ALGIERS REFINERY

REHABILITATION AND ADAPTATION PROJECT

Dry Out Refractory Procedure

100-F-501
ITT SPA
Vendor Reference: RB-10009-PRO-004 Revision : 1
Requisition Reference: 9952T-000-SR-0110-0001 Purchase Order : 0013

ADU-ATMOSPHERIC HEATER

Dry Out Refractory Procedure

100-F-501

Antonio Navas
2013.12.13
17:30:59
+01'00'

1 22/07/13 Revised per client comments – IFC V. Granato L. Meroni R. Lener

0 02/04/12 Issue for approval V. Granato L. Meroni R. Lener

Rev Date STATUS WRITTEN BY CHECKED BY APPROVED BY

(name & visa) (name & visa) (name & visa)

Sections changed in last revision are identified by a vertical line in the margin
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CONTENTS

1. SCOPE

2. PRE-DRY OUT

3. PREPARATION

4. HEAT GAS FLAME BLOWING EQUIPMENT

5. THERMOCOUPLE AND RECORDER

6. PROCEDURE

7. RECORDS

8. APPLICABLE DRY OUT

TABLE-1 Diagrams of Dry-Out (Refer to MFG.(SIRC)

Fig. - 1 Dry-Out for Convection Modules (SAMPLE)
Fig. - 2 Gas Burner Application
Attach #1 MFG.SIRC-Dry out Book & General Dry out Procedure




 





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1 SCOPE

This procedure shall be applied to refractory dry out for Convection /Breeching/Stack/Flue Gas Duct
to be supplied for Rehabilitation & Adaptation Project Algiers Refinery, Algeria. Reference Document
and specification of manufacturer SIRC and code standard. See Attach #1


Refractory Installation Quality Control

API 936
Guidelines Inspection and testing Code Book
Ed.2004
monolithic Refractory Lining and Materials
Steel work supply & Fabrication, Coil
prefabrication & WHS Modularization, Material Requisition No. ITT : 16052
Lining application for ADU, NHT and CCR
MR. ITT.
Rev.1 
Heaters.
Fabrication and Erection Fired Heater Project Spec. 6-17-0001-3
Specification For Refractory Lining Project Spec. 6897-000-06-43-DB-01-0
Specification For Refractory Lining Project Spec. 6897-000-06-43-QP-01-0
Specification For Refractory Lining Project Spec. 6897-000-06-43-SP-01-0
Refractory SIRC –Dry-out Book & General Manufacturer SIRC Doc.13050-8.
Dry-out Procedure Specification 

1.1 The refractory material was not normally thermally cured at the factory.
It is not uncommon for moisture to be absorbed by the refractory during final stages of in-
shop fabrication, transit to the job residual moisture and any absorbed moisture must be
removed after installation but prior to commencement of start-up operations. Otherwise,
trapped moisture will steam, causing cracking, and in many cases, the Refractory will separate
from the metal in large pieces. As a minimum, follow these Steps to protect the refractory
from damage.

2 PRE-DRY OUT

2.1 Pre-dry out shall be performed after completion of refractory curing and inspections.
2.2 The pre-dry out for the convection modules and breechings at the shop shall be done by
electric resistance heaters.

2.3 The dry out curve to be taken as shown in TABLE-1.

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3 PREPARATION
3.1 Dry-out shall be performed after completion of refractory curing for specification
requirement Hour. and before coil installation.

3.2 All the specified inspection and test on the completed.

3.3 During dry-out, contaminants such as grease, paint, oil, etc. on the surface of parts to be heat-
treated shall be removed.

3.4 All machined surfaces and threads must be protected.

3.5 Rain protection shall be installed prior to start dry-out works.

3.6 All the equipment and devices to be used for dry-out shall be installed.

4 HEATING EQUIPMENT (This section to be checked )

4.1 The equipment shall be heat-treated by electric heater with internal details as shown on Fig.1.
The drying equipments shall be used gas flame flow out method

4.2 The dry out equipment shall be used as below items.

Power regulator : 380V / 60 KVA / 12 set
LPG or Butane Gas cylinder xxxxM3 or xxxxx Ltr
Temp recorder : 1200°C / 1 set / 12 points
Electric heater : 220V / 4 KW / 48 set Gas burner Type : type number / 48 set

*Should be operated gas burner flame and gas flow regulator with auto control valve Etc:

5 THERMOCOUPLE AND RECORDER

5.1 The calibrated temperature recorder shall be used for temperature control of the heat- treated
parts. The equipments used to verity the PWHT temperature shall have been calibrated within
six months of the performance of the heat treatment.

5.2 The thermocouple wire shall be used the nickel chrome/nickel aluminum (k-type) directly
capacitance discharge welded to the vessel.

5.3 Each temperature of the thermocouples will be recorded with automatic time temperature
recorder. The type of temperature recorder is strip chart type. The minimum chart speed of
strip chart shall not be less than 1 inch per hour.

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5.4 Minimum holding time shall be considered as a period when all thermocouples recorded the
required holding temperature.

5.5 Thermocouples to measure and control the temperature of the heat-treated material shall be
located properly. The distance of thermocouple shall be max. 4.6 m. to each other.

5.6 The number and location of thermocouples shall be as shown on Fig.1.

6 PROCEDURE

6.1 The site supervisor shall be responsible for all document information, and ensuring
compliance with all procedure to met on specification requirements. Documentation shall
include:
1) Recording of calibration certificate
2) Thermocouple conformation certificate
3) Thermocouple allocation Map
4) Temperature monitored recorder and charts.

6.2 The pre-dry out curve for convection, stack and duct as follows. See Attach #1 
1) Heating rate ; as per spec. require (ºF/Hr) (SIRC Dry out book)
2) Holding : as per spec. require (Hr/ inch) (SIRC Dry out book)
3) Heating up to as per spec. require ( ºF) (SIRC Dry out book)
4) Cooling rate up to spec. require ( ºF) (SIRC Dry out book)
5) Remove the heat source and allow the refractory to cool by natural radiation.
6) Do not introduce cold air with a fan.

7 RECORDS

7.1 The record and/or report of “DRY OUT “ result shall include the following information.
1) Recorder calibration certificate and thermocouple conformance certificate.
2) Heater No. and /or product No.
3) Time - temperature recorder No.
4) Number and placement of thermocouples.
5) Heating and cooling rates.
6) Holding time and temperature.

7.2 The record and/or report shall be written in English.

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8 APPLICABLE DRY OUT

Please see dry out diagrams for convection, stack and duct in Attach #1

TABLE-1. Diagrams of “DRY OUT” (Sample)

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(Hold 1Hr./inch)
500ºF Max 100ºF/Hr.
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(500ºF)
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(300ºF)
Max 50ºF/Hr.
(Hold 1Hr./inch)
250ºF (250ºF)
Max 50ºF/Hr.
 ą%*T

5 Hr. Hr. 5 Hr. Hr. 2 Hr.

















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Fig. 1. Dry-Out for Convection Modules (Sample)

Location of Thermocouples

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+Fig. 2. BURNER SPECIFICATION

Capacity
Min 400,000 Kcl/Hr
Max 4,000,000 Kcl/Hr

OPERATING /AUTOMATIC SYSTEAM

1. POWER ON

2. POWER SOURCE LAMP ON

3. FUEL SUPPLY TO UNIT

4.F.D FAN START

5.INTER LOCK RESET BUTTON ON

6. FUEL INTER LOCK LAMP ON

7. F.D.FAN RUN LAMP ON

8.BURNER START BUTTON ON

9. PRE-PURGE /5MIN.

10. PILOT BURNER ON

11. FLAME ON

12. MAIN BURNER ON

13. PILOT BURNER OFF

14. AUTO RUN

No direct flam on the refractory walls will be applied. And the Max. in creasing gradient
temperature is 20 ºC /Hr.

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Attach. #1 Dry out Book & General Dry out Procedure

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 General Refractory Procedure
____________________________________________________________________________________

General notes for dry-out

Reference temperatures are generally temperatures of gas in contact with face rather than
castable temperatures. A thermocouple into castable near surface is a valid instrument to
measure castable temperatures. Always check heating diagram for the heater zones of
plant, remaining parts will be heated as consequence. In possible big blocks where source
of heat shall warm a big volume, it’s advisable to decrease the heat velocity into this “heat
zone”, this in order to keep the correct heat velocity into other zones.
Any casting could be heated at velocity lower than what recommended and however it’s
better to “make a mistake” using a lower velocity, if this could be accepted.
The heating program should occur without interruptions until ending.
A good air flow is essential into all phases to facilitate water elimination.

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ITT P.O. RB-10009-14/111 ALGIERS REFINERY PROJECT