TECHNICAL STANDARD

INSTALLATION OF FURNACE CASTABLE

LININGS (SHOP OR FIELD) MB11-1TS

DATE: 01 JUL 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 1 OF 8

TABLE OF CONTENTS

Section Title Page No.

1. GENERAL ......................................................................................................................................1
1.1 Scope..............................................................................................................................................1
1.2 KBR Documents, and Industry Standards......................................................................................1
2. MATERIALS ...................................................................................................................................2
2.1 Storage ...........................................................................................................................................2
3. PREPARATION FOR PLACEMENT..............................................................................................2
3.1 Surface Preparation........................................................................................................................2
3.2 Requirements and Limitations ........................................................................................................2
3.3 Preparation of Aggregate for LHV Castable ...................................................................................3
4. MIXING AND PLACEMENT PROCEDURE...................................................................................3
4.1 Mixing..............................................................................................................................................3
4.2 Pneumatically Applied Linings ........................................................................................................3
4.3 Poured Linings ................................................................................................................................4
5. CURING AND DRYING..................................................................................................................4
5.1 Moist Curing and Air Drying............................................................................................................4
5.2 Membrane Curing ...........................................................................................................................4
5.3 Artificial Drying ................................................................................................................................5
6. TESTING, INSPECTION, AND MAJOR REPAIRS OF PROPRIETARY CASTABLE .................5
6.1 General ...........................................................................................................................................5
6.2 Testing ............................................................................................................................................5
6.3 Inspection........................................................................................................................................7
6.4 Disposition of Failed Castable Material ..........................................................................................7
6.5 Major Repairs..................................................................................................................................8
7. Miscellaneous .................................................................................................................................8
7.1 General ...........................................................................................................................................8

1. GENERAL

1.1 Scope

1.1.1 This standard covers general requirements for the installation of furnace castable linings. Only those
requirements pertaining to the specified type(s) of lining shall be applicable. Any modifications to this
specification and applicable abbreviations are in accordance with KBR Technical Standard MB15-1TS (Note:
KBR will be referred to as the Purchaser).

1.1.2 The locations and extent of the various types of linings are shown by symbols on the Purchaser's
Furnace General Arrangement Drawings or the Furnace Lining Drawings.

1.1.3 The details, materials and anchorage of the linings are specified on the Purchaser's Furnace Lining
Schedule.

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 and codes
shall be as indicated in the KBR Technical Standards MB15-1TS.

KBR DOCUMENTS
MB15-1TS, “General Furnace Specification”
 TECHNICAL STANDARD
INSTALLATION OF FURNACE CASTABLE
LININGS (SHOP OR FIELD) MB11-1TS

DATE: 01 JUL 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 2 OF 8

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM C133, "Cold Crushing Strength and Modulus of Rupture of Refractories"
ASTM C134, "Size, Dimensional Measurement, and Bulk Density of Refractory Brick and Insulating
Firebrick"
ASTM C184, "Fineness of Hydraulic Cement by the 150 µm (No. 100) and 75 µm (No. 200) Sieves"
(Discontinued, No Replacement)
ASTM C309, "Liquid Membrane-Forming Compounds for Curing Concrete"
ASTM C860 "Determining and Measuring Consistency of Refractory Concretes"
ASTM C862 "Preparing Refractory Concrete Specimens by Casting"
ASTM C865 "Firing Refractory Concrete Specimens"
ASTM C903 "Preparing Refractory Concrete Specimens by Cold Gunning"

2. MATERIALS

2.1 Storage

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

2.1.2 All castable material packaging shall be stamped with the date of manufacture. Materials that have
exceeded the manufacturer's stated shelf life shall not be used.

3. PREPARATION FOR PLACEMENT

3.1 Surface Preparation

3.1.1 All steel surfaces that are to be lined shall be thoroughly cleaned to remove all loose rust and mill
scale, grease and other deleterious material.

3.1.2 Block insulation over which the castable is to be applied shall be covered with a layer of waterproof
paper or coated with an impervious compound to prevent absorption of water. Precautions shall be taken to
close staple waterproof paper when applied to vertical surfaces to prevent it sagging due to the weight of the
liner. An acceptable compound is one which is equivalent to Stalastic, Spray Grade SH8831017 (61036)
manufactured by:

Exxon Mobil Southwest Grease

1400 South Harrison, PO Box 1974
Olathe, KS 66051-1974

3.2 Requirements and Limitations

3.2.1 The castable may be pneumatically applied or poured. The selection of the method of application shall
be based on consideration of the specific areas to be lined and thicknesses required.

a. If poured, care shall be taken to ensure a uniform lining free of void inclusions.

b. Troweling is not permitted, except where required to form difficult contours.

c. A smooth finish is not allowed.

d. Where surfaces are to be made level, excess material should be removed off with a wooden screed.

3.2.2 The castable shall not be installed when the surface being lined or the lining mix temperatures exceed
90 oF (32 oC). The temperature shall be maintained below this limit by any proven method such as external
water cooling, night application or shading from the sun.
 TECHNICAL STANDARD
INSTALLATION OF FURNACE CASTABLE
LININGS (SHOP OR FIELD) MB11-1TS

DATE: 01 JUL 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 3 OF 8

3.2.3 The castable shall not be installed in cold weather unless precautions are taken to keep both the
surface and the castable temperatures above 40 oF (5 oC) during application and for at least 24 hours
thereafter.

3.2.4 No other cements, limes or admixtures shall be added to the castable mixtures. All tools and
equipment used for mixing and placing shall be clean and free from all foreign or deleterious material.

3.2.5 Tolerances on specified in-place thicknesses shall be 1/8 inch (3 mm). Installed thickness shall be
closely monitored and adequately checked for compliance with this tolerance.

3.2.6 The castable over 3 inches (75 mm) in thickness shall be scored in two perpendicular directions,
1/4 inch (6 mm) wide by 3/4 inch (19 mm) deep on a maximum of 2 foot (600 mm) centers. Scoring may be
done before or after hardening of the linings. A circular saw shall preferably be used to score castable after
it has set.

3.2.7 The water percentage shall be as recommended by the castable material supplier. Any deviation shall
be approved by the castable material supplier.

3.2.8 The mixing equipment shall be of the revolving blade, mortar batch type. Rotating tumbler type mixers
shall not be used.

3.3 Preparation of Aggregate for LHV Castable

The Haydite aggregate shall be wetted and kept thoroughly moistened for at least 12 hours immediately
before use. Provision shall be made for draining excess water.

4. MIXING AND PLACEMENT PROCEDURE FOR LHV CASTABLE

4.1 Mixing

4.1.1 The cement shall have a fineness in accordance with the following:

4.1.2 The residue on a No. 200 sieve shall not exceed 10% by weight when tested in accordance with
ASTM C184.

4.1.3 The lining mix proportion shall be 1:2:4 by volume. (One part alumina cement, two parts Haydite
aggregate, and four parts vermiculite aggregate).

4.1.4 When mixing the prewet Haydite, dry Vermiculite shall be introduced into the mixer with sufficient
water added to thoroughly wet the Vermiculite. The resultant mass shall be mixed to a uniform consistency.
The alumina cement shall then be added to produce a plastic and cohesive mixture. The mixing time after all
ingredients have been placed in the mixer shall be between 3 to 5 minutes.

4.2 Pneumatically Applied Linings

4.2.1 On vertical walls, the lining shall be placed by working upward from the bottom. During application,
the nozzle shall be kept as nearly normal (90o angle) to the surface as the work permits. The full thickness of
the lining shall be placed at one time to avoid laminations or cleavage planes.

4.2.2 The area of application shall be limited by the quantity of lining material which can be applied to the
specified thickness within a 20 minute period.
 TECHNICAL STANDARD
INSTALLATION OF FURNACE CASTABLE
LININGS (SHOP OR FIELD) MB11-1TS

DATE: 01 JUL 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 4 OF 8

4.2.3 If it is necessary to interrupt the application of the lining, the work shall terminate at a straight, square
edge of full thickness. Before placing the adjoining work, the abutting edge shall be thoroughly cleaned,
roughened and wetted. Any rebound materials on areas which are to be subsequently covered shall be
removed. Rebound materials shall not be reused.

4.3 Poured Linings

4.3.1 Linings shall be placed in suitable forms and in a manner which will prevent segregation of the
materials. Lining material shall not be poured in large quantities at a given point and be allowed to run or be
worked over long distances in the form. Linings shall be compacted and consolidated by paddling.
Mechanical vibrators shall not be employed.

4.3.2 Excess water which may rise during compacting operations is indicative of an overwet mix. Such
overwet batches shall be removed and repoured. Subsequent batches shall be corrected by using less
mixing water.

4.3.3 Work shall not terminate until a panel or section is finished with a straight, square edge of full
thickness. When work is resumed, the contact edge of the lining in place shall be thoroughly cleaned,
roughened and wetted.

5. CURING AND DRYING

5.1 Moist Curing and Air Drying

5.1.1 The exposed surface of linings shall be kept thoroughly wet during the hardening period by intermittent
light spraying with a fine mist of clear, cool water. Curing shall be started as soon as the concrete surface is
sufficiently hard to permit spraying without washing out the cement. This can be determined by rubbing the
surface with a moistened finger. Spraying shall not be started until such time that no cement adheres to the
finger. This check should be made at half hour intervals until the surface is ready.

5.1.2 Hot weather applications may require that curing begin within 3 or 4 hours after placement.

5.1.3 Moist curing, once started, shall be continuous for at least 24 hours and at no time during the curing
period shall the intervals between spraying be longer than 30 minutes.

5.1.4 Following the 24 hour moist curing period, the lining shall be air dried for at least 48 hours after which
artificial drying may be employed. Adequate ventilation shall be provided to permit the escape of moisture.
In case the lining is not artificially dried out in 72 hours after installation, the lining surface shall be spray
coated with the sealant Kao-Seal (by Thermal Ceramics) at the rate of approximately 250 ft2 per US Gallon
(6.0 m2 per liter) to prevent alkali hydrolysis. A non-detrimental pigment shall be used with Kao-Seal that will
enable complete coverage to be easily identified.

5.2 Membrane Curing

5.2.1 The lining may also be cured by the application of a membrane forming compound. When curing by
this method, water spraying is not required. The compound shall be applied immediately after final finishing
by spraying the exposed surface with a "Hudson type" or similar sprayer at the rate of 100 to 125 ft2 per
US gallon (2.5 to 3.0 m2 per liter). A non-detrimental pigment shall be used with the membrane forming
compound that will enable complete coverage to be easily identified. Kaoseal (by Thermal Ceramics) shall
not be used as a curing membrane.

5.2.2 The compound shall be a resin-base, fugitive dye membrane curing compound conforming to
Type 1-D, Class B of ASTM C309. The compound shall be thoroughly mixed in accordance with
manufacturer's instructions.
 TECHNICAL STANDARD
INSTALLATION OF FURNACE CASTABLE
LININGS (SHOP OR FIELD) MB11-1TS

DATE: 01 JUL 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 5 OF 8

5.2.3 Membrane compounds contain a volatile vehicle which is flammable, therefore care shall be taken to
prevent fires.

5.2.4 Following the application of the compound, the lining shall be cured for 24 hours. All lining surfaces
shall then be spray coated with the sealant Kao-seal (by Thermal Ceramics) at the rate of approximately
250 ft2 per US gallon (6.0 m2 per liter) to prevent alkali hydrolysis. A non-detrimental pigment shall be used
with Kao-Seal that will enable complete coverage to be easily identified.

5.2.5 Lining surfaces stored beyond sealant service life shall be recoated or dried out artificially.

5.3 Artificial Drying

5.3.1 Artificial drying when employed shall not begin sooner than 72 hours after the curing period has
started for moist cured liners and 24 hours for membrane cured liners.

5.3.2 The drying out process shall consist of mild heating and air cooling of the lining for a period of at least
26 hours using the burners provided in the furnaces or temporary dry-out facilities. The temperature of the
flue gas shall be limited to a maximum increase of 100 oF (56 oC) per hour up to temperature of 250 oF
(121 oC) and 50 oF (28 oC) per hour during the remaining dry out at 500 oF (260 oC). Care shall be taken to
avoid high localized temperatures. The temperatures shall be maintained at:

a. 250 oF (121 oC) for 1 hour/inch (25 mm) of lining thickness with a minimum of 8 hours.

b. 500 oF (260 oC) for 1 hour/inch (25 mm) of lining thickness with a minimum of 8 hours.

Note that when drying large fireboxes with the project burners, the number of burners which can be lit at any
one time is typically limited to a small percentage of the total. To assure a uniform dry out, the lit burners
must be rotated to ensure adequate coverage. This may significantly extend the minimum hold time shown.

5.3.3 After drying, the lining shall be allowed to air cool at a rate of no more than 150 oF (83 oC per hour).

5.3.4 During dry out, temperature of the flue gas shall be monitored using the temperature indicators
installed in the furnace as shown on the design drawings. Additional temperature indicators may be
necessary when dry out is carried out for individual furnace sections.

6. TESTING, INSPECTION, AND MAJOR REPAIRS OF PROPRIETARY CASTABLE

6.1 General

The inspector representing the Purchaser shall have entry at all times, while work on the contract of the
Purchaser is being performed, to all parts of the manufacturer's works that concern the manufacture of the
material installed. The manufacturer shall afford the inspector all reasonable facilities to ensure that the
material is being installed in accordance with this specification. All required tests and inspection shall be
made at the place of manufacture prior to shipment unless otherwise specified, and will be conducted so as
not to interfere unnecessarily with the operation of the work.

6.2 Testing

6.2.1 Standard test specimens shall be prepared which are representative of the quality of the furnished
mixture and its method of application.

6.2.2 Sampling techniques, number of required specimens; molding, curing and firing of the specimens;
strength and density testing shall be in accordance with the applicable portions of the industry standards
specified in Table I.
 TECHNICAL STANDARD
INSTALLATION OF FURNACE CASTABLE
LININGS (SHOP OR FIELD) MB11-1TS

DATE: 01 JUL 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 6 OF 8

TABLE I
SAMPLING AND TESTING STANDARDS
REQUIREMENTS IN ACCORDANCE WITH
Specimen Preparation:
Casting ASTM C862
Cold Gunning ASTM C903
Consistency ASTM C860
Firing ASTM C865
Strength Testing ASTM C133
Density Testing ASTM C134

6.2.3 One test specimen and the test result data shall be kept available for inspection and record purposes.
The dry unit weight of the lining shall be recorded as part of the test data.

6.2.4 The Inspector shall have the right to require laboratory testing of production samples after 10% of the
lining has been installed and may halt further installation until the test results have been returned. Additional
samples and testing may be required at the discretion of the inspector.

6.2.5 The installer (shop or field) shall perform the following tests on proprietary castable materials at the
frequency indicated below:

a. Bulk Density - ASTM C134

b. Cold crushing strength - ASTM C133

c. The frequency of testing shall be one (1) per day for the first week, then two (2) per week thereafter.
Additional testing shall be performed at the discretion of the inspector.

d. For published data based on average results from controlled testing, the allowable deviations from the
published ranges are as follows:

Deviation
Density ±5%
Shrinkage Zero
Cold Crushing Strength -10%
Thermal Conductivity +10%
Chemical Composition Supplier Specify

Notes for LHV (1:2:4)

1. At least two specimens shall be tested for cold crushing strength after 3 (three) days of curing. The
minimum acceptable cold crushing strength shall be 150 psi (1.03 MPa)(10.5 kg/cm2).

2. Dry unit weight applied by gunning shall be 55-65 lb/ft3 (0.88-1.04 g/cm3) after drying at 220-230 oF
(104-110 oC).

6.2.6 All accessible areas shall be hammer tested after installation of castable once a month up to first six
months, once a week thereafter until the castable is dried out. The testing is required to detect onset of alkali
hydrolysis.
 TECHNICAL STANDARD
INSTALLATION OF FURNACE CASTABLE
LININGS (SHOP OR FIELD) MB11-1TS

DATE: 01 JUL 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 7 OF 8

6.2.7 Once alkali hydrolysis is suspected by the deterioration of the castable further testing of random core
samples be conducted. One chemical analysis and minimum of three cold crushing strength tests shall be
conducted. Castable dryout shall be carried out if alkali hydrolysis is confirmed. Cold crushing results would
indicate if the original installation met the specified requirements.

6.2.8 Results of each test shall be recorded and reviewed by the Purchaser Inspector.

6.3 Inspection

6.3.1 The entire refractory lining shall be visually inspected and hammer tested before dry out and prior to
installing tubes in the convection section modules and prior to shipping panels or ductwork. The hammer
testing will detect the presence of voids, areas that may be filled with dry materials, spalling, crumbling and
improper installation. The inspection shall be carried out no sooner than 72 hours after application of
refractory.

6.3.2 The hammer test shall consist of striking the entire refractory surface with a hammer at about 12 inch
(300 mm) intervals. When areas with voids, laminations or areas filled with dry material are struck with the
hammer, a dull sound will be produced. Such areas are considered defective and shall be repaired.

6.3.3 The lining shall also be inspected for cracking. Random surface cracks up to 1/16 inch (1 mm) wide
are considered normal on thick linings. Areas containing cracks wider than 1/8 inch (3 mm) or loose pieces
of refractory are considered defective. Such defective areas shall be repaired.

6.4 Disposition of Failed Castable Material

6.4.1 If testing indicates a failed sample, the material represented by that sample must be removed and
samples for insulation installed before and after the failed portion must be tested.

6.4.2 If any test fails, all insulation installed on the failed side on that day must be removed.

6.4.3 When removing defective material, an area large enough to expose at least 3 anchors shall be
chiseled out completely to the equipment shell and until there is sound material on all sides. The minimum
area to be removed shall be 1 ft2 (600 cm2). All cuts shall be tapered back to the shell at a 45o angle so that
the area at the shell is larger than the area at the internal face of the lining. The hole shall be cleared of all
loose refractory. For hydraulically bonded refractories, the adjacent material shall be thoroughly wetted
before new refractory is applied. Never apply new refractory adjacent to material which is still warm to the
touch as a result of the dryout operation.

6.4.4 Refractory adjacent to areas removed for repair shall be hammer tested for soundness before
reinstallation of refractory.

6.4.5 All repaired areas shall be subjected to the same cure and dryout procedures given in this standard.

6.4.6 Purchaser shall have the right to request that core samples be cut from the lining if the quality of the
lining is questionable. Taking of these core samples and subsequent repairs shall be at refractory installer's
expense.

6.4.7 Refractory not meeting the specified properties or other provisions of this standard shall be replaced at
the installer's expense.
 TECHNICAL STANDARD
INSTALLATION OF FURNACE CASTABLE
LININGS (SHOP OR FIELD) MB11-1TS

DATE: 01 JUL 2004 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 8 OF 8

6.5 Major Repairs

6.5.1 Any part of the work which is defective due to the presence of voids, honeycombing, insufficient curing
or construction damage shall be removed to the full thickness of the lining. The minimum area to be
removed shall be one square foot (900 cm2) and expose a minimum of three (3) anchors with all edges
tapered inward at a 45o angle.

6.5.2 The method of repair and curing, shall be as near as possible in accordance with the original
installation procedure.

7. MISCELLANEOUS

7.1 General

7.1.1 Nosing in castables shall be trowelled or gunned to provide a rounded contour with no sharp corners.

7.1.2 Anchors shall be provided and installed in accordance with the Purchaser's design drawings.

7.1.3 Corbels and corbel anchors shall be installed in accordance with Purchaser's design drawings.
Tolerance on specified in-place thickness of corbel shall be ±1/8 in. (3 mm).