X Approval

Total Sheet 21 X Review

( incl. Cover )
Construction
As Built
Reference
Preliminary
Information
OWNER : IRPC PUBLIC COMPANY LIMITED, (IRPC)
CLIENT : PETRO-CHEM DEVELOPMENT CO.,INC. (PCD)
PROJECT : IRPC UHV PLANT PROJECT , RAYONG, THAILAND
EQUIPMENT No. : STEAM METHANE REFORMER ( UNIT : 51B010 )
LOCATION : RAYONG, THAILAND

REFRACTORY INSTALLATION PROCEDURE

FOR
SHOP FABRICATION
OF
STEAM METHANE REFORMER ( UNIT : 51B010 ) Distribution
IRPC UHV PLANT PROJECT , RAYONG, THAILAND VPE -
PCD 1

1 MR. KHONGSAK T. 10/08/2013 MR. KWANCHAI K. 10/08/2013 MR.SARAWUT W. 10/08/2013

0 MR. KHONGSAK T. 25/05/2013 MR. KWANCHAI K. 25/05/2013 MR.SARAWUT W. 25/05/2013

Rev. Prepared By Checked By Approved By Total 1

VPE Job No. Client P.O. No. VPE DOCUMENT NO.
Rev.
P256009 F122043-16 P256009-REFRAC-01 1

VATANA PHAISAL ENGINEERING CO.,LTD.

99 Moo 4 Nikompattana District, King Amphur Nikompattana, Rayong 21180, Thailand

TEL : 038-606253 FAX : 038-606254

 Sheet 1 OF 20
Rev. 1
Date. 10/8/2013

REFRACTORY INSTALLATION PROCEDURE

- CHAPTER 1 GENERAL

- CHAPTER 2 CASTABLE REFRACTORY

- CHAPTER 3 CERAMIC FIBER BLANKET

 Sheet 2 OF 20
Rev. 1
Date. 10/8/2013

CONTENTS

CHAPER 1 GENERAL SHEET

1. General 3 OF 20
2. Specification, Standard and Related Drawing 3 OF 20
3. Material Storage 3 OF 20
4. Preparation 3 OF 20
5. Welding of anchor and hammer test 3-4 OF 20
6. Stud. Welding 4 OF 20

CHAPER 2 CASTABLE REFRACTORY

1. Material Control ( For Castable ) 4 OF 20
2. Water for Mixing with Refractory 4-5 OF 20
3. Forming and Shuttering 5 OF 20
4. Measuring / Thickness Guage 5 OF 20
5. Moisture Protection 5 OF 20
6. Installation Method by Pouring / Casting 5-6 OF 20
7. Installation Method by gunniting 6 OF 20
8. Curing compound of Refractory 7 OF 20
9. Qualification & Inspection 7-8 OF 20
10. Production Sampling 8 OF 20
11. Precautions 8 OF 20
12. Repair of Refractory 9 OF 20
13. Drying Chart : Bulk Density 10 OF 20
14. Drying Chart : Cold Crushing Strength and 11 OF 20
Permanent Linear Change
15. Report 12 OF 20

CHAPER 3 CERAMIC FIBER BLANKET

1. Apply of Mastic Coating for ceramic fiber blanket 13 OF 20
2. Material Control ( For Ceramic fiber blanket ) 13 OF 20
3. Installation Ceramic fiber. 13-14 OF 20
4. Repaired of Ceramic fiber. 14 OF 20
5. Table 1. Refractory Schedule 15-18 OF 20

ATTACHMENT FOR INSPECTION REPORT FORM

- Attachment No. 1 : Refractory Lining report form. 19 OF 20
- Attachment No. 2 : Refractory Lining crack map report form. 20 OF 20
 Sheet 3 OF 20
REFRACTORY INSTALLATION PROCEDURE Rev. 1
Date. 10/8/2013

CHAPTER 1 GENERAL

1. General
This procedure is to be used for refractory lining work of the STEAM METHANE REFORMER ( UNIT : 51B010 )
for IRPC UHV Plant Project , RAYONG, THAILAND. The work will be performed at Vatana Phaisal Engineering Co.,Ltd.
At Khao Hin Sorn Factory, Prachinburi , Thailand. By VPE subcontractor.

2. Specification, Standard and Related Drawing.

1 The required documents must be prepare as per Para 12.0 of UHV-SP-M-008 as a minimum
2.1) Job Specification no.
- API 560
- API RP 936
- Doc. No. UHV-SP-M-008
- Doc. No. UHV-SP-M-007
2.2) Job Drawing no.
- DWG. No.F-12-2043-02-03 Rev. A
- DWG. No.F-12-2043-02-04 Rev. A
- DWG. No.F-12-2043-02-15 Rev. A
- DWG. No.F-12-2043-02-16 Rev. A

3. Material storage 1
All material will be stored in warehouse or under shelter on pallets, to be free from moisture, rain, ground water,
and contaminated materials.
All stored materials must be grouped, tagged, for easy access to avoid mistake in use. All incoming
and withdraw must be recorded, traceable and inspection accessibility.
4. Preparation
4.1 Clean surface areas where dusty, mill scaled, rust, oily, wet shall be removed and cleaned to meet
SSPC SP-6 Nace No. 3 Commercial blast cleaning. New metal surfaces that are free of rust, dirt, grease, or oil
are acceptable for most linings covered under this specifications.
4.2 Inspection studs to verify they conform to construction drawing. Installation procedure will follow the
client standard, if not the following will be served as guideline or our practice for installing.

5. Welding of anchor and hammer test 1

5.1) All anchor shall be welded by qualified welder. Welder qualification must be available for
Purchaser's inspection
5.2) Anchor materials size and spacing are indicate on the drawings.
1 5.3) Maximum anchor distance to the edge or corners of a wall shall not be more than 0.5 x nominal pitch.
It shall be also show on design Dwg.
 Sheet 4 OF 20
REFRACTORY INSTALLATION PROCEDURE Rev. 1
Date. 10/8/2013

5.4) Refractory anchor shall be welded to the casing by full penetration weld or a fillet weld at 100%
of the circumference.
5.5) Stainless steel anchors shall be welded to casing by type 25Cr-12Ni ( TP-309 ) electrodes.
5.6) The test anchors shall be bent by hammering through approximately 90º and then returned to the
upright position. The anchor should bend without breaking the weld. Subsequently the weld quality to be
tested by striking moderately at random about 10% of welded anchor using a 0.5 Kg ball hammer.
A clear metallic sound shall indicate good welding if faulty welding is found than all anchors to be tested
as described above and faulty welds repaired.

6. Stud welding
1. Mark out stud centers in appropriate patterns as per drawing spot grind to prepare
2. Weld stud as per construction drawing and all anchor shall be bend tested 5% as per AWS.
and 100% visually inspected.
3. Remove all slag from welds before inspection.
Note: Qualify a stud welding procedure per AWS using the same stud gun used on the furnace.

CHAPTER 2 CASTABLE REFRACTORY

1. Material Control ( For Castable )

1.1) Temporary storing and protection.
1.1.1 All withdrawal material will be stored on pallet, indoor or with weather protection at the work front.
1.1.2 Catable materials should not be stored outdoors. If anything should happpen to the coverings, or
If the bottom of the pallets are not sealed off from any moisture in the ground, damage material can be the result.
Outside storage would be acceptable if an enclosure is built over and around the refractory material.
1.2) A mapping format to be made for traceability of type, lot or batch number of materials at each
vessel locations.
1.3) Mixing just sufficient quantity for each area to be lined for the period.
1.4) All surplus materials after work completion will be returned to the warehouse and be record /
reported for further actions.

2. Water for Mixing with Refractory

2.1 All water & ice used for mixing refractory material shall be clean, potable, and have no more than 50 ppm.
chloride, and shall be enough cool so that refractory water mixture temperature must at all times be
not less than 5°C.
 Sheet 5 OF 20
REFRACTORY INSTALLATION PROCEDURE Rev. 1
Date. 10/8/2013

In case the water temperature is higher, ice my be used to cool down the water in storage tank
The temperature of water in storage tank shall be periodically checked. When the shell/metal
temperature exceeds 35°C the exterior of the area to be line shall be cooled by water spray and/or
shading prior to and while the refactory material is being placed.

3. Forming and Shuttering

3.1) Wooden plank and struts will be used for making form works or shuttering in pouring / casting
3.2) Surface of the forms / shuttering shall be coated with non-soluble grease or oil for the purpose of waterproofing
and easy removal after the hardening of refractory.
3.3) The form / shuttering shall be tough enough to endure pressure of lining application, and leaving no gap
between all mating surfaces.
3.4) The form / shuttering shall be well braced so that they will not move or buckle, and be checked for spare of the
specified thickness.

4. Measuring / Thickness Gauge

4.1) Refractory shall be installed monolithically
4.2) For single-component gunned linined and for the hot face layer of multi-component lining, the final installed
thickness shall be as show on the design drawings with a tolerance of - 0 mm, + 6 mm

5. Moisture Protection
Plastic sheet continuously wetted during 24 hours will be used for protecting water to be evaporated after
casting / pouring for the first 24 hrs during curing. Horizental paddle mixers driven by electric motors will be used
for mixing refractory with water prior to transferring to pour. Steel trolley and plastic buckets will be used for transiting
of ready mixed refractory. These are for casting / pouring method.
Noted: Plastic must be sucuring at all end to prevent the plastic from exposing the refractory.

6. Installation Method by Pouring / Casting

6.1) Checking all welded anchors and dimensions and have them to be verified prior to proceeding.
6.2) All pouring / casting equipment will setting up near to the panels to be lined.
6.3) Cleaning all application areas with compressed air or brushing. No oil,millscale, rust or other foreign material.
Completion of cleaning prior to refractory application constitutes a hold point for initial witness and refractory material
shall not be installed prior to written sign off by owner.
6.4) Start to install the wooden form to obtain the required thickness starting from bottom to top surfaces.
Care should be taken if necessary cut be needed for dressing up.
6.5) Weigh the refractory bags before placing refractory in the mixer. All opening should be plugged with tapping plugs
6.6) Thin polyethylene sheet is needed for preventing moisture absorption from refractory in the board.
 Sheet 6 OF 20
REFRACTORY INSTALLATION PROCEDURE Rev. 1
Date. 10/8/2013

6.7) Castable bags shall be opened one by one for inspection of lump prior to pouring into the mixer.
Any bags showing lump / harden have to be put aside and consult with client's inspector for taking further action.
Any bag of material containing lumps due to water penetration are to be discarded.
6.8) All tools, equipment must be checked for cleanliness prior to using.
6.9) Pouring sufficient amount of castable into the mixer, after that dry mixing the castable in / about 6-10 turns.
6.10) Add water from a calibrated container marked in liter and mililiter into the mixer gradually up to 90% of total
weight of water as specified by maker for the mixing castable weight. Care should be taken for water content.
6.11) Then testing the mixture by tossing the ball on hand method, and add the remaining water and toss-check
until obtaining the required consistency. The wet mixing will not last longer than 4 minutes. (For the ball-in-hand
method, ASTM C860 should be referenced as the standard.) Water content shall be within the range qualified prior
to installation during the applicator procedure qualification tests.
6.12) Well mixed castable will be transferred by plastic buckets for pouring into the required block / area by starting
from one side until covering the whole area fully. Each blocking area must be poured continuously until full.
6.13) Checking with thickness gauge and fills up or scrape out any excess with wooden trowel until full even
thickness is obtained but not to finish the top surface.
6.14) Vibrators can cause separation of the refractory material. If the material is mixed to ball-in-hand per ASTM C860
it will place very well by hand packing and water content will be reasonable.
6.15) Pouring of further blocking areas shall be done in the same way but with skipping of the adjacent blocks
throughout the whole length and then return to the empty skipped blocks by removing out the shuttering prior to pouring.
However, make sure that shuttering can not be removed before the poured castable has been set for 24 hours same as
curing period. Stagger all longitudinal cold joints. Continuous cold joints are not allowed.

7. Installation Method by Gunniting

7.1) Horizontal & Vertical surface ; the zones to be gunnited shall be set up before-hand with wooden frames
of a height equal to the thickness to be projected vertically: 1 m, horizontally : 1.5 m. The projection shall be
made, as far as possible, continuously, from bottom to top by staggered frames up to final thickness.
The rebound material utilization is strictly forbidden. After projection, the thickness of the lining shall be
equalized by means of a straight edge (smoothing with a trowel is not authorized). After the setting of a first
series of sprayed panels for 6 hours, the frames shall be lifted out and the intermediate panels shall be
gunnited without the interposition of jointing materials. All joint will be prepared as per PCD drawings.
In order to ensure that the gunniting operator is in a suitable position at all times during the application,
a fixed or mobile scaffolding shall be installed at 800-1,000 mm distance from the panels to be gunnited.
7.2) Overhead surfaces ; When the total thickness is obtained or, it is necessary to apply the concrete
in two coatings which is designed as dual-layer (dual-layer anchorage shall be provide). The gunniting of the second
coat must start between 4 and 12 hours after completing the first one. Frame supporting during lining; to secure
the load of the structural frame during lining
7.3) Verification of application ; Preinstallation tests – Sampling and testing ; the preinstallation test shall be carried out
for new lining suppliers and/or new material trade names. In addition, these tests qualify the lining contractor.
For quality testing of consignments of refractory concretes, sampling involves the selection of relatively small quantities
of material which must be considered to be representative lining contractor shall carry out (one) 1 set of testing panel
with dimensions 500 x 500 x 100 mm. under the actual conditions of application.
 Sheet 7 OF 20
REFRACTORY INSTALLATION PROCEDURE Rev. 1
Date. 10/8/2013

8. Curing of Refractory
To prevent the moisture loss during the setting, the castable lining has to be cured as soon as the hydraulic
setting start. The curing has to be done until the castable is completely set.Time elapse minimum 24 hours.
Curing method can be done by moistening the lining with fine water spray for prior of 24 hours or by cover the
surface of the lining with wet cloth and keep it wet for at least 24 hours, or cover the entire surface with plastic sheet.

9. Qualification & Inspection

9.1) Application Procedure Qualification ( Demonstration )
9.1.1) Applicator for installation of refractory castable shall be qualified prior to start the work.
9.1.2) The applicators shall perform the procedure test to demonstrate that this working methods, equipment and
team operator can produce refractory lining in accordance with the required specification. Each team shall perform
one procedure test.
9.2) Inspection
Refractory lined equipment shall be inspected after installation by visual inspection and hammer testing
with a 1 pound (450 g) hammer after castable lining has been set for more than 24 hours.

Unacceptable defects
- Thickness beyond tolerance -0.0 mm, and + 6 mm.
- Patches of material which have not been dispersed enough or have been cast to dry.
- Air pocket that is larger than 6 mm.
- Crack wider than 3 mm. and deeper than 40 mm.
Acceptable defects
- Thickness deviations are within tolerance.
- Print of seams of formwork, provided no leaching has taken place.
- Air pocket that the size is 6 mm or smaller.

10. Production Sampling

10.1) Production sampling shall be prepared one set per piece mark.
10.2) Each set of Production samples for cast and gunned shall consist of :-
- Five (5) cubes size 50 x 50 x 50 mm. for bulk density (BD) and cold crushing strength (CCS) testing.
- One (1) Bar size 50 x 50 x 230 mm. for permanent linear change (PLC) testing.
Dimensional tplerance of specimens is ±1 mm.
The samples will be proper cured and air dry, and keep in office for further testing. Each sample shall be clearly
marked and traceable.
- Bulk density following as per ASTM C134
- Cold crushing strength testing following as per API 936 which adds requirements to ASTM C-133.
- Permanent linear change testing following as per ASTM C210
 Sheet 8 OF 20
REFRACTORY INSTALLATION PROCEDURE Rev. 1
Date. 10/8/2013

Production Sampling for casting

50 MM.

50 MM.
50 MM. 50 MM.

230 MM.
50 MM.

Sample ( 5 ) pcs. size 50 x 50 x 50 mm. Sample ( 1 ) pc. size 230 x50 x 50 mm.

Production Sampling for gunniting

Test pieces for gunned lining shall be cut from 500 x 500 x 100 test panels.

500 MM.

100 MM.

500 MM.

Sampling ( 1 set per piece ) size 500 x 500 x 100 mm.

10.3) Each selected sample will be tested ( if application ) for :-

- Cold Crushing Strength and Permanent linear change after dried 110oC @ 24 hours,
and fired at 815 oC @ 5 hours.
- Bulk density after dried 110oC @ 24 hours
Test to be conducted with in 2 hours after cool down to ambient temperature.
- Chart Diagram see Figure. 7 and Figure. 8

11. Precautions
11.1) Under extremely hot weather conditions, the castable shall be placed during the cooler hours of the day
or during the night and the mix shall be stored in a cool shaded place. The surface to be lined shall not be
exposed to the sun or other heat just prior to the application, cooling with a water spray of the outside surface
of the equipment to be lined may be advisable.
11.2) Linings containing water shall be protected against freezing, however, live steam shall not be used.
 Sheet 9 OF 20
REFRACTORY INSTALLATION PROCEDURE Rev. 1
Date. 10/8/2013

12. Repair of Refractory

12.1) Prior to resuming the application, the exposed surfaces, to which a bond must be made, shall be
thoroughly wetted and castable of the mix as originally used applied.
12.2) The replaced castable must be cured and dried as per this specification.
12.3) Single-layer linings or backup of multi-layer linings-defect beyond acceptable criteria found after curing
shall be chiseled out and reapplied per figure 2.
12.4) Multi-layer linings-defect areas found in the facing after curing shall be removed to the insulating backup
material, and the facing castable reapplied.
12.5) For any unacceptable defects, the defective refractory castable lining shall be removed to expose
at least 3 anchors. The edge shall be chiseled out in a slightly taper to provide the locking edge.
The surrounding edge of the repair area shall be thoroughly wetted prior to fill-in the new mixed castable material.
12.6) All repairs in the horizontal position must use shuttering forms or surrounding refractory; repairs in the
veritcal orientation must use shuttering forms for the free surface.
 13.
Temp.

T 110°C @ 24.0 hr.

=drying

Max. = 4.6 °C/min

Drying Chart : Bulk Density

Max. = 2.8 °C/min Use Time 29 min Use Time 18 min

T (30°C ) T (30°C )
room room

Time
REFRACTORY INSTALLATION PROCEDURE

Heating rate = 2.8°C / min Accroding to ASTM C865-02 (6.5)

Rev.
Date.
Sheet

Cooling rate = 4.6°C / min Accroding to ASTM C865-02 (6.8)

Figure. 7
1
10/8/2013
10 OF 20
COLD CRUSHING STRENGTH AND PERMANENT LINEAR CHANGE 14.

Temp. T = 815 °C @ 5.0 hr.

firing

Max. = 2.8 °C/min

Use Time 4 hr.

T = 110°C
drying
@ 24.0 hr. Max. = 4.6 °C/min
12 min.
Use Time 2 hr. 51
i
Max. = 2.8 °C/min Use Time 29 min
T (30°C )
room
T (30°C )
REFRACTORY INSTALLATION PROCEDURE

room Time.

Heating rate = 2.8°C / min Accroding to ASTM C865-02 (6.5)

Drying Chart : Cold Crushing Strength and Permanent Linear Change
Rev.
Date.
Sheet

Cooling rate = 4.6°C / min Accroding to ASTM C865-02 (6.8)

1

Figure. 8
10/8/2013
11 OF 20
 Sheet 12 OF 20
REFRACTORY INSTALLATION PROCEDURE Rev. 1
Date. 10/8/2013

15. Report
Daily report shall be prepared by QC inspector during the application of refractory lining operation.
The report shall contain the following information as a minimum :-
- Date, ambient temperature, water temperature
- Panel no./item no., thickness required
- Material type
- Batch no.
- Installer/application name
- Mixing time
- Quantity of refractory material used
- Water amount
- Sample code/marking
- Inspector name
Please see refractory lining report form on attachment no. 1
 Sheet 13 OF 20
REFRACTORY INSTALLATION PROCEDURE Rev. 1
Date. 10/8/2013

CHAPTER 3 CERAMIC FIBER BLANKET

1
Ceramic fiber shall be supplied in accordance with ASTM C892
1. Applying of Mastic Coating for ceramic fiber blanket
The specified mastic coating is needed only for the ceramic fiber lining areas/panels but no need
for castable linning area. The wet film thickness will be 3 mm. as per specification . Application fo mastic to
steel surface will be made on the panel in vertical leveling stage and be made by steel spatula spading to
have even surface. The coating areas will leave to dry / set for at least two days before applying of ceramic
fiber or board. Should install protective covers over all refractory anchor ( Module anchor ) during application
of mastic then remove them prior to installing the ceramic fiber blanket and / or modules.

2. Material Control ( For Ceramic fiber blanket )

2.1 Temporary storing and protection.
2.1.1) All withdrawal material will be stored on pallet, indoor or with protection at the work shop.
2.1.2) Ceramic materials should not be stored outdoors. If anything should happen to the
coverings, or if the bottom of the pallets are not sealed off from any moisture in the ground, damage material can
be the result. Outside storage would be acceptable if an enclosure is built over and around the refractory material.
2.2 A mapping format be made for traceability of type, lot or batch number of materials at each locations.

3. Installation Ceramic fiber.

Installation of ceramic fiber blanket will be carried out as follows:
3.1 All reference drawing must be checked for insuring of using correct materials as per
Specification requirements.
3.2 Ceramic fiber blanket must be installed to be match tightly with the adjacent ones and
not to damage the either.
3.3 Joint for layer must be staggered and be butted firmly, no gap is allowed.
3.4 The hot face ceramic fiber blanket should be follow "Gas Flow" at overlap joint.
3.5 The lining surface must be clean and smooth.
3.6 At each step of work, Inspection closely while work proceeding to avoid accumulation mistake.
3.7 Keep the working area clean.
3.8 The thickness of refractory to be set on each area shall be conformed to those indicated in the
Insulation Schedule accordance to drawing.
3.9 Normally the studs for fixing blanket will be welded by the steel section as described in Chapter 1
item 5 and 6. However, re-checking should be made by the lining applicator due to these might be damaged
during transporting to the lining areas.
3.10 Applying mastic coating as per specification requirement to a thickness of about 3 mm. as given in
Chapter 3 item 1 above. This is to ensure that the remain thickness will be about 3 mm. as per specification
requirements.
 Sheet 14 OF 20
REFRACTORY INSTALLATION PROCEDURE Rev. 1
Date. 10/8/2013

3.11 Leaving the coating to dry or evaporating out the volatile material for a few days before starting to
install the CF blanket. However due to ambiant temperature does affect to the curing sometime it take 1 day
for such setting, checking for ensuring prior to lining is the best way instead of basing on the numbers of days.

4. Repaired of Ceramic fiber

Repairing of ceramic fiber products will follow those given in the above procedure except damaging
the mastic coating. If so, the coating layer have to be re-applied to good condition as before.
 Sheet 16 OF 20
REFRACTORY INSTALLATION PROCEDURE Rev. 1
Date. 10/8/2013

5. Table 1. Refractory Schedule continued (Ref. Dwg. No. 130087-51B010-VP-018 (F-12-2043-02-16))

Anchor Refractory Lining

Item Part Name
Mat's Type Shop Field Mat's Thk ( mm. ) Shop Field

Radiant to
Convection HFG
Transfer Duct
Kaoseal Castable
Q Floor & - None - - - N/A √
Sealant
Convection
Module CM01
Floor ( Hot Face )

Radiant to
Convection HFG
Transfer Duct
Floor & Kaolite 2200HS (or
R - None - - 125 N/A √
Convection Approved equal)
Module CM01
Floor ( Middle
Layer )
Radiant to
Convection HFG
Transfer Duct
Floor & Kaolite 1600 (or
S - None - - 75 N/A √
Convection Approved equal)
Module CM01
Floor (Bottom
Layer )
Radiant to
Convection HFG
Footed Wavey "V"
T Transfer Duct 304SS √ N/A Greenlite 23LI 75 √ N/A
( Mk. No. AS-10 )
Walls & Roof ( Hot
Face )
Radiant to
Convection HFG
Footed Wavey "V" Kaolite 19L ( or
V Transfer Duct 304SS √ N/A 125 √ N/A
( Mk. No. AS-17 ) Approved Equal)
Walls & Roof (
Backing Layer )
- Conv. Module
CM01 Sidewalls &
Endwalls
- Conv. Module
CM02 Sidewalls &
Footed Wavey "V" Kaolite 2200HS (or
W ( Endwalls Expect 304SS √ N/A 100 √ N/A
( Mk. No. AS-10 ) Approved equal)
@ End Tubesheet
)
-Conv. Module
CM03 Sidewall (
Hot Face )
 Sheet 17 OF 20
REFRACTORY INSTALLATION PROCEDURE Rev. 1
Date. 10/8/2013

5. Table 1. Refractory Schedule continued (Ref. Dwg. No. 130087-51B010-VP-018 (F-12-2043-02-16))

Anchor Refractory Lining

Item Part Name
Mat's Type Shop Field Mat's Thk ( mm. ) Shop Field

- Conv. Module
CM01 Sidewalls &
Endwalls
- Conv. Module
CM02 Sidewalls &
"V" Longhorn ( Kaolite 1600HS (or
X ( Endwalls Expect 304SS √ N/A 100 √ N/A
Mk. No. LS-4 ) Approved equal)
@ End Tubesheet
)
-Conv. Module
CM03 Sidewall (
Backing Layer )
- Conv. Module
CM02, CM03,
Corbell @ Coil Footed Wavey "V"
Kaolite 2200HS (or
Y 51B001, Coil 304SS ( Mk. No. AS-10 ) √ N/A A=102, B=302 √ N/A
Approved equal)
51B002, Coil "L" Welding Pin
51B003, Coil
51B004
- Conv. Module Footed Wavey "V"
Kaolite 2200HS (or
Z CM03, Corbell @ 304SS ( Mk. No. AS-10 ) √ N/A A=152, B=352 √ N/A
Approved equal)
Coil 51B0055 "L" Welding Pin
- Conv. Module
CM04, CM05
Sidewalls &
(Endwalls except Footed Wavey "V" Kaolite 2200HS (or
AA 304SS √ N/A 75 √ N/A
End tubesheet) (Mk. No. AS-8) Approved equal)

- HFG Crossover
ducts (Hot face)
- Conv. Module
CM04, CM05
Sidewalls &
(Endwalls except Footed Wavey "V" Kaolite 1600 (or
BA 304SS √ N/A 75 √ N/A
End tubesheet) (Mk. No. LS-3) Approved equal)

- HFG Crossover
ducts (Hot face)
- Conv. Module
CM04, CM05
Footed Wavey "V"
Corbels @ Coil Kaolite 2200HS (or
CA 304SS (Mk. No. AS-8) "L" √ N/A A=76, B=226 √ N/A
51B006A, Coil Approved equal)
Welding Pin
51B006B, Coil
51B007
 Sheet 18 OF 20
REFRACTORY INSTALLATION PROCEDURE Rev. 1
Date. 10/8/2013

5. Table 1. Refractory Schedule continued (Ref. Dwg. No. 130087-51B010-VP-018 (F-12-2043-02-16))

Anchor Refractory Lining

Item Part Name
Mat's Type Shop Field Mat's Thk ( mm. ) Shop Field

- Conv. Module
CM02, CM03,
"V" Longhorn ( Kaolite 1600HS (or
DA CM04, CM05 304SS √ N/A 100 √ N/A
Mk. No. LS-4 ) Approved equal)
Floating end
tubesheets
- Conv. Module Pin w / Anchor
CM02, CM03, Washer (Hanlock Ceramic fiber blanket
EA 304SS √ N/A 50 √ N/A
CM04, CM05 HL-315 No.4) (or 96 Kg/m3 (1260 ºC)
Headerboxs Approved equal)
Bottom five
courses of all
Insulating firebrick
radiant flue gas
FA - None - - 114.3 x 228.6 (Rated 63.5 N/A √
tunnels & conv.
@ 1260 ºC)
Module [CM01]
target walls

Upper courses of
all radiant flue gas High duty firebrick
GA tunnels & conv. - None - - 114.3 x 228.6 (Rated 63.5 N/A √
Module [CM01] @ 1430 ºC)
target walls

Radiant flue gas AP. Green hollow

tunnels wall tops block CTX-HT 152.4 x
HA - None - - -- N/A √
for 100% rediant 228.6 (or Approved
flue gas tunnels equal)

Radiant flue gas AP. Green hollow

tunnels wall tops block CTX-HT 152.4 x
KA - None - - -- N/A √
for 65% rediant 228.6 (or Approved
flue gas tunnels equal)

- I.D. Fan inlet duct

- I.D. Fan Kaolite 2000HS (or
MA - C.S. √ N/A 75 √ N/A
discharge duct Approved equal)
- Stack
Combustion air
ducts (Externally
Mineral wool w /
NA lined) - C.S. √ N/A 50 √ N/A
304SS Jacketing
Downstream from
saph
Field erection joint
Ceramic fiber blanket
PA w / internal - None - - 25 N/A √
128 Kg/m3 (1260 ºC)
castable lining
 ATTACHMENT No. 1 19 OF 20

REFRACTORY LINING REPORT Report No.______

Mixing/Test-sampling RECORD
Location : SFPC ref. : - VPE JOB No. :
VPE ref. :
Mixing No. Material Type / Quantity Batch Sample Part no/Unit No. Installers (s) Mixlng time (min.) Water Date Temp ( oC ) Thickness Remark
Refractory
code code (location) name (s) (for casting) amount (l.) amb. water mix (mm)

Record By : Witness By : Approve By :

Date : Date : Date : Date :
SP-Mechanical Vatana Phaisal Engineering CLIENT
 ATTACHMENT No.2 20 OF 20

SHEET NO ____ OF____

Refractory Lining Crack Map Report
REPORT NO. ______

PROJECT : PART NAME :

CLIENT : PART NO. :
NAME OF EQUIPMENT : HEATER NO. :
VPE JOB NO. : DATE/TIME OF INSPECTION :
PURCHASE ORDER :
LOCATION : INSPECTION FOR CRACK MAP
TYPE LENGTH WxL RESULT
POINT NO.
OF CRACK ( MM. ) ( MM. ) ACC REJ

SKETCH OF CRACK LOCATION

TYPE OF CRACK A = Open clack larger than 1.5 mm. Length over 300 mm. B = Open crack larger than 1.5 mm. Length not over 300 mm. C = Open crack smaller than 1.5 mm. Length over 300 mm.
D = Open crack smaller than 1.5 mm. Length not over 300 mm. E = Hairline crack

INSPECTED WITNESSED / REVIEWED WITNESSED / APPROVED

QC INSPECTOR : QC ENGINEER : QC ENGINEER :
DATE : DATE : DATE :
VATANA PHAISAL ENGINEERING VATANA PHAISAL ENGINEERING