Shell DEP 44.24.32.30-Gen.

DEP SPECIFICATION
UNSHAPED REFRACTORY MATERIALS FOR MONOLITHIC

REFRACTORY LININGS
Copyright Shell Group of Companies. No reproduction or networking permitted without license from Shell. Not for resale
DEP 44.24.32.30-Gen.
February 2017
ECCN EAR99
DESIGN AND ENGINEERING PRACTICE
© 2017 Shell Group of companies
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Zeeco, Inc. Denise_Godfrey@zeeco.com 16/11/2020 10:54:08
ECCN EAR99 DEP 44.24.32.30-Gen.
February 2017
Page 2
PREFACE
DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions
International B.V. (Shell GSI) and, in some cases, of other Shell Companies.
These views are based on the experience acquired during involvement with the design, construction, operation and
maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international,
regional, national and industry standards.
The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and
gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help
achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each
locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
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quality of their work and the attainment of the required design and engineering standards. In particular, for those
requirements not specifically covered, the Principal will typically expect them to follow those design and engineering
practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or
Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal.
The right to obtain and to use DEPs is restricted, and is typically granted by Shell GSI (and in some cases by other Shell
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a Service Agreement or otherwise).
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2)
which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said
users comply with the relevant standards.
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All administrative queries should be directed to the DEP Administrator in Shell GSI.

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TABLE OF CONTENTS
1. INTRODUCTION ........................................................................................................ 4
1.1 SCOPE ....................................................................................................................... 4
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 4
1.3 DEFINITIONS ............................................................................................................. 4
1.4 CROSS-REFERENCES ............................................................................................. 6
1.5 SUMMARY OF MAIN CHANGES............................................................................... 6
1.6 COMMENTS ON THIS DEP ....................................................................................... 7
1.7 DUAL UNITS............................................................................................................... 7
1.8 NON NORMATIVE TEXT (COMMENTARY) .............................................................. 7
2. THERMAL DESIGN OF MONOLITHIC LINING SYSTEM ........................................ 8
3. LINING SYSTEMS...................................................................................................... 9
3.1 SINGLE LAYER DESIGN ........................................................................................... 9
3.2 DUAL LAYER DESIGNS .......................................................................................... 10
4. UNSHAPED REFRACTORY MATERIALS ............................................................. 11
4.1 REFRACTORY LINING MATERIALS....................................................................... 11
4.2 AUXILIARY UNSHAPED MATERIALS..................................................................... 13
5. ANCHORING SYSTEMS ......................................................................................... 14
5.1 GENERAL ................................................................................................................. 14
5.2 ANCHOR MATERIALS ............................................................................................. 14
5.3 ANCHOR TYPES...................................................................................................... 15
5.4 ANCHORING PATTERNS........................................................................................ 17
5.5 ANCHOR WELDING................................................................................................. 18
6. LINING INSTALLATION .......................................................................................... 19
7. CURING, DRYING AND FIRING OF MONOLITHIC LINING SYSTEMS ................ 19
7.1 CURING .................................................................................................................... 19
7.2 DRYING AND FIRING .............................................................................................. 19
8. QUALITY ASSURANCE AND QUALITY CONTROL (QA/QC) .............................. 20
8.1 INSPECTION AND TEST PLAN (ITP)...................................................................... 20
8.2 QA/QC FOR ANCHORING SYSTEM ....................................................................... 20
8.3 QA/QC FOR LINING MATERIALS AND LINING INSTALLATION ........................... 21
9. TRANSPORTATION AND HANDLING OF REFRACTORY LINED
EQUIPMENT............................................................................................................. 27
10. REFERENCES ......................................................................................................... 28

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1. INTRODUCTION
1.1 SCOPE
This DEP specifies requirements and gives recommendations for unshaped refractory
materials as used for monolithic refractory linings in furnaces, heaters, boilers, flue gas
systems, stacks (if refractory lined) and general applications. For these applications, the
lining materials are exposed to neutral or oxidising conditions. This DEP is not intended to
be used for processes whereby the refractory lining materials are in contact with process
conditions like in FCC, sulphur plants and syngas processes. For FCC and for sulphur
plants, separate refractory DEPs exist.
This DEP focusses upon lining design and engineering and upon quality assurance and
quality control.
This DEP applies to refractory materials in fired heaters (previously covered by
DEP 31.24.00.30-Gen). This DEP largely follows the section(s) on refractory castables in
API560/ISO 13705 and includes some amendments as well as several additions.
DEP 64.24.32.12-Gen. addresses specialized application of unshaped materials used in
catalytic cracking units, it provides the final basis for all aspects of specification, supply,
installation and quality control and supersedes this DEP in areas of conflict.
DEP 44.24.90.34-Gen. covers refractory mortars.
Requirements and recommendations for shaped materials are in DEP 44.24.90.31-Gen.,
applicable with this DEP if shaped and unshaped refractory are required.
This DEP does not cover man made vitreous fibres, which are addressed in
DEP 64.24.32.35-Gen.
This is a revision of the DEP of the same number dated September 2012; see (1.5)
regarding the changes.
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell
companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated
by them. Any authorised access to DEPs does not for that reason constitute an
authorisation to any documents, data or information to which the DEPs may refer.
This DEP is intended for use in facilities related to oil and gas production, gas handling, oil
refining, chemical processing, gasification, distribution and supply/marketing. This DEP
may also be applied in other similar facilities.
When DEPs are applied, a Management of Change (MOC) process shall be implemented;
this is of particular importance when existing facilities are to be modified.
If national and/or local regulations exist in which some of the requirements could be more
stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable with regards to the safety, environmental, economic and legal aspects. In all
cases, the Contractor shall inform the Principal of any deviation from the requirements of
this DEP which is considered to be necessary in order to comply with national and/or local
regulations. The Principal may then negotiate with the Authorities concerned, the objective
being to obtain agreement to follow this DEP as closely as possible.
1.3 DEFINITIONS
1.3.1 General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.

February 2017
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The Manufacturer/Supplier is the party that manufactures or supplies equipment and

services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for it. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The word should indicates a recommendation.
The word may indicates a permitted option.
1.3.2 Specific definitions
Term Definition
Applicator The party that is responsible for the installation of the material utilizing
approved procedures produced by the refractory Contractor and
approved by the Principal.
Batch A number of raw material components traceably formulated by weight in

a proportional and quality controlled recipe collected in a mixer for
blending of a single repeatable finished product brand of material for
packaging in individual bags or pails.
Cold Face The surface of a refractory section which is not exposed to the source
of heat
Dual-layer A refractory lining consisting of two different types of monoliths.

lining Typically this would consist of a low density insulating lining material
behind a stronger and more dense lining material.
Hot Face The surface of a refractory section exposed to the source of heat
Maximum The term used by most material Manufacturer/Suppliers to suggest a

Continuous limit temperature after which products can no longer be expected to
Use work for extended periods without adverse affects on physical
Temperature properties.
Monolithic A relative jointless lining from unshaped materials.

Lining
Production The quantity of refractory having the same formulation that is prepared
Run in an uninterrupted manufacturing operation.
Production Physical property tests done on samples prepared during installation of

Testing unshaped materials to confirm consistency and quality of workmanship
of actual installation. Individual test values are evaluated respective of
industry wide generally acceptable deviation from normal compliance
data recognising variability in laboratory versus field preparation of
samples.
Refractory The party that carries out all or part of the construction design,
Contractor engineering, material procurement and installation of refractory
materials. The refractory Contractor has the final overall responsibly for
the total quality control of the materials and services including those of
any Subcontractors or Manufacturer/Suppliers related to the installation.

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Term Definition
Sample The quantity of refractory taken from a single container or installation

sequence that is used to make a complete set of test specimens to
determine various physical properties and/or chemical composition.
Specimen Individual cube, bar, plate or other test pieces used for physical property
testing.
1.3.3 Abbreviations
Term Definition
API American Petroleum Institute
APQ Applicator's procedure qualification
ASTM American Society for Testing and Materials
CCS Cold Crushing Strength
EN European Standard
FCAW Flux Core Arc Welding
FCCU Fluid Catalytic Cracking Unit
GMAW Gas Metal Arc Welding
GTAW Gas Tungsten Arc Welding
ISO International Organization for Standardization
ITP Inspection Test Plan
LW Light Weight Material
MW Medium Weight Material
PWHT Post Weld Heat Treatment
QC/QA Quality Control And Quality Assurance
TC Thermocouple
XLW Extra Light Weight Material
1.4 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section or
clause number is shown in brackets ( ). Other documents referenced by this DEP are listed
in (10).
1.5 SUMMARY OF MAIN CHANGES

This DEP is a full revision of the DEP of the same number dated September 2012. This
revision combines seven DEPs as follows into one DEP and the changes are too numerous
to list individually:

February 2017
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Section/Clause Change
DEP 44.24.32.31-Gen. Classification of unshaped refractory lining materials
DEP 44.24.32.32-Gen. Specification for sampling and testing of unshaped refractory
lining materials
DEP 44.24.32.33-Gen. Specification for anchoring systems of unshaped refractory
lining materials
DEP 64.24.32.33-Gen. Guidelines for curing, drying and firing of unshaped refractory
lining materials
DEP 64.24.32.34-Gen. Refractory contractor selection and applicator qualification for
installation of unshaped refractory lining materials
DEP 64.24.32.35-Gen. Construction design details of unshaped refractory materials
1.6 COMMENTS ON THIS DEP

Comments on this DEP may be submitted to the Administrator using one of the following
options:
Shell DEPs Online Enter the Shell DEPs Online system at

https://www.shelldeps.com
(Users with access to
Select a DEP and then go to the details screen for
Shell DEPs Online)
that DEP.
Click on the “Give feedback” link, fill in the online
form and submit.
DEP Feedback System Enter comments directly in the DEP Feedback

System which is accessible from the Technical
(Users with access to
Standards Portal http://sww.shell.com/standards.
Shell Wide Web)
Select “Submit DEP Feedback”, fill in the online form
and submit.
DEP Standard Form Use DEP Standard Form 00.00.05.80-Gen. to record

feedback and email the form to the Administrator at
(other users)
standards@shell.com.
Feedback that has been registered in the DEP Feedback System by using one of the above
options will be reviewed by the DEP Custodian for potential improvements to the DEP.
1.7 DUAL UNITS

This DEP contains both the International System (SI) units, as well as the corresponding
US Customary (USC) units, which are given following the SI units in brackets. When
agreed by the Principal, the indicated USC values/units may be used.
1.8 NON NORMATIVE TEXT (COMMENTARY)

Text shown in italic style in this DEP indicates text that is non-normative and is provided as
explanation or background information only.
Non-normative text is normally indented slightly to the right of the relevant DEP clause.

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2. THERMAL DESIGN OF MONOLITHIC LINING SYSTEM

The refractory lining system provides thermal resistance to reduce heat losses and to
protect the casing from high temperature damage.
1. External insulation shall not be applied to refractory lined equipment.
2. The following information shall be provided to the lining designer to enable a proper
thermal design of the lining system(s):
a. minimum, normal and normal high process temperatures as well as upset
temperatures;
b. gas composition including content of high conductivity components like hydrogen;
c. ambient conditions including average temperature and average wind velocities
over the year.
Ambient conditions can be based upon available meteorological data.
3. Local conditions for the specific equipment shall be taken into account.
Wind data measurements for meteorological purposes are typically taken at
elevation (10 m (33 ft) or more) and not at ground level. Wind velocities at ground
level and inside a plant might be significantly lower. This effect has to be taken into
account for the thermal design.
4. The design calculations shall be based upon the average conditions.
a. Calculations for extreme conditions shall be performed for information only.
5. Thermal calculations shall be performed on the basis of a standard calculation method
like ASTM C-680 (version 2002 or later) or VDI Waermeatlas (1997 or later), with the
following assumptions:
a. take a high value (>1000 W/m2/K) for the heat transfer coefficient at the process
side;
b. base the thermal conductivity data used in the calculations on the hot wire
method (DIN EN 993-14 and 993-15, ISO 8894-1 and 8894-2 or ASTM C1113).
i. Thermal conductivity data from calorimetric methods (ASTM C201, C202,
C417 and C182) should be corrected.
ii. Thermal conductivity values for monolithic materials shall be based on an
ascending temperature curve.
c. Use a value of 0.8 for the surface emissivity ε of the vessel, unless the surface
condition deviates significantly from normal steel (e.g., coating or severe scaling).
6. The temperature for the outside casing of radiant and convection sections and hot
ducting shall exceed 82 °C (180 °F).
7. The temperature for the outside casing of radiant floors, roofs and arch areas shall not
exceed 90 °C (195 °F).
8. Stack and hot flue gas duct casing temperatures beyond any heat recovery section
where personal protection is not required, shall not exceed the lower of the following:
a. 121 °C (250 °F);
b. the capability of the external surface coating.
9. The design hot face temperature of the lining system shall be calculated from the
maximum hot-face temperature plus 165 °C (300 °F).
10. The design interface temperature(s) shall be the calculated interface temperature(s)
plus 165 °C (300 °F), based on the maximum flue gas temperature.

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11. The refractory material’s continuous use temperatures as stated in the refractory data
sheets shall be greater than the design hot face or the design interface
temperature(s).
12. All the thermal design calculations and all refractory lining material selections shall be
subject to review and approval by the Principal.
3. LINING SYSTEMS
1. For all lining systems, the minimum thickness of any monolithic layer shall be
75 mm (3 in), with the exception of the lining for header boxes where a minimum
layer thickness of 50 mm (2 in) is allowed.
3.1 SINGLE LAYER DESIGN

Figure 1 Single layer lining system
Figure 1 shows a single layer lining design with a type A anchor (see (5)). For
thicker linings, type B anchors can be used. Lining installation can be done by
gunniting (vertical walls or roofs) or casting.
1. Formwork shall be used for the casting of vertical walls or roofs.
Casting of a floor or a panel in horizontal position normally does not require
formwork.
To keep the formwork in position, welding of additional threaded studs (stainless
steel) to the wall is required.
After lining installation, these threaded studs do not have to be removed.

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3.2 DUAL LAYER DESIGNS

3.2.1 Dual layer design for fully monolithic lining systems
Figure 2 Dual lining system for two monolithic layers
Figure 2 shows a typical lining design for two layers of monolithic material in
combination with a B type anchor. This design is only suitable for gunniting vertical
walls or for casting in horizontal position.
The transition to a wider opening angle for the B type anchors is positioned in the
vicinity of the interface between the two layers.
The pitch of the anchors is determined by the thickness of the hot face layer. By
positioning this transition close to the interface between the two layers, a regular
pattern of the anchor tips in the hot face layer is achieved.
1. After gunniting of the back-up lining, the anchors shall be cleaned before the hot face layer
is gunnited.
The transition to a wider opening angle for the B type anchors is at the half height of the
anchor.
If the two layers are of equal thickness, this position is close to the interface between the
two layers and the transition does not have to be positioned at the interface between the
two layers.
3.2.2 Dual layer lining design for combination of materials types
Figure 3 Dual layer lining design for combination of material types

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Figure 3 shows a universal design for two layer lining systems. The anchors
for the monolithic hot face lining are screwed onto (long) threaded studs which
are welded onto the casing. This system is suitable for a back-up lining
consisting of board or insulating bricks but can also be used for a monolithic
back-up layer. In that case, the lining designer can decide upon the connection
between the V anchor and the stud (inner thread on the stud-outer thread on
the V anchor as alternative), depending on the lining installation method.
3.2.3 Dual layer system for furnace roofs (radiant section)
Lining designs with two layers of monolithic material or a combination of insulating board
and monolithic material as shown in Figure 2 and Figure 3 can also be used for
overhead positions. The pitch of the anchors is determined by the thickness of the hot
face layer.
1. The monolithic layer against the steel shell shall have additional anchoring with V
anchors.
The pitch of these anchors is similar to the pitch of the hot face anchors and the
anchors are centered relative to the hot face anchors.
3.2.4 Dual layer design for furnace roof with ceramic anchors
In the rare case that the hot face temperature of the lining becomes too high for metallic
anchors, a design with ceramic anchors is required.
1. The ceramic anchors shall extend to the hot face.
2. The ceramic anchors shall be attached to the steel shell by metallic clips.
3. The ceramic anchors shall be installed in a square pitch (typically 300 mm-350 mm
(12 in-14 in)).
4. Ceramic anchors shall be fired to a full ceramic bond.
5. Material selection for the ceramic anchors shall take into account the operating
temperature and the (tensile) load onto the anchor during operation.
3.2.5 Lining design for floor of furnace radiant section
The floor consists of two monolithic layers against the steel shell as LW or XLW material.
1. The top monolithic layer shall be MW material.
2. The maximum service temperature for the MW layer shall be in line with the operating
temperature.
3. On top of the MW layer a layer (minimum 64 mm (2.5 in)) of high-duty fireclay bricks
shall be installed.
4. The high-duty fireclay bricks shall not be mortared.
4. UNSHAPED REFRACTORY MATERIALS
4.1 REFRACTORY LINING MATERIALS

The major properties for generic unshaped refractory materials which are suitable for the
applications as outlined in the scope of this standard are listed in Table 1. The
classification on the basis of material weight as used in this table is not standardised and
there can be differences between different Manufacturer/Suppliers, although the
terminology of extra light weight, light weight and medium weight materials is common
practice. The ranges given in API 936 are too wide and impractical for the applications
as outlined in the scope of this standard.
1. For the refractory applications as per the scope of this standard, conventional calcium
aluminate cement bonded materials (hydraulic bonding) shall be applied.

February 2017
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a. Lining materials shall be installed by dry gunniting, casting or pump casting.

b. The use of low cement castables, no-cement castables, self-flow materials,
vibrocast materials, pumpable, or chemically bonded materials shall be subject to
approval from the Principal.
2. Lining materials with a bond system on the basis of Portland cement shall not be used.
3. Lining materials which show thermal growth (positive value for PLC) shall not be used.
Table 1 Properties of the lining materials
USC equivalents are in Extra Light Light weight Medium

parentheses below () Weight material weight
material LW material
XLW MW
Bulk density (BD) 500 – 800 800 – 1200 1200 – 1750
after 815 °C (1500 °F) (31 – 50) (50 – 75) (75 – 110)
kg/m3 (lb/ft3)
Required properties
Cold crushing strength (CCS) >1 >3 >8

after 815 °C (1500 °F) (>145) (>450) (>1160)
MPa (psi) per ISO 1927-6
Cold crushing strength (CCS) >0.85 >2.6 >7
after 815 °C (1500 °F) >125 >380 >1000
MPa (psi) per ASTM C133
Permanent Linear Change (PLC) <1 < 0.5 <0.3
after 815 °C (1500 °F) Specified
as shrinkage in (%)
Maximum recommended 1050 - 1300 1100 - 1300 1150 - 1400
temperature
information
(°C)
Thermal Conductivity <0.20 <0.30 < 0.5
(400 °C–800 °C) (752 °F- (<1.388) <2.10 <3.5
1472 °F)
W/mK (Btu/hr-ft2-°F/in)
NOTES:
1. The required properties refer to Manufacturer/Supplier’s compliance data or
guaranteed values.
2. Test methods given in Table 9.
3. Permanent Linear Change (PLC) values are given as shrinkage and the dimensions
of the green material are used as reference. Shrinkage numbers represent the traject
from green material to firing at 815 °C (1500 °F)
4. The material specifications are for neutral or oxidising conditions only. Material
compositions are not suitable for reducing conditions (e.g., CO atmospheres or
syngas applications).
5. If a refractory material is suitable for casting as well as for gunniting, typically the
gunnited material has a higher bulk density and higher cold crushing strength
(especially for XLW and LW materials). The cast material and gunnited material can
fall into different categories.
6. The Maximum Recommended Temperatures are for information only.

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4. All of the physical properties (bulk density, cold crushing strength and permanent
linear change) in Table 1 shall be determined after firing at 815 °C (1500 °F).
a. Manufacturer/Supplier technical data sheet (TDS) values shall be considered to
be for information only until confirmed explicitly for the installation.
5. Extra light weight (XLW) material shall be used primarily as back-up lining in two layer
lining designs.
6. XLW material may be used as a single layer for the lining of header boxes.
7. XLW material may be used as hot face lining material in dual lining system if the
requirement of CCS as for LW material can be met.
8. Lightweight (LW) materials may be used as hot face lining material in gas fired
furnaces and heaters with moderate to low sulphur contents (typical < 100 ppm SO2 in
flue gas).
9. MW material shall be used as hot face lining material for a convection section with
soot blowers.
a. LW material shall not be used as hot face lining material for a convection section
with soot blowers.
10. The hot face lining in oil fired units (>400 ppm vanadium and or >0.5% sulphur) shall
be made from MW material having an alumina content greater than 50 wt%.
11. If co-firing small waste streams in a furnace or heater where sodium could be present,
a MW based hot face lining with at least 60 wt% Al2O3 shall be used.
The presence of sodium can significantly shorten the life time of a refractory lining
due to the formation of low-melting point phases.
4.2 AUXILIARY UNSHAPED MATERIALS

4.2.1 Curing compounds
1. The application of curing compounds shall be subject to approval from the Principal.
a. The application of curing compound on the hot face of a newly installed lining
should be avoided.
2. Coating used to seal moisture into castables (curing compound) shall be a solution of
resin non-fluxing material mixture of hydrocarbon base that forms a protective
membrane when dried in air and decomposes below 150 °C (300 °F).
3. Curing compounds shall be non-flammable, non-toxic and contain a factory added
pigment that allows visual inspection after application.
4.2.2 Anti-corrosive coatings
1. Anti-corrosive coatings shall be applied on the inner surface of the steel shell for lining
systems with alkaline earth silicate (AES) fibrous materials or insulating firebricks
against the steel shell.
2. The need for anti-corrosive coating shall be determined jointly by the corrosion
engineer and process engineer.
Anti-corrosive coatings are not required in case of a monolithic lining against the
steel shell.
Only in case of intermittent operation (frequent periods of several months per year
with the unit not in operation operation) would an anti-corrosive coating be required.
AES fibers have a natural inhibition effect on sulfurous / sulfuric acid corrosion.
3. Organic (bitumen based) coatings may be applied for temperatures up to 200 °C
(392 °F).

February 2017
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4. Inorganic acid resistant coatings may be used for temperatures over 200 °C (392 °F).
5. Coatings shall be applied in one or two layers after welding of the anchoring system.
a. The anchors shall be kept free of coating material.
4.2.3 Anti-alkaline hydrolysis coatings
1. A newly installed refractory lining should be dried out as quickly as possible after
curing is completed to minimise the likelihood for the occurrence of alkaline hydrolysis.
The occurrence of alkaline hydrolysis is difficult to predict. Especially, but not
exclusively, XLW and LW materials can be sensitive for this damage mechanism.
For short periods of time (< 3 months before dry-out), ventilation of the equipment is
considered to be sufficient.
2. The lining material Manufacturer/Supplier shall indicate whether the applied lining
materials are prone to the occurrence of alkaline hydrolysis.
a. Measures to minimise the damage (e.g., dry out, protective coatings) shall then
be provided.
b. Application of a protective coating shall be subject to approval by the Principal.
5. ANCHORING SYSTEMS
5.1 GENERAL
The anchoring systems as specified in this section are only valid for the applications as
per the scope of this DEP (1.1), the lining materials as specified in Table 1, and the
installation methods as indicated in (4.1).
5.2 ANCHOR MATERIALS

Selection of anchor material in relation to the maximum tip temperature is given in
Table 2. This table is only valid for neutral and oxidising conditions.
Table 2 Maximum temperatures for anchor tips in neutral and oxidising
atmospheres
Anchor material Maximum anchor temperature

°C °F
TP 304, 304L, 304H, 316 800 1470

TP 310 1000 1830
TP 330 1050 1920
Alloy 601 1100 2010
Ceramic anchors >1100 >2010
1. TP330 and Alloy 601 shall not be used for conditions with relatively high sulphur levels
(>1000 ppm) because of their high nickel content.
2. All anchors on the basis of austenitic materials (300 series stainless steel, alloy 330
and Alloy 601) shall be supplied in the fully solution annealed condition.
a. Austenitic anchors should be supplied as bright solution annealed.
3. Wire diameter shall be 6 mm (1/4 in).
4. Anchors shall either be colour coded or laser labelled to indicate the metallurgy.

February 2017
Page 15
5. Metallic anchors shall be kept clean and free of any coating material.
6. Anchor caps shall not be used.
5.3 ANCHOR TYPES

The basic anchor type for the lining systems as specified in this standard are straight or
corrugated V anchors as shown in Figure 4. Anchor wire diameter is 6 mm (1/4 in).
1. The anchor height shall be 20 mm - 25 mm (0.8 in – 1.0 in) less than the lining
thickness of the refractory layer.
The basic anchors are designed for hand welding.
a. The minimum weld length for the anchors shall be 20 mm (0.8 in).
b. Welding shall be performed at both sides (i.e., 10 mm (0.4 in) per side).
Figure 4 Standard V anchors for lining thicknesses from 50 mm (2 in) to
230 mm (9 in)
The left hand side of Figure 4 shows the A type anchor which is suitable for
lining thicknesses up to 125 mm (5 in).
2. Anchor type B shall be applied for lining systems from 125 mm (5 in) up to
230 mm (9 in) and for dual lining systems.
a. Alternatively for dual lining systems or lining systems with a thickness over
175 mm (7 in), a combination of type A anchor welded onto a threaded stud may
be used.
b. For dual lining systems, the transition from a 15° opening to a 60° opening shall
be positioned within 10 mm (0.4 in) of the interface between the two layers.

February 2017
Page 16
Table 3 Dimensions and codes for V anchors
Length Length Code Length Length Code

“H” “H” “H” “H”
mm (in) mm (in)
40 1.6 A4 110 4.3 B11
50 2.0 A5 130 5.1 B13
60 2.4 A6 150 5.9 B14
70 2.8 A7 170 6.7 B15
80 3.1 A8 190 7.5 B16
90 3.5 A9 210 8.3 B17
100 3.9 A10 230 9.1 B18
NOTE:
1. Anchor types A4, A5 and A6 are straight V anchors without
corrugations. All other types are corrugated. Depending on the
way of attachment there are types with different details for the
base of the anchor
Figure 5 shows typical versions for semi automated stud welding.

Other alternatives are footed anchors or anchors with a nut welded at the base
as Figure 6.
Figure 5 V anchors for stud welding

February 2017
Page 17
Figure 6 Footed anchor
The footed version can be used for hand welding as well as for attachment to a
threaded stud with a nut. Welding of the footed anchor is along the outer
radius of the foot. Minimum weld length is 25 mm (1 in). The inner radius for
the foot is at least 8 mm (1/4 in). The stud can be welded by hand or by semi
automated stud welding. Both attachment methods are suitable for A type as
well as for B type V anchors.
5.4 ANCHORING PATTERNS

1. Anchors shall be installed in a square pattern.
2. Anchors orientation shall be staggered perpendicular to each other.
Anchor spacing is given in Table 4. The resulting number of anchors per square
meter is given in Table 5.
Table 4 Anchor spacing in relation to layer thickness and lining orientation
Layer thickness Anchor spacing

mm (in) mm (in)
Horizontal roof Vertical wall
min max min max
50 (2) 80 (3) 100 (4) 100 (4) 125 (5)
75 (3) 125 (5) 150 (6) 150 (6) 175 (7)
100 (4) 175 (7) 200 (8) 200 (8) 225 (9)
125 (5) 200 (8) 225 (9) 225 (9) 250 (10)
150 (6) 225 (9) 250 (10) 250 (10) 275 (11)
175 (7) 225 (9) 250 (10) 275 (11) 300 (12)
200 (8) 225 (9) 250 (10) 275 (11) 300 (12)
230 (9) 225 (9) 250 (10) 275 (11) 300 (12)
3. The minimum spacing values as given in Table 4 shall be used for gunnited lining
systems.
4. The maximum spacing values in Table 4 shall be used for cast lining systems.

February 2017
Page 18
Table 5 Number of anchors per square meter in relation to layer thickness and
lining orientation
Layer thickness Number of anchors per square meter

mm (in) (number per square foot)
Horizontal roof Vertical wall
min max min max
50 (2) 100 (9.3) 156 (14.5) 64 (5.9) 100 (9.3)
75 (3) 44 (4.1) 64 (5.9) 33 (3.1) 44 (4.1)
100 (4) 33 (3.1) 44 (4.1) 20 (1.9) 25 (2.3)
125 (5) 25 ((2.3) 33 (3.1) 16 (1.5) 20 (1.9)
150 (6) 20 (1.9) 25 (2.3) 13 (1.2) 16 (1.5)
175 (7) 16 (1.5) 20 (1.9) 11 (1.0) 12 (1.1)
200 (8) 16 (1.5) 20 (1.9) 11 (1.0) 12 (1.1)
225 (9) 16 (1.5) 20 (1.9) 11 (1.0) 12 (1.1)
5. If a lined part has to be transported, then the anchor spacing shall be as for a vertical
wall.
The standard anchor spacing for a floor section is 300 mm (12 in).
6. The anchor spacing for cylindrical vessels shall be projected to the inner surface of the
refractory lining, particularly for ducting, piping and the outside of curvatures.
Consequently, the anchor spacing on the base metal is larger when welded on
inner surfaces and smaller when welded on outer surfaces.
7. For vertical cylindrical vessels, anchor spacing as for vertical walls shall be
maintained.
8. For horizontal cylindrical vessels, the following anchor spacing shall be used:
a. for the upper 180 degrees section, spacing as for horizontal roofs.
b. for the lower 180 degrees section, spacing as for vertical walls.
c. for prefabrication of a horizontal cylinder, the top position (0 degrees) and bottom
position (180 degrees) shall be indicated on the shell.
9. The anchor spacing for dual lining systems shall be based upon the thickness of the
hot face layer.
a. Additional anchoring for the back up layer shall be applied for overhead positions
and for the upper half of horizontal cylinders only.
5.5 ANCHOR WELDING

Anchor welding can be done by hand or by semi automated stud welding.
1. Hand welding shall be by GTAW or GMAW.
a. FACW shall not be used.
2. The use of stud welding processes other than the semi automated Rapid Arc Welding
technique shall be subject to approval by the Principal.
3. All weld procedures and welders shall be approved by the Contractor.

February 2017
Page 19
4. The surface on which any anchor component is to be welded shall be cleaned free of
grease, mill scale, loose rust or other foreign materials prior to installation of the
anchoring system by blast cleaning per SSPC SP-6 / NACE 3 / SA – 2 (commercial
blast cleaning).
5. Anchor welding shall be completed before any PWHT of the base metal.
6. LINING INSTALLATION
1. For lining installation, API 936 (section 9 - Installation/Execution) shall be followed.
2. For surface preparation, the abrasive cleaning shall be as per SSPC SP 6 (NACE 3;
SA - 2).
7. CURING, DRYING AND FIRING OF MONOLITHIC LINING SYSTEMS
7.1 CURING
1. After completion of the lining installation, the lining shall be protected against freezing
and extreme hot weather conditions.
2. The minimum curing time for all lining materials with a calcium aluminate cement
binder shall be 24 hours.
3. During the curing period, the lining system shall be kept moist to allow for completion
of the hydration reactions in the monolithic lining material.
4. The temperature shall be maintained between 10 °C (50 °F) and 32 °C (90 °F) to
achieve optimum mechanical properties of the lining materials and to minimise the
likelihood for cracking.
7.2 DRYING AND FIRING

1. The Contractor shall supply a detailed dry-out procedure for the refractory lined
equipment including the following:
a. detailed working procedures including management of interruptions;
b. recommended temperature profile (heating rates, holding times);
c. temperature monitoring positions.
2. Dry-out of the lining shall be performed from the hot face.
a. Dry out by external heating of the equipment shall not be permitted.
3. Thermocouples (TC) shall be installed to measure flue gas temperature, lining hot face
temperature (slightly embedded in the lining) and casing temperature.
a. TCs shall be installed close to the heat source (to control heating rates and
holding times) and close to the outlet (to monitor temperatures during hold
periods and to ensure that temperature differences do not exceed the
temperature difference as specified in the dry out procedure).
4. A full IR scan of the refractory lined equipment should be performed after a minimum
time of 48 hours at the operating temperature to check for the occurrence of hot spots.
5. IR scanning may be repeated after a minimum period of two weeks.

February 2017
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8. QUALITY ASSURANCE AND QUALITY CONTROL (QA/QC)
8.1 INSPECTION AND TEST PLAN (ITP)

1. Prior to the start of any project with unshaped materials, the refractory Contractor shall
submit an appropriate project-specific ITP for approval by the Principal addressing the
following:
a. defining each work step in the work scope;
b. acceptance criteria for materials, applicator qualification and as installed testing.
2. For each party involved in the project, the ITP shall indicate their role and
responsibility for each work step including the following minimum categories:
a. for information;
b. for review and approval;
c. witness point;
d. hold point.
3. Hold points for the Client, Principal shall at least be the following:
a. pre installation meeting;
b. inspection of the equipment prior to start of the installation work;
c. inspection of equipment after anchor welding and prior to lining installation;
d. inspection of lined equipment prior to dry out.
4. Review points for the Client, Principal shall at least be the following:
a. design review (material selection, drawings);
b. installation procedures;
c. welding procedures and welder qualification (WPS/PQR);
d. material acceptance;
e. applicator qualification;
f. as installed testing;
g. dry out procedure;
h. end documentation (final inspection certificates, as built drawings);
i. confirmation of completion.
8.2 QA/QC FOR ANCHORING SYSTEM

8.2.1 Anchors
1. Anchors shall be checked for dimensions with the following tolerances:
a. anchor height tolerance +/- 5 mm (1.4 in);
b. tip to tip distance tolerance +/- 5%.
2. Material certificates (ISO 10474; type 3.1) shall be supplied including the following
properties:
a. chemical composition;
b. yield strength;
c. ultimate tensile strength.

February 2017
Page 21
3. Certificates (ISO 10474 type 3.1) for the solution anneal heat treatment shall be
supplied by the anchor Manufacturer/Supplier.
4. Each anchor shall be stamped or laser etched or supplied in sealed traceable
packaging to identify alloy and forming Manufacturer/Supplier.
5. Per package at least one piece shall be checked for chemical composition (PMI).
6. Anchors from open packaging which are not stamped or laser etched shall be
confirmed by 100% PMI.
8.2.2 Weld procedures and welder qualification
1. Welding procedures (WPS) and welder qualification (PQR) certificates shall be
supplied
2. Unless otherwise specified, welding of all anchors shall be in accordance with the
applicable parts of ASME IX and DEP 30.10.60.18-Gen.
8.2.3 Installation inspection and testing
1. Pitch and anchor orientation shall be checked against design drawing.
2. Welds inspection shall confirm the following:
a. welds are fully fused;
b. no undercutting or under sizing of weld length;
c. no visible porosity or cracks.
3. A light hammer (200 gr (0.1 lb)) shall be used to tap the anchor and without bending
the anchor.
4. Hammer testing of anchors shall be performed for 2.5 % of the anchors (randomly
distributed) with a minimum of 200 anchors.
a. If more than 5 % of the first sampling fails, then the inspection shall be repeated
to cover an additional 5 % of the remaining installation, with the process repeated
by doubling the amount of additional anchors to be tested in the case of more
defects until all welds have been inspected.
i. Failed anchors shall be removed and replaced.
8.3 QA/QC FOR LINING MATERIALS AND LINING INSTALLATION

8.3.1 General
The QA/QC procedure as specified is only of insulating materials (XLW, LW and MW as
defined in Table 1) and not for materials with a higher bulk density.
QA/QC for lining materials and lining installation consists of three steps: material
acceptance testing, applicator qualification and as installed testing.
1. Testing for physical properties shall be performed according to API 936 /modified-
ASTM methods or by ISO 1927 methods.
2. Testing shall be performed by an independent testing laboratory or by the refractory
Manufacturer/Supplier.
a. In the latter case, the Manufacturer/Supplier should have a functional in-house
department for quality control which is certified by a Standards Association and
which is independent of the manufacturing department.
b. Testing by the Manufacturer/Supplier shall be subject to approval by the
Principal.
An audit might be part of the approval procedure.

February 2017
Page 22
3. Each bag of material shall have a unique code for the production run and production
date.
4. Cutting of test pieces or removal from the moulds shall only be done after at least
24 hours curing.
5. All physical testing of lining materials shall be done for test pieces fired at 815 °C
(1500 °F).
6. Test pieces shall not be wet cut after firing.
Wet cutting of fired specimens can result in too high values for the cold crushing
strength (due to partial rehydration of the cement binder)
8.3.2 Test methods and test specimens as per API 936- modified ASTM methods
Table 6 Test methods and test specimen for testing per API 936 - modified
ASTM methods
Type of test Number of Size of Specimens Test method

specimens
Cold Crushing Strength 3 50 mm * 50 mm*50 mm ASTM C133
(CCS) (2 in * 2 in * 2 in) API 936 modified
Permanent Linear 1 50 mm * 50 mm * 230 mm ASTM C113
Change (PLC) (2 in * 2 in * 9 in) API 936 modified
Bulk Density (BD) CCS and or PLC specimens API 936 (section on density
in testing and test
procedures)
1. The number and size of the specimens per sample shall be as Table 6.
2. For each property, the average value shall be reported.
3. PLC (shrinkage) shall be determined as green-to-fired.
8.3.3 Test methods and test specimens for testing per ISO 1927 methods
Table 7 Test methods and test specimens for testing per ISO 1927 methods
Type of test Number of Size of Specimens Test method

specimens
Bulk Density (BD) 2 230 mm * 114 mm* 64 mm ISO 1927 – 6
(9 in * 4.5 in * 2.5 in) Geometric bulk density
Permanent Linear 2 B.D. specimens ISO 1927 – 6
Change (PLC) Permanent linear change
Modulus of Rupture 2 B.D. specimens ISO 1927 – 6
(MOR) Cold modulus of rupture
Cold Crushing 3 Broken halves from MOR test ISO 1927 – 6
Strength (CCS) Cold crushing strength
1. The number and size of the specimens per sample shall be as Table 7.
2. For each property, the average value shall be reported.
3. Test specimens shall be prepared according to ISO 1927-5.
a. For the lining materials in this DEP, only shape A shall be used.

February 2017
Page 23
4. All testing shall be performed on 2 test specimens (shape A) as follows:

a. First use the shapes for the non destructive tests (BD and PLC).
b. Then use the shapes for cold MOR testing.
c. Then use the broken pieces from the MOR tests for CCS testing.
5. PLC (shrinkage) shall be determined as green-to-fired.
8.3.4 Lining material acceptance
8.3.4.1 Sampling
1. Each bag of material shall have a batch code and production date stated.
a. Pallets shall be numbered.
2. The sampling of insulating castables (XLW, LW and MW) shall be done according to
one of the following:
a. API 936 - 1 sample per 3 pallets;
b. minimum of 2 plus one per every 20 pallets;
c. according to Table 8 if approved by the Principal.
Table 8 Number of samples for acceptance testing
Property XLW LW MW
Bulk Density min 90 90 90
max 110 110 110
Cold Crushing Strength min 65 70 75
max - - -
Permanent Linear Change min 0 0 0
max 200 200 200
3. Sampling for chemical composition of the lining material may be limited to three
samples per production run.
A production run can take several days.
a. One sample for the chemical composition of the lining material shall be taken
from the first production batch.
b. The other samples shall be taken randomly over the production period.
4. Samples for physical testing shall be randomly taken from the pallets.
5. For the acceptance testing, the Manufacturer/Supplier shall only prepare test pieces of
gunniting material by casting if a product specific correlation between cast and
gunnited material properties is provided.
8.3.4.2 Data to be recorded
1. The following data shall be recorded for each of the test samples:
a. test date;
b. batch code and pallet number for material;
c. ambient temperature during preparation of the test panel or test specimens;
d. water dosing (in case of casting);
e. mixing time (in case of casting);

February 2017
Page 24
f. test standards which were used;

g. test results (average values).
8.3.4.3 Acceptance and retesting
1. The chemical composition and physical properties testing shall be in accordance with
the Manufacturer/Supplier's compliance data sheet or guaranteed values.
2. If a sample fails to meet the requirements, it may be retested once.
a. The retest shall be conducted using a new sample from the same pallet of the
same batch as the failed sample.
b. If the retest is unsuccessful, the refractory represented by the sample shall not be
used.
8.3.5 Applicator qualification
8.3.5.1 General
1. The applicator qualification shall be done to qualify the applicators as well as the
equipment, and to perform a check on the installation procedures.
2. Equipment used for the actual installation shall be used for the qualification testing.
For gunniting that means that items like the gunning machine, the water pump
pressure, air pressure, hose length and (preferably) the working height relative to
the position of the gunning machine are representative of the actual lining
installation.
8.3.5.2 Samples for casting
1. Each applicator team shall perform a mock up test as per API 936, section 8.3.2
simulating the most difficult piece of the installation work.
2. After a minimum of 24 hours curing, the formwork shall be removed for visual
inspection of the installed lining.
Eventually the part might be cut or broken into smaller parts.
a. The applied lining shall be homogeneous and free of voids, laminations and
segregations.
3. Each applicator team shall prepare a sample for testing of physical properties as
described in section (8.3.2) or (8.3.3).
4. An applicator team is qualified to cast a lining if the visual examination of the mock up
test shows acceptable results and if the results for the physical testing of the sample
are within the tolerances see (8.3.7).
a. If an applicator team is not qualified in the first round, one requalification is
allowed.
5. Equipment used for the actual installation shall be used for the qualification testing.
8.3.5.3 Samples for gunniting
1. Test panels shall be prepared with the equipment and line up that will be used for the
actual installation job.
2. Each application team shall perform a mock up test for the gunniting as per API 936
section 8.3.1 for each material that will be gunnited.
3. The mock up test panel shall be visually inspected for voids, laminations, non
uniformities and entrapped rebounds.
a. After sectioning (cutting or breaking), the exposed surfaces shall be inspected for
homogeneity, voids, laminations, non uniformities, entrapped rebounds and
shadowing effects due to the anchors.

February 2017
Page 25
4. For testing of the physical properties, a separate square test panel shall be gunnited
into wooden form work (without anchors).
a. The inner dimensions of the formwork shall be 300 mm*300 mm*100 mm (12
in*12 in*4 in).
b. The formwork shall have an open edge at the bottom to minimize inclusion of
rebound material.
c. During gunniting the formwork should be standing vertical or slightly tilted
forward.
5. A set of test pieces as described in (8.3.2) or (8.3.3) shall be cut from the gunnited
panel (after 24 hour curing).
6. An applicator team shall be qualified to gunnite a lining if the visual examination of the
mock up test shows acceptable results and if the results for the physical testing of the
sample are within the tolerances see (8.3.7).
7. An applicator team shall be qualified to cast a lining if the visual examination of the
mock up test shows acceptable results and if the results for the physical testing of the
sample are within the tolerances see (8.3.7).
8. Each application team shall perform a mock up test for the gunniting as per API 936,
section 8.3.1 for each material that will be gunnited.
a. A set of test pieces shall be cut from the gunnited panel, (after 24 hour curing).
1. The following data shall be recorded for applicator qualifications:
a. applicator team;
b. equipment used;
c. mixing time (if casting);
d. equipment line up (including height difference between gunniting position and
gunniting machine and hose length) (if gunniting);
e. air pressure and water pressure (if gunniting);
f. orientation of test panel (if gunniting).
8.3.6 As installed testing
8.3.6.1 Sampling
1. Each applicator team shall prepare at least one sample per material per shift as per
(8.3.2) or (8.3.3).
2. Samples shall remain at least 24 hours in the same environment as the actual
installation.
3. Records shall be kept to identify the samples and the areas of the installed lining that
they represent.
4. The number of samples to be tested shall be specified in the Inspection and Test Plan
(ITP).
8.3.6.2 Samples for casting
1. Samples for casting shall be made according to API 936, section 8.4.2.
a. Casting may be done directly in moulds with the proper dimensions for testing.
b. Alternatively test specimens may be cut from a larger cast piece of material.
2. Samples shall remain at least 24 hours in the same environment as the actual
installation.

February 2017
Page 26
8.3.6.3 Samples for gunniting

1. Samples for gunniting shall be made as specified in (8.3.5.3, item 4).
a. Wire mesh baskets as well as wooden panels may be used.
There is no need to incorporate anchors in the test panels.
2. After gunniting, the test panels shall remain at least 24 hours in the same environment
as the actual installation.
1. Refer to (8.3.4.2) and (8.3.5.4) for the data to be recorded.
8.3.6.5 Acceptance and rejection
1. After installation, the lining surface shall be visually inspected for surface defects and
excessive cracking.
a. Fine hair cracks may be accepted.
2. At random areas of the total lining shall be tested by striking with a ball-peen hammer
(approximately 500 g, (1 lb)).
Any voids or dry filled areas will produce a dull sound.
3. The lining shall be accepted if the visual inspection and the hammer testing does not
show major irregularities and when the results for the physical testing are within the
tolerances, see (8.3.7).
4. Failure to meet the criteria as given in (8.3.6.5, Items 1 through 3), shall result in
rejection of the lining that the sample represents.
a. If the lining is rejected, core samples may be taken from the questionable area for
testing.
8.3.7 Acceptance criteria physical properties
1. For each project, the Contractor, Manufacturer/Supplier, Client and Principal shall
agree upon acceptance criteria in the ITP, prior to the start of the project.
2. The acceptance criteria for the physical properties of the samples from the Applicator
Qualification testing and from the As-installed testing should be as per Table 9.
Acceptance criteria as given in Table 9 are considered as guidance.
Table 9 Acceptance criteria for testing of applicator qualification samples and
as-installed samples
Property XLW LW MW
Bulk Density min 90 90 90
max 110 110 110
Cold Crushing Strength min 65 70 75
max - - -
Permanent Linear Change min 0 0 0
max 200 200 200
NOTES:
1. Bulk Density per API 936, section 8.1.4
2. Numbers represent %.
3. Table 9 should be used for the average of all specimen results per sample.

February 2017
Page 27
4. The minimum and maximum values per physical property in Table 9 should only be
used if the Manufacturer/Supplier specifies single values as guaranteed values or
compliance data.
5. When the Manufacturer/Supplier's compliance data sheet specifies a range for the
physical properties, then the applicable limits shall apply to the upper and lower values
of the compliance datasheet range.
9. TRANSPORTATION AND HANDLING OF REFRACTORY LINED EQUIPMENT

1. If lined equipment is to be transported or rigged, the following precautions shall be
implemented to ensure linings are not damaged:
a. preparation and approval of a preservation plan;
b. supporting to prevent cracking, deformation and dislodgement caused by shock,
bending or vibration;
c. suitably designed stiffeners designed to be assembled, used, and disassembled
without causing damage to the lining;
d. suitable weather protection at openings, durable enough to withstand the
dynamics of weather, transportation and rigging, yet flexible enough to allow for
visual lining inspections;
e. inspection planning including hold, witness, specification reference and
documentation for new tasks of storage, moving, loading, unloading, erection and
post-erection inspection;
f. procedures to protect all external nozzles flanges and other components from
physical damage during transportation or thermal pre-treatments as required;
g. clear lines of responsibility for each task area.

February 2017
Page 28
10. REFERENCES
In this DEP, reference is made to the following publications:
NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards/.
SHELL STANDARDS
DEP feedback form DEP 00.00.05.80-Gen.

Shell HSSE & SP Control Framework, Design Engineering Manual DEM1
(DEM) 1 – Application of Technical Standards
https://eu001-
sp.shell.com/sites/AAAAA8432/CF/Web/Design Engineering Manual 1 DEM1.aspx
Refractory bricks and shapes DEP 44.24.90.31-Gen.

Refractory lining for fluidized catalytic cracking unit (FCCU) DEP 64.24.32.12-Gen.
Guidelines for curing, drying and firing of unshaped refractory lining DEP 64.24.32.33-Gen.
materials
Refractory contractor selection and applicator qualification for DEP 64.24.32.34-Gen.
installation of unshaped refractory lining materials
AMERICAN STANDARDS
Fired Heaters for General Refinery Service API STD 560

Refractory installation quality control - Inspection and testing API STD 936
monolithic refractory linings and materials
Standard terminology relating to refractories ASTM C71
Standard Test Method for Reheat Change of Refractory Brick ASTM C113
Standard Test Methods for Cold Crushing Strength and Modulus of ASTM C133
Rupture of Refractories
Standard Test Method for Thermal Conductivity of Insulating Firebrick ASTM C182
Standard Test Method for Thermal Conductivity of Refractories ASTM C201
Standard Test Method for Thermal Conductivity of Refractory Brick ASTM C202
Standard Test Method for Thermal Conductivity of Unfired Monolithic ASTM C417
Refractories
Standard practice for estimating of the heat gain or loss and surface ASTM C680
temperature of insulated flat, cylindrical and spherical systems by use
of computer programs
Standard Test Method for Thermal Conductivity of Refractories by Hot ASTM C1113
Wire (Platinum Resistance Thermometer Technique)
Joint Surface Preparation Standard Commercial Blast Cleaning NACE No 3
Commercial Blast Cleaning SSPC SP 6
Brush-off blast cleaning - NACE No. 4 SSPC SP 7
Power tool cleaning SSPC SP 3
INTERNATIONAL STANDARDS
Prepared unshaped refractory materials (dense and insulating) - ISO 1927

Classification

February 2017
Page 29
Monolithic (unshaped) refractory products- Part 1: Introduction and ISO 1927-1

classification
Monolithic (unshaped) refractory products- Part 2: Sampling for testing ISO 1927-2
Monolithic (unshaped) refractory products- Part 3: Characterization as ISO 1927-3
received
Monolithic (unshaped) refractory products- Part 4: Determination of ISO 1927-4
consistency of castables
Monolithic (unshaped) refractory products- Part 5: Preparation and ISO 1927-5
treatment of test pieces
Monolithic (unshaped) refractory products- Part 6: Measurement of ISO 1927-6
physical properties
Monolithic (unshaped) refractory products- Part 7: Tests on pre-formed ISO 1927-7
shapes
Monolithic (unshaped) refractory products- Part 8: Determination of ISO 1927-8
complimentary properties
Refractory materials — Determination of thermal conductivity — Part 1: ISO 8894-1
Hot-wire methods (cross-array and resistance thermometer) - Second
Edition
Refractory materials — Determination of thermal conductivity — Part 2: ISO 8894-2
Hot-wire method (parallel) - Second Edition
Steel and steel products - Inspection documents ISO 10474
Petroleum, petrochemical and natural gas industries Fired heaters for ISO 13705
general refinery service


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DEP SPECIFICATION

UNSHAPED REFRACTORY MATERIALS FOR MONOLITHIC

DESIGN AND ENGINEERING PRACTICE

© 2017 Shell Group of companies

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This document has been supplied under license by Shell to:

This document has been supplied under license by Shell to:

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

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The Manufacturer/Supplier is the party that manufactures or supplies equipment and

Batch A number of raw material components traceably formulated by weight in

Dual-layer A refractory lining consisting of two different types of monoliths.

Maximum The term used by most material Manufacturer/Suppliers to suggest a

Monolithic A relative jointless lining from unshaped materials.

Production Physical property tests done on samples prepared during installation of

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Sample The quantity of refractory taken from a single container or installation

API American Petroleum Institute

APQ Applicator's procedure qualification

ASTM American Society for Testing and Materials

CCS Cold Crushing Strength

FCAW Flux Core Arc Welding

FCCU Fluid Catalytic Cracking Unit

GMAW Gas Metal Arc Welding

GTAW Gas Tungsten Arc Welding

ISO International Organization for Standardization

ITP Inspection Test Plan

LW Light Weight Material

MW Medium Weight Material

PWHT Post Weld Heat Treatment

QC/QA Quality Control And Quality Assurance

XLW Extra Light Weight Material

1.5 SUMMARY OF MAIN CHANGES

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1.6 COMMENTS ON THIS DEP

Shell DEPs Online Enter the Shell DEPs Online system at

DEP Feedback System Enter comments directly in the DEP Feedback

DEP Standard Form Use DEP Standard Form 00.00.05.80-Gen. to record

1.7 DUAL UNITS

1.8 NON NORMATIVE TEXT (COMMENTARY)

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2. THERMAL DESIGN OF MONOLITHIC LINING SYSTEM

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3.1 SINGLE LAYER DESIGN

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3.2 DUAL LAYER DESIGNS

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4. UNSHAPED REFRACTORY MATERIALS

4.1 REFRACTORY LINING MATERIALS

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a. Lining materials shall be installed by dry gunniting, casting or pump casting.

USC equivalents are in Extra Light Light weight Medium

Cold crushing strength (CCS) >1 >3 >8

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4.2 AUXILIARY UNSHAPED MATERIALS

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5.2 ANCHOR MATERIALS

Anchor material Maximum anchor temperature

TP 304, 304L, 304H, 316 800 1470

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5.3 ANCHOR TYPES

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Table 3 Dimensions and codes for V anchors

Length Length Code Length Length Code