specified in the control
procedure. Photos must also state the layout of the sectioning and the placed expansion / relief
joints in the monolithic casting.

8.4 Supervision personnel

The refractory contractor will be responsible for the appointment of a sufficient number of
supervisors to ensure full time supervision of the complete installation.

Supervisors, who are appointed by the refractory contractor, must have proven experience of
identical installations. Detailed CV for each nominated supervisor is to be submitted upon request
to Topsoe for review and acceptance.
Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be
used by or disclosed to third parties without written approval of Haldor Topsøe A/S.

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The appointed personnel are responsible to the refractory contractor and Topsoe for the set up and
performance of the supervision and inspection work as described in the main quality control plan.

8.5 Protocol
When the complete refractory lining has been installed and accepted, a protocol confirming this
must be signed by the client, the refractory installer and Topsoe. This protocol will not release the
refractory supplier from any guarantees.

9 Dry-out
It is the responsibility of the refractory vendor to provide a dry-out procedure. The procedure
must in addition to a dry-out temperature vs. time diagram address the issues of temperature
measurements and recording, means and location of heat source, etc. to be reviewed by Topsoe.

The dry-out will only be considered complete when the thermocouples measuring the shell
temperatures register a temperature in excess of 110oC. In practice this is achieved only with
external insulation of the shell and with an internal temperature in excess of 550oC.

The ideal dry-out temperature for these units is 800oC so that the maximum shrinkage of the
castables and mortars is achieved, and the refractory lining is put through a thermal cycle as close
as possible to what it will be during an operational run.

The dry-out may be part of the commissioning activities of the plant and consequently, the dry-
out may take place using heated gas produced by some plant auxiliary equipment. If this is an
option, the procedure is to be discussed with Topsoe.

10 Documentation
10.1 Documentation in the design phase
The following documents are to be submitted for Topsoe review / acceptance:
- Documentation index
- Refractory assembly drawing
- Refractory detail drawing
- Heat transfer calculations
- Refractory expansion calculations
- Bill of materials
- Guaranteed material specification sheets
- Material safety sheets
- Quality control plan for material supply
- Installation procedure
- Installation quality control plan
- Dry-out procedure
- Maintenance and repair instructions
- Preliminary installation time schedule.

Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be
used by or disclosed to third parties without written approval of Haldor Topsøe A/S.

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10.2 Documentation required for the material supply

The following documents are required before shipment of materials:
- Packing lists
- Remaining shelf life of delivered monolithic materials
- Material certificates
- Quality control plan
- Inspection report(s)
- Release note(s).

10.3 Documentation required for site installation

The following documents are to be submitted and accepted prior to commencement of the
installation work:

- Final time schedule

- Site organisation description
- Site safety plan
- Installation inspection record sheets

10.4 Final documentation

The final documentation comprises final and where relevant as-built versions of the above
documents. In addition, the final documentation must comprise the signed off quality control plan for
the installation and all certificates, records and inspection reports pertaining thereto.

11 Packing and marking

The refractory materials shall be properly packed for overseas transportation. The following
instructions must as a minimum be respected:

- Large quantities of formed shapes shall be packed on pallets and protected by plastic foil and
stowed in containers.

- Small quantities may be supplied in wooden boxes internally protected by plastic foil.

- Large quantities of castable refractory supplied in dry form can be packed in bags on pallets
and protected by plastic foil and stowed in containers.

- Small quantities may be supplied in drums.

- Any ceramic fibre materials shall be supplied in waterproofed bales or in cardboard boxes,
properly protected by plastic wrapping.

- Each package is to be clearly marked with the specific content and identification code as
specified by Topsoe. Furthermore, part numbers for specially shaped bricks must be clearly
indicated on the brick to facilitate easy identification on site.

Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be
used by or disclosed to third parties without written approval of Haldor Topsøe A/S.

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- All relevant information regarding storage temperature, storage humidity, limited storage life,
etc. must be clearly indicated on the appropriate packages.

- Packing and storage details must be submitted for review.

- A packing list shall be included in all crates or pallets.

12 References
Ref 1: 4-2725/E Topsoe standard for metal anchors
Ref 2: 4-2724/E Topsoe standard, Refractory installation of castable and gunning mix
Ref 3: 4-2732/E Topsoe standard, Refractory installation gunning, Pre-qualification
Ref 4: 4-1100/E Topsoe standard, Vertical cylindrical vessels, Tolerances.
Ref 5: M51202-HE-02: HTER pressure shell, assembly and details
Ref 6: M51202-HE-04: HTER refractory lining, assembly and details

Information contained herein is confidential; it may not be used for any purpose other than for which it has been issued, and may not be
used by or disclosed to third parties without written approval of Haldor Topsøe A/S.

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