TECHNICAL STANDARD

INSTALLATION OF HIGH ALUMINA CASTABLE

IN FURNACES MB11-2TS

DATE: 01 MAY 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 1 OF 6

TABLE OF CONTENTS

Section Title Page No.

1. GENERAL ......................................................................................................................................1
1.1 Scope..............................................................................................................................................1
1.2 KBR Documents, and Industry Standards......................................................................................1
2. MATERIALS (Bubbled and Tabular Alumina) ............................................................................2
2.1 Storage ...........................................................................................................................................2
3. INSTALLATION..............................................................................................................................2
3.1 General ...........................................................................................................................................2
3.2 Trial Mix Testing..............................................................................................................................2
3.3 Material Inspection..........................................................................................................................3
3.4 Mixing and Installation ....................................................................................................................3
4. CURING AND DRYING..................................................................................................................4
4.1 Curing .............................................................................................................................................4
4.2 Drying..............................................................................................................................................4
5. INSPECTION, RADIOGRAPHY, TESTING, AND REPAIRS ........................................................5
5.1 Inspection........................................................................................................................................5
5.2 Radiographic Examination..............................................................................................................5
5.3 Testing ............................................................................................................................................5
5.4 Repairs............................................................................................................................................6
6. TRANSPORTATION OF SHOP-LINED EQUIPMENT ..................................................................6
6.1 General ...........................................................................................................................................6
6.2 Field Acceptance Examination .......................................................................................................6
7. FIELD INSTALLATION ..................................................................................................................6
7.1 General ...........................................................................................................................................6

1. GENERAL

1.1 Scope

1.1.1 This standard covers the requirements of shop and field applied linings for the reformer riser transition
assembly and similar applications. Exceptions to this standard, if any, and abbreviations are in accordance
with KBR Technical Standard MB15-1TS.

1.1.2 The locations and the extent of the various types of lining are indicated on the KBR riser transition
assembly drawing or the furnace lining drawings.

1.2 KBR Documents, and Industry Standards

The following documents are referenced herein and form part of the Order. Additional KBR documents,
when applicable, will be listed in the Requisition. Applicable dates of issue of industry standards shall be as
indicated in the KBR Technical Standards MB15-1TS.

KBR DOCUMENTS
MB15-1TS, “General Furnace Specification”

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM C113, "Reheat Change of Refractory Brick"
ASTM C133, "Cold Crushing Strength and Modulus of Rupture of Refractories"
ASTM C860, "Determining the Consistency of Refractory Castable Using the Ball-in-Hand Test"
ASTM C862, "Preparing Refractory Concrete Specimens by Casting"
ASTM C865, "Firing Refractory Concrete Specimens"
 TECHNICAL STANDARD
INSTALLATION OF HIGH ALUMINA CASTABLE
IN FURNACES MB11-2TS

DATE: 01 MAY 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 2 OF 6

2. MATERIALS (Bubbled and Tabular Alumina)

2.1 Storage

2.1.1 Refractory materials shall be palletized, shrink wrapped and stored in a dry weather tight structure.

2.1.2 All bags shall be stamped to show the date of manufacture and shelf life of the material. Materials
which have exceeded the Manufacturer's shelf life shall be discarded.

3. INSTALLATION

3.1 General

3.1.1 The equipment fabricator shall subcontract the installation of the refractory to a qualified Refractory
Installation Contractor (RIC) with satisfactory previous experience of installing bubbled and tabular alumina
type refractory unless the fabricator has past experience in installing the refractory.

3.1.2 Alumina castable in the riser transition assembly shall be installed with the transition assembly vertical.

3.1.3 The RIC shall submit a complete lining application procedure to the Purchaser for acceptance. This
shall include but not be limited to the following:

a. Method of installation.

b. Number, size and types of mixers to be used.

c. Quantity of material mixed and mix time.

d. Percentage of water to be used to minimize voids and the corresponding reduction in cold crushing
strength.

e. Storage of material.

3.2 Trial Mix Testing

3.2.1 Using the above accepted procedure, the RIC shall make a trial mix for testing the physical properties
of the materials. Sufficient time shall be allowed (before the actual installation) to obtain test results and to
alter the mixing and installation procedure if the tests are unacceptable. The minimum quantity of material to
be mixed for these tests shall be 200 lbs (90 kg) for bubbled alumina and 200 lbs (90 kg) for tabular alumina.
The following tests shall be made on the trial mix of each material:

a. Cold Crushing after heating to 1500 °F (816 °C) in accordance with ASTM C133. Minimum acceptable
strength is 90% of manufacturer data sheet value (average of three test specimens).

b. Density after heating to 220 °F (105 °C): Acceptable density is manufacturer data sheet value ±5%.

c. Reheat shrinkage after heating to 1500 °F (816 °C) in accordance with ASTM C113, C860, C862 and
C865. Maximum value acceptable is 0.3%.
 TECHNICAL STANDARD
INSTALLATION OF HIGH ALUMINA CASTABLE
IN FURNACES MB11-2TS

DATE: 01 MAY 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 3 OF 6

3.3 Material Inspection

Immediately prior to mixing, when opening bags for mixing, the dry materials shall be dumped from the
shipping bags into an open container and inspected for any signs of hydration. Any bag which contains
suspect materials shall be discarded in its entirety. Any bags which are ripped, torn or otherwise damaged in
such a manner as to expose the contents to the open atmosphere shall also be discarded at this time.

Note: Care shall be exercised and discretion employed in rejecting bags in said condition, (e.g., bags torn or
damaged while being moved on the day of pouring are acceptable if no hydration has occurred).

3.4 Mixing and Installation

3.4.1 The surface of the equipment against which a lining is to be applied shall be wire brushed or
sandblasted to remove all loose mill scale and other foreign material.

3.4.2 Linings shall not be applied or poured when the surface against which the lining is being applied
exceeds 90 °F (32 °C) or is below 40 °F (4 °C). The lining mix temperature shall be maintained between
60 °F (16 °C) and 75 °F (24 °C) during installation. This measurement shall be made by inserting a
thermometer into the just mixed material.

3.4.3 Linings shall not be applied or poured in freezing weather unless precautions are taken to keep the
material above 60 °F (16 °C) during application and for 24 hours thereafter.

3.4.4 Admixtures to lining materials are not permitted.

3.4.5 High alumina refractory material shall not be applied by pumping, but shall be poured.

3.4.6 The quantity of lining material mixed at one time shall not be greater than can be poured prior to initial
set (20 minutes). In transporting the lining material, precautions shall be taken to prevent the separation of
aggregate and cement. The speed of pouring shall be fast enough to ensure that cold construction joints
and voids do not occur in any monolithic section.

3.4.7 Poured lining material shall be deposited in uniform layers and in a manner which will prevent
segregation of the materials.

3.4.8 Poured linings shall be compacted by spading, vibrating and by tapping of the shrouds. Compacting
shall be done with care so as to avoid segregation of the materials and damage to previously placed portions
of the lining. Vigorous and extended vibration will damage refractory and it is therefore prohibited.

3.4.9 Work shall not be stopped until a section is finished.

3.4.10 The RIC shall mix the refractory with optimum water percent to ensure the refractory can be properly
installed and that it will develop adequate strength as defined in this standard. Manufacturer’s recommended
optimum water percentage (by weight) for reformer riser transition is as specified below:
 TECHNICAL STANDARD
INSTALLATION OF HIGH ALUMINA CASTABLE
IN FURNACES MB11-2TS

DATE: 01 MAY 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 4 OF 6

Amount of Water by Amount of Water by

Material Weight of Material Material Weight of Material

Kast-o-lite 97L 16.5% Greencast 94 9.5%

CA 333 14.5% CA 334 9.5%

Alfrax Bl 57 18% Alfrax 66 10.5%

Plicast
LWI-606KK 20% Plicast 40 10.0%
(Kwik Kure)

Note: These are manufacturer’s recommended quantities and will not relieve the refractory contractor
from complying with the other requirements of this specification.

3.4.11 Water used for preparing lining material shall not contain oil, acid, alkali, organic matter or such
substances that would affect lining integrity. The chloride content of the water shall not exceed 30 ppm.

4. CURING AND DRYING

4.1 Curing

The refractory shall be allowed to cure for a minimum of 24 hours after installation.

4.2 Drying

For the reformer riser transition, the tabular alumina shall be allowed to air dry for a minimum of 24 hours
prior to installation of the bubbled alumina. Artificial drying of the composite lined transition assembly shall
be done, in a furnace, at the Equipment Fabricator's shop, in accordance with the time-temperature curve
shown below in Figure 1. Artificial drying shall be performed prior to pneumatic test of the pressure shell and
application of the water jacket assembly.

FIGURE 1
 TECHNICAL STANDARD
INSTALLATION OF HIGH ALUMINA CASTABLE
IN FURNACES MB11-2TS

DATE: 01 MAY 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 5 OF 6

5. INSPECTION, RADIOGRAPHY, TESTING, AND REPAIRS

5.1 Inspection

5.1.1 A Purchaser's field representative, thoroughly familiar with the placement of linings shall be
continuously present during all phases of major lining installation and shall be authorized to reject any part of
the work which does not conform to this standard.

5.1.2 It is the responsibility of the Purchaser's representative to complete a lining report listing all deviations
from this standard together with the reasons for allowing those deviations. The lining shall also be certified
for use or rejected, either of which is to be stated in the report. These reports shall be submitted to the
Purchaser for review.

5.2 Radiographic Examination

5.2.1 The shop installed tabular and bubbled alumina section of the transition assembly shall be
radiographed. This examination is to be performed prior to drying out of the lining. Radiographic
requirements of the shop installed castable are as follows:

a. The radiographic source shall be Iridium 192 located on the axial center line of the riser transition liner
with the film wrapped around the outside of the pressure shell to permit examination of the entire
circumferential area in a single exposure. The film shall be Kodak AA or equivalent, and the density of
the developed film shall be between 1.5 and 2.0.

b. A sufficient number of test shots shall be taken to establish a technique capable of detecting voids in the
castable lining. Acceptance or rejection of the castable shall be based on the following:

1. Voids 1/2 inch x 1/2 inch (0.25 inch2) (13 mm x 13 mm) (160 mm2) or larger must be repaired
regardless of depth.

2. No voids are acceptable for the lower 6 inches (150 mm) of the cone. Acceptable voids shall not be
closer to each other than 8 inches (200 mm) edge to edge for the remaining section.

c. The radiographic technique and qualifying results shall be approved by the Purchaser's inspector before
any production radiography is performed. All production radiography must be approved by the
Purchaser's inspector.

5.3 Testing

5.3.1 The following tests shall be performed by the RIC during lining application for each material installed:

a. Cold crushing after heating to 1500 °F (816 °C) in accordance with ASTM C133. Minimum acceptable
strength is 90% of manufacturer data sheet value (average of three test specimens).

b. Density after heating to 220 °F (105 °C). Acceptable density is manufacturer data sheet value ±10%.

c. Reheat shrinkage after heating to 1500 °F (816 °C) in accordance with ASTM C113, C210, C860, C862
and C865. Maximum value acceptable is 0.3%.

5.3.2 Frequency of testing shall be as follows:

a. One test, each of Subparagraphs 5.3.1 a, b, and c, for each 500 lbs (225 kg) or portion thereof of
tabular alumina for reformer riser transition.
 TECHNICAL STANDARD
INSTALLATION OF HIGH ALUMINA CASTABLE
IN FURNACES MB11-2TS

DATE: 01 MAY 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 6 OF 6

b. One test, each of Subparagraphs 5.3.1 a, b, and c, for each 2000 lbs (900 kg) or portion thereof of
bubbled alumina for reformer riser transition.

c. As stated in the Order for other than reformer riser applications.

5.4 Repairs

Before any repair work is carried out, it is mandatory that approval be obtained from the Purchaser.

6. TRANSPORTATION OF SHOP-LINED EQUIPMENT

6.1 General

6.1.1 When refractory lining is shop installed, the RIC and the Lining Material Supplier shall confirm in
writing their agreement that such equipment can be transported to the in-site plant position without refractory
lining damage based on the method of handling and transport agreed with the Purchaser.

6.1.2 After installation of the refractory lining, equipment shall not be moved within the shop, excessively
vibrated, jarred or handled in a manner that would disturb the refractory lining.

6.1.3 Rigging and hoisting attachments to this equipment shall be such that flexure and distortion of the
shell, etc., will not disturb the refractory linings.

6.1.4 After cleaning and dryout, water, dirt or foreign debris shall not be allowed to enter the equipment and
come in contact with refractories. After final repairs and cleanout are completed and accepted, all openings
are to be waterproofed by installing wood and polyethylene in place securely so as to effectively remain in
place until received in the field.

6.2 Field Acceptance Examination

Immediately upon receipt of the riser transition on the job site, it shall be examined to ensure that the
protective wrapping and seals are still effective. Damaged seals shall be replaced and not removed until
work or installation has started. If seals are not effective as received and damage has occurred, a report
shall immediately be made to the Purchaser for further instructions.

7. FIELD INSTALLATION

7.1 General

7.1.1 For field installed castable, the same care in selection of castable materials, mixing and pouring, shall
be observed as called for in the Equipment Fabricator's shop. An inspection report shall be made for the
Purchaser's information.

7.1.2 Dryout of the field installed castable in the reformer riser transition will be carried out during the start-
up of the unit.