JERES-N-100 Refractory Systems PDF

Jubail Export Refinery
Engineering Standard
JERES-N-100
Refractory Systems
Revision Responsibility 03 February

1 JER Engineering Division 2009
JERES-N-100
Rev. 1
Refractory Systems 03 February 2009
Revision Tracking
Revision Revision Date Scope of Revision
1 03 February 2009 Revised to update paragraphs: 7.2.2 and 7.2.3
0 29 April 2008 Issued for bid package.
General revision for consistency with links, incorporated comments from

04 18 April 2008
Total specialist.
03 31 March 2008 Issue for Bid Package, only for review
02 23 January 2008 Revision links consistency, refractory limitations
01 03 May 2007 The first official JERES-N-100 is issued.

First draft issued is based on Saudi Aramco SAES-N-100 “Refractory
00 5 February 2007 Systems” issue date November 30, 2004. Document was modified to
incorporate amendments and modifications.
This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by
any means without prior approval by the Company.
Page 2 of 25
JERES-N-100
Rev. 1
Table of Contents
Section Contents Page
1 Scope 4
2 Conflicts, Deviations and Clarifications 4
3 References 5
4 Definitions 7
5 Responsibilities and Documentation 9
6 Design 10
7 Physical Properties 13
8 Metallic Components 13
9 Refractory Systems 15
10 Refractory Installation 15
11 Materials Pre-Shipment Testing 15
12 Claus Unit Special Requirements 16
13 Refractory Material Shipment 18
Appendixes
Table A – Design Parameters for Castable Refractory
A 19
Figure 1 – Y Anchor for Dual Layer Gunned Lining
B Table 2 – Design Data for Castable Refractory 21
C Table 3 – Mandatory Refractory Systems 22
Page 3 of 25
JERES-N-100
Rev. 1
1 Scope
1.1 This standard establishes the minimum mandatory requirements for the design and
selection of refractory systems for pressure vessels, boilers, process heaters, stacks,
breechings, heat exchangers, flare tips, sulfur recovery unit equipment and piping.
For Fluid Catalytic Cracking unit vessels and transfer lines application, Contractor
shall refer to JERES-N-150.
1.2 Refractory selections shall be limited to material used for erosion resistance and
thermal resistance such as castable refractory systems, , and fireclay brick systems.
Refractory fiber can only be used when no other technical solution is available; and
upon Company written approval. Biosoluble fiber could be used only upon Company
approval.
1.3 The requirements detailed in this standard are aimed at standardizing refractory
systems used in Jubail Export Refinery facilities.
1.4 For equipment and refractory systems not covered by this standard, the Company
Representative shall be contacted for guidance in determining the extent to which
this standard is applicable.
1.5 This entire standard may be attached to and made a part of purchase orders.
1.6 This standard covers the design requirements and material selection of refractory
system for new and existing equipment.
2 Conflicts, Deviations and Clarifications

2.1 Any conflicts between this standard and other applicable Company Engineering
Standards (JERES), Material Specifications (JERMS), Standard Drawings (JERSD),
Engineering Procedures (JEREP), Company Forms or Industry standards,
specifications, Codes and forms shall be brought to the attention of Company
Representative by the Contractor for resolution.
Until the resolution is officially made by the Company Representative, the most
stringent requirement shall govern.
2.2 Where a licensor specification is more stringent than those of this standard, the
Licensor’s specific requirement shall apply.
2.3 Where applicable Codes or Standards are not called by this standard or its
requirements are not clear, it shall be brought to attention of Company
Representative by Contractor for resolution.
Page 4 of 25
JERES-N-100
Rev. 1
2.4 Direct all requests for deviations or clarifications in writing to the Company or its
Representative who shall follow internal Company procedure and provide final
resolution.
3 References
The selection of material and equipment, and the design, construction, maintenance,
and repair of equipment and facilities covered by this standard shall comply with the
latest edition of the references listed below as of the CUT-OFF DATE as specified
in the Contract unless otherwise noted.
3.1 Company References
Company Engineering Standards
JERES-N-110 Installation Requirements-Castable Refractories

JERES-N-120 Installation Requirements Extreme Erosion Resistant
Refractories
JERES-N-130 Installation Requirements-Fireclay Bricks
JERES-N-150 Erosion Resistant Refractory Lining in FCC Piping and
Vessels
Company Materials Specification
JERMS-F-3222 Manufacture of Components for Flare Systems

Company Standard Drawings
JERSD-N-0002 Hexsteel Details

JERSD-N-0003 Anchoring Details for Castable Refractories
JERSD-N-0007 Support Details at Nozzles and Manways for Castable
Refractories
JERSD-N-0009 Refractory Repairs and Terminations
Commentary Note:
Page 5 of 25
JERES-N-100
Rev. 1
The Company Drawings listed above and referenced in this standard shall be used as
general guide only for the generation of detailed refractory system drawings,specific
for each application.
3.2 Industry Codes and Standards
American Society for Testing and Materials
ASTM C20 Standard Test Methods for Apparent Porosity, Water

Absorption, Apparent Specific Gravity and Bulk Density of
Burned Refractory Brick and Shapes by Boiling Water
ASTM C24 Standard Test Method for Pyrometric Cone Equivalent (PCE)
of Fireclay and High Alumina Refractory Materials
ASTM C113 Standard Test Method for Reheat Change of Refractory Brick
ASTM C133 Standard Test Methods for Cold Crushing Strength and
Moudulus of Rupture of Refractory Brick and Shapes
ASTM C134 Standard Test Methods for Size, Dimensional Measurement,
and Bulk Density of Refractory Brick and Insulating Firebrick
ASTM C182 Standard Test Method for Thermal Conductivity of Insulating
Firebrick
ASTM C201 Standard Test Method for Thermal Conductivity of Refrctories
ASTM C704 Standard Test Methods for Abrasion Resistance of Refractory
Materials at Room Temperature
ASTM C1113 Standard Test Method for Thermal Conductivity of
Refractories by Hot Wire
American Petroleum Institute
API STD 560 Fired Heaters for General Refinery Service
API RP 936 Refractory Installation Quality Control Guidelines-Inspection

and Testing Monolithic Refractory Linings and Materials
ISO Standards
ISO 1109 Refractory Products-classification of dense shape
Page 6 of 25
JERES-N-100
Rev. 1
ISO 10081-1 Basic Refractory Products-Classification Part1: Products

Containing Less than 7% Residual Carbon.
ISO 10059-1 Dense, Shaped Refractory Products-Determination of Cold
Compressive Strength-Part1: Referee without Packing
ISO 8895 Shaped Insulating Refractory Products-Determination of Cold
Crushing strength.
ISO5014 Refractory Products-Determination of Modulus of Rupture at
Ambient Temeprature.
ISO5016 Shaped Insulating Refractory Products-Determination of Bulk
Density and True Porosity
ISO8894-1 Refractory Matrials-Determination of Thermal Conductivity-
Part1: Hot Wire Method.
ISO8894-2 Refractory Materials-Determination of Thermal Conductivity-
Part2: hot wire Method.
ISO2477 Shaped Insulating Refractory Products-Determination of
Permanent Change in Dimensions on Heating
ISO2478 Dense, Shaped Refractory Products-Determination of
Permanent Change in Dimensions on Heating.
4 Definitions
4.1 Definitions presented in the Standard and any other JER document has precedence
over other definitions. Conflicts between various definitions shall be resolved by the
Company Representative.
Company: Jubail Export Refinery.
Company Representative: A designated person from the Company or an assigned

third party representative.
4.2 List of Definitions
Anchors: “V” or “Y” shaped hardware that supports and holds castable refractory in
place.
Page 7 of 25
JERES-N-100
Rev. 1
Air Setting: A curing procedure for refractories that develop a strong bond at air
ambient temperatures by virtue of chemical reactions within the binder phase that is
usually activated by water additions.
Back-up Layer: In a dual-layer lining, the refractory near the shell.
Casing Temperature: The temperature on the outside surfaces of a fired process
heater, including radiant/convection sections, hot flue gas and hot air ducts.
Cold Crushing Strength: A measure of a refractory’s ability to resist failure under a
compressive load as determined at room temperature after drying or firing.
Design Engineer: The contracting company that is responsible for specifying
refractory system requirements on data sheets or equipment specifications.
Equipment Manufacturer: The company that is responsible for the fabrication of
boilers, process heaters, pressure vessels, heat exchangers, and flare tips to which
refractory is installed.
Gas bypassing: The ingress of gases between the refractory lining and the shell of
equipment.
Gunniting and Gunning: A method of applying castable refractories using
pneumatic force.
Hexsteel and “S” bars: Metal supports for extreme erosion-resistant castable
refractory.
Hot face: The layer that is exposed to high temperatures and erosion on top of the
back-up layer in a dual layer system.
“K” Factor: Thermal conductivity expressed in W/m °C (Btu-in/ft² °F Hr).
“Kcr” Factor: A factor used for correcting the “K” value of a refractory material in
air to the “K” value of the material in a hydrogen atmosphere.
Maximum Continuous Use Temperature: The maximum temperature at which a
refractory material can be used continuously.
Maximum Service Temperature: The maximum value of the gas temperature or
design temperature of a process stream.
Metal Fibers: Stainless steel needles added to refractory castables to increase
strength.
Page 8 of 25
JERES-N-100
Rev. 1
Modulus of Rupture (MOR): A measure of transverse or “cross-breaking” strength

of a solid body.
MSDS: Material Safety Data Sheets for refractory material, supplied by the
Refractory Manufacturer.
RCF: Stands for Refractory Ceramic Fiber
Plastic Refractory: A pre-mixed, phosphate-bonded refractory material.
Refractory Manufacturer: The company that manufactures refractory products
from raw materials.
Refractory Systems: A lining system that is designed to resist high temperatures,
hot gases, and the action of erosive materials. Components include anchors,
reinforcement, vapor barriers, and refractory materials needed for complete
installation.
Jubail Export Refinery Engineer: The Supervisor of the Piping and Valves Unit,
Consulting Services Department, Dhahran.
Vapor Barrier: A high-temperature coating that is applied to the shell of equipment
to protect the steel from condensing corrosive gases.
Vibration Casting: Castable installation technique where by refractory is mixed
with water and placed in a formed enclosure with the aid of vibrator which causes the
refractory to become “fluid like” and thereby flow and consolidate to the desired
shape of the formed enclosure.
5 Responsibilities and Documentation

5.1 The Design Engineer (Contractor) is responsible for specifying the minimum lining
thickness(s) and the refractory systems that are to be used for specific applications, in
accordance with this standard.
5.2 The Equipment Manufacturer is responsible for preparing fully detailed engineering
drawings of the refractory system and shall submit them to the Company
Representative for approval. As a minimum, the drawings shall include anchorage
design including spacing and orientation, refractory thicknesses, all materials,
surface preparation, and welding details.
5.3 In case RCF use is unavoidable and a written authorization from Company is
granted, RCF use will be allowed. In this case, the RCF Manufacturer is responsible
Page 9 of 25
JERES-N-100
Rev. 1
for the complete design of the RCF system in accordance with the specifications
supplied by the Design Engineer (Contractor).
5.4 The Manufacturer shall warrant and provide written documentation, for Company
approval, certifying that the supplied product meets the physical properties listed in
table 2, Appendix B. For the FCC unit application’s product physical properties to be
warranted, refer to a similar table in JERES-N-150.
5.4 The Manufacturer shall provide the restriction on the mixing water composition for
each product type. As a minimum the water composition shall be within the
limitation presented in paragraph 10.1.9, JERES-N-110.
5.5 For the required documentation from the Installer refer to Installation specifications
JERES-N-110, JERES-N-120, JERES-N-130 and JERES-N-150.
6 Design
6.1 General
The use of Refractory Ceramic Fiber (RCF) is forbidden; and it would ONLY be
allowed in cases where its use is proved to be unavoidable; such as caulking material
for ferrules in waste heat boiler in Claus unit and in spaces between refractory blocks
to accommodate thermal expansion.
Biosoluble Refractory Ceramic Fiber is allowed and may be used ONLY with prior
Company approval.
6.1.1 The design and selection of a refractory system shall be based on the following
considerations:
1) The allowable shell metal temperatures.
2) Outside casing temperatures.
3) Maximum service temperatures.
4) Velocities of flue gases or fluids to which the refractory system is exposed.
5) Composition of flue gases and fluids to which the refractory system is exposed.
6) Abrasive particles in the flue gases and fluids to which the refractory system is
exposed.
7) Casing or shell pressure and pressure fluctuations.
8) Optimum heat conservation.
Page 10 of 25
JERES-N-100
Rev. 1
6.1.2 Section 9 of this standard details the minimum design requirements for refractory
systems to be specified by the Design Engineer (Contractor).
6.1.3 The Design Engineer (Contractor) shall review and approve the Equipment
Manufacturer’s and Refractory Manufacturer’s drawings, as applicable, for
compliance with this standard.
6.1.4 Prior to fabrication and production welding, all welding procedures are to be
submitted to the Contractor’s Welding Specialist, or a representative designated by
the Company.
6.1.5 The continuous-use temperature of hydraulic-setting castable refractory materials

shall be a minimum of 95°C above the maximum service temperature of the
equipment ‘s hot face layer. For back-up layer, the continuous-use temperature shall
be a minimum of 165°C above the calculated temperature of the back-up layer.
6.1.6 The continuous-use temperature of RCF materials shall be a minimum of 150°C

above the maximum service temperature of the equipment.
6.1.7 The increase in the value(s) of thermal conductivity of refractory materials in

hydrogen rich gases versus the thermal conductivity in air must be considered by the
Design Engineer (Contractor). The design “K” values specified in paragraph 7 of this
standard are values in air and shall be corrected as required based on the percentage
of hydrogen in the process gas.
6.1.8 The minimum thermal coefficient correction factors for increased thermal
conductivity due to hydrogen pressures shall be determined as follows:
1) For refractory materials with dry bulk densities up to and including 1280 kg/m3
(80 lb/ft3):
Kcr = (% hydrogen X 0.01) + 1.0.
2) For refractory materials with dry bulk densities above 1280 kg/m³ (80 lb/ft³) up
to and including dry bulk densities of 1920 kg/m³ (120 lb/ft³):
Kcr = (% hydrogen X 0.0025) + 1.0.
6.2 Minimum Lining Requirements
6.2.1 Single-Layer Castable Linings

1) This type of lining shall consist of a single layer of a castable refractory to
provide thermal insulation and/or erosion resistance.
Page 11 of 25
JERES-N-100
Rev. 1
2) Unless otherwise specified in this standard the minimum thickness of a single

layer of castable refractory supported by anchors shall be 75 mm.
3) The minimum thickness of an erosion-resistant castable refractory supported by
hexsteel or “S” bars shall be 25 mm.
6.2.2 Dual Layer Castable Linings

1) This type of refractory lining shall consist of a layer of an insulating back-up
refractory covered by a layer of a dense refractory on the hot face.
2) The minimum thicknesses of individual castable layers shall be the thicknesses
that are specified in 6.2.1.
6.2.3 Extreme Erosion-Resistant Castable Linings

1) This type of extreme erosion-resistant refractory shall not have an erosion loss
that exceeds 6 cm³ after firing at 815°C, in accordance with the procedures
specified in ASTM C704.
2) This type of extreme erosion-resistant refractory shall not be used for heat
insulation.
3) This type of extreme erosion-resistant refractory shall be supported by means
of hexsteel or “S” bars.
4) Fiber reinforcing shall not be used in refractory for hexmetal linings.
6.2.4 Extreme Erosion-Resistant Plastic Castable Linings
This type of extreme erosion-resistant refractory shall have the same erosion
resistance characteristic as required for extreme erosion-resistant castable linings.
6.2.5 Void
6.3 Fired Process Heaters
6.3.1 The design temperature of the outside casing surfaces of process fired heaters shall
be specified in accordance with API STD 560 and the requirements of this standard.
6.3.2 The casing outside surface design temperature shall be determined in accordance
with the criteria below:
The design ambient air temperatures shall be in accordance with JERES-A-112,

corresponding to the average annual temperature for the specific site location and
still air.
Page 12 of 25
JERES-N-100
Rev. 1
7 Physical Properties
7.1 General
7.1.1 The use of refractory materials containing asbestos is strictly prohibited.
7.1.2 The Design Engineer shall specify materials with physical properties that are
sufficient to meet the design requirements of this standard.
7.1.3 The physical properties for castable refractories shall be in accordance with the
Jubail Export Refinery refractory types as specified in 7.2.2.
7.2 Design Data for Castable Refractories
7.2.1 The design parameters to be specified on data sheets and used in design calculations
shall, as a minimum, include those listed in Table A, Appendix A, Design
Parameters for Castable Refractory. The design values shall be in accordance with
values specified in Table 2 Appendix B.,For severe service in FCC unit the design
values are found in JERES-N-150.
7.2.2 VOID.
7.2.3 VOID
8 Metallic Components
8.1 General
The material selection for anchorage, supports, and metallic fiber reinforcement shall
be based on the design hot-face temperature and corrosion resistance.
8.2 Anchors
8.2.1 Anchors for single-layer, castable linings shall be “V” shaped types. Anchors for the
support of dual-layer linings including insulating castable refractory shall be “Y”
types.
8.2.2 All “V” and “Y” type anchors shall be specified with rubber or plastic caps.
8.2.3 For details of anchors for castable refractory linings, refer to JERSD-N-0003.
Page 13 of 25
JERES-N-100
Rev. 1
8.2.4 Individual anchors shall extend a minimum of 75% of the lining thickness. For
anchors with unequal leg lengths, the longest leg shall extend a minimum of 75% of
the lining thickness.
8.2.5 Void.
8.2.6 Void.
8.3 Hexsteel
8.3.1 Hexsteel shall be the offset-lance, tight-clinched type.
8.3.2 Riveted type hexsteel construction shall only be used on external surfaces of piping
that is 12 inch NPS and less.
8.3.3 Hexsteel that is to be supported by “T” studs for two component linings shall be
specified as 19 mm, 14 gauge bars.
8.3.4 Hexsteel that is to be welded directly to equipment or piping for the support of 25
mm thick extreme-erosion resistant refractory is to be 25 mm, 14 gauge bars.
8.3.5 All ends of hexsteel are to be welded to edging bars or to adjacent hexsteel. Loose
ends are prohibited.
8.3.6 For installation details of hexsteel, refer to JERSD-N-0002.
8.4 Nozzles and Manways
Details of nozzle and manway openings in refractory lined pressure vessels and
piping shall be in accordance with JERSD-N-0007.
8.5 Metallic Fiber Reinforcement (Needles)
8.5.1 Unless otherwise specified in this standard, the density of metallic fiber
reinforcement shall be 80 kg/m³ (5 lb./ft³).
8.5.2 Metallic fiber reinforcement shall be manufactured from melt extracted material,
approximately 0.5 mm in thickness and approximately 25 mm long.
8.6 “S” Bars
“S” bars shall be used only for the support of extreme erosion-resistant refractory
where hexsteel is not applicable.
Page 14 of 25
JERES-N-100
Rev. 1
9 Refractory Systems
9.1 The refractory systems for specific equipment shall be in accordance with the
requirements in Table 3, Appendix C, Mandatory Refractory Systems.
9.2 The types of castable refractory material that are specified in Table 3 are the Jubail
Export Refinery Refractory Standard Type.
9.3 Complete generic descriptions corresponding to the Jubail Export Refinery refractory
type are detailed in the Jubail Export Refinery Materials System (SAMS) catalog.
10 Refractory Installation
10.1 Refractory systems whether shop or field applied shall be installed in accordance
with the procedures as detailed in the below listed standards. Vessels and transfer
lines in Fluid Catalytic Cracking units shall be in accordance with JERES-N-150.
JERES-N-110 Installation Requirements-Castable Refractories

JERES-N-120 Installation Requirements-Extreme Erosion Resistant
Refractories
JERES-N-130 Installation Requirements-Fireclay Bricks
JERES-N-150 Erosion Resistant Refractory Lining in FCC Piping and
Vessels
11 Materials Pre-shipment Testing

Prior to delivery of refractory materials from the Manufacturer's plant, pre-shipment
testing shall be performed as follows:
Refractory purpose Test specimens per sample Sampling Frequency

Heat insulating 3 cubes for compressive strength + density; 1 per batch of 5tons or less
Type 1 1 bar for linear change
Erosion resistant/heat insulating 3 cubes for compressive strength + density; 1 per batch of 2 tones or less.
Type 2 1 bar for linear change;
2 plates for erosion
Extreme duty, erosion resistant 3 cubes for compressive strength + density; 1 per batch of 2 tones or less
Type 3 1 bar for linear change;
2 plates for erosion
Samples sizes:
Cold crushing cubes 50x50x50mm
Permanent Linear Change bars: 230x50x50mm
Page 15 of 25
JERES-N-100
Rev. 1
Erosion plates 114x114x25mm

All test specimens shall be prepared without metallic fibers.
Certification of pre-shipment test results shall be forwarded to the Company
Representative for review prior to any lining application being performed.
Sample test results shall meet the values specified in Table 2, Appendix B. For FCC
unit application, refer to JERES-N-150.
If test results for cold crushing fall below the specified value by more than 10%, or if
the test result for erosion is more than 10% above the specified value then either re-
testing will be required or the relevant batch shall be rejected.
12 Claus unit, special requirements

12.1 General
12.1.1.1 The following requirements prevail on the more general requirements listed in
JERES-N-110, JERES-N-120 and JERES-N-130.
12.1.2 The equipments in Claus unit having refractory coating are: Thermal Reactor, Waste
heat boiler, converter (reactor), and sulfur storage pit.
12.2 Anchors
V-anchors for single component linings shall be as follows:
o Design and layout for single layer linings shall be either straight tine or wave V
anchors;
o For cast and gunned installations, anchor tips shall be 10 minimum to 25 mm
maximum from the refractory lining surface;
o For gunned single layer linings behind shrouds, V-anchor tips shall be flush with
the specified lining surface to provide for accurate measurement of the applied
lining thickness;
o For cast pipe linings, anchors are not required if the lining ID is 26" (660mm) or
less, provided that the lining thickness is equal to 75 mm or greater.
o Y or V anchors shall be provided with plastic cap at the extremity to allow
thermal expansion without breaking the refractory surface.
Y-anchors for dual-layer linings shall be as per Figure 1, Appendix A. When
installed by gunning, the first layer shall be gunned with the stud-welded threaded
stud in place, with tape or plastic caps covering the exposed threads. The "V"
portion shall then be attached before the second layer is gunned.
Page 16 of 25
JERES-N-100
Rev. 1
Anchors shall be of the hand-weldable type. Stud gun weldable anchors shall not be
used unless approved by Company Representative.
Austenitic stainless steel V and Y-anchors shall be supplied in the fully solution-
annealed condition. Solution annealing shall be performed after the anchor is
formed.
Metallurgy shall be based on the maximum long-term temperature to which the

anchor is exposed at a depth of 25 mm from the lining hot face as per following
table.
Maximum Permissible Anchor T° [°C], Material (1) (2)

25mm from hot face
540 Carbon Steel 0.30 wt% Carbon max.
650 12 percent Cr (410S, 405)
870 AISI304, AISI310
1) Metallurgy selection for anchors in high H2S service (i.e., reforming) shall be
approved by the Owner's Engineer.
2) Anchors shall be properly identified using color code per API RP936, appendix C.
12.2.1 Refractory construction specifications
12.2.1.1 Thermal reactor:
• A single layer of 230 mm thick, 95 percent alumina firebrick (Babcock and
Wilcox SR90, or equivalent) shall be used for the inner layer of the thermal
reactor to protect it during short periods of excessive temperature, and to provide
adequate mechanical keying strength between bricks. The Contractor shall also
provide an alternative bid with 99 percent alumina firebrick. For temperatures
over 1430°C, 99 percent alumina firebrick shall be used.
• Lightweight castable (Harbison-Walker LW No. 28, or equivalent), 115 mm thick
(suitable for temperatures up to 1540°C shall be used for the outside refractory
layer to provide a better seal with the reactor shell. Type 310 stainless steel V-
anchors shall be used to support the castable. Anchor ends shall be located 38mm
from the hot inside surface of the castable. V-anchors shall be supplied preferably
bent to shape. They shall be annealed after bending. Anchors shall not be bent
after welding in place. Anchors shall be 6 mm thick and spaced a maximum of
300 mm apart. Refer to JERES-N-110 for anchor installation requirements.
12.2.1.2 Waste heat-boiler:
• The hot inlet tubesheet shall have refractory insulation of high-alumina castable
material (A. P. Green, Greencast 97, or equivalent), either poured or trowelled
Page 17 of 25
JERES-N-100
Rev. 1
between ferrules. Minimum insulation thickness shall be 100 mm. Anchors shall
be 3 mm thick UNS R0556 (Haynes 556 or equivalent) material.
• Tube ferrules shall be furnished at the hot inlet end. They shall be of 85 percent
alumina ceramic material. Ferrules shall be wrapped with ceramic fiber (Fibrefax
or equivalent) on that portion inserted in the tube.
• Proprietary systems such as hex-head ferrules, two-components hexagon ferrules,
etc., may be used for tube sheet lining.
12.2.2 Reactor:
• The section at the higher catalyst bed level and below shall be protected with
refractory material. Anchor ends shall be located 38mm from the hot inside
surface of the castable. Anchors shall be 6 mm thick and spaced a maximum of
300 mm apart. V-anchors shall be AISI310 or equivalent, supplied preferably bent
to shape. They shall be annealed after bending. Anchors shall not be bent after
welding in place. The refractory material shall be able to resist temperature of
1540°C, to prevent deformation of the vessel in case of fire.
12.2.3 Sulfur storage pit:
• The sulfur storage pit shall be in concrete, having resistance to sulfidation
Portland Cement Grade111A or equivalent. The coverage on reinforcement shall
be 60mm minimum.
13 Refractory Material Shipment
All shipments shall have each batch and refractory type clearly identified on the
containers.
The water ratio used in qualification testing shall be marked on the refractory
containers (except for chemical setting, refractory lining material).
Refractory heat resistant bricks shall be pre-sliced at the design thickness and then
packaged in heat-sealed plastic wrap. The qualification testing shall be marked on
the containers and included with the installation instructions.
Page 18 of 25
JERES-N-100
Rev. 1
Appendix A
Table A – Design Parameters for Castable Refractory.
o Cold crushing strength in accordance with ASTM C109 or C133.

o Modulus of Rupture in accordance with ASTM C133 or C583.
o Permanent Linear change (PLC) and return thermal expansion (RTE).
o Erosion loss (not required for insulating castables) in accordance with ASTM C704.
o Thermal conductivity values for the intented service temperature in accordance with
ASTM C201 and C417 or C113.
o Bulk density after drying to 110°C.
o Return thermal expansion expressed in millimeters per linear meter (5640-815°C).
o Percentage of water to be used for mixing and installation.
o Volumetric yield (without losses).
o Type of binder, aggregates and maximum grain size.
o Type of packaging for shipment.
o Requirements for storage and expected shelf-life.
o Maximum long-term service temperature (°C).
o Chemical composition (confirm rapid fire Technology RFT fibers are used).
Page 19 of 25
JERES-N-100
Rev. 1
Figure 1: Y-Anchor for Dual Layer Gunned Linning.
Page 20 of 25
JERES-N-100
Rev. 1
Appendix B
Table 2 – Design Data for Castable Refractory
Type of Castable Refractory [1][4]
A B C D E F G H I
Bulk Density kg/m³
(lb/ft³) Cured and 880 (55) [2] 1120 (70) 880 (55) [3] 1280 (80) 2080 (130) 2240 (350) 2720 (170) 2720 (170) 2720 (170)
[3] [3] [2] [2] [2] [2] [2]
Dried at 815°C
Cold Crushing Strength
kg/cm² (lb/in²) after 20 (300) 21 (300) 31 (300) 105 (1500) 525 (7500) 350 (5000) 560 (8000) 560 (8000) 350 (5000)
firing at 815°C
MOR after firing at 20 (300) 7 (100) 12 (180) 25 (350) 70 (1000) 98 (1400) 86 (1200) 105 (1500) 70 (1000)
815°C kg/cm² (lb/in²)
Permanent Linear -1.5% -0.5% -1.2% -0.2% -0.1% -0.2% -0.1% -0.4% -0.2%
Change
Thermal Conductivity K
value in W/m.°C 0.21 (1.50) 0.18 (1.30) 0.35 (2.47) 0.40 (2.80) 0.24 (1.70) 0.95 (6.30) 1.56 (10.8) 1.61 (11.5) 1.61 (11.5)
(Btu-in/ft².F.Hr) 0.25 (1.70) 0.20 (1.40) 0.38 (2.63) 0.42 (1.95) 0.23 (1.65) 0.97 (6.90) 1.41 (9.8) 1.75 (12.5) 1.75 (12.5)
at 260°C 0.26 (1.80) 0.23 (1.60) 0.40 (2.79) 0.44 (3.10) 0.26 (1.80) 1.08 (7.70) 1.40 (9.7) 1.96 (14.0) 1.96 (14.0)
at 540°C
at 815°C
Max. Continuous 1095°C 980°C 1540°C 1200°C 1215°C 1315°C 1700°C 1650°C 1705°C
Use Temperature
Notes: [1] Type A Lightweight Insulating Castable (SAMS S/N 32163500)

Type B Lightweight Insulating Low Iron Castable (SAMS S/N 32163510)
Type C Special Lightweight Insulating Low Iron Castable (SAMS S/N 32163520)
Type D Special Medium Weight Insulating Castable (SAMS S/N 32163530)
Type E Medium Weight Erosion Resistant Fused Silica Castable (SAMS S/N 32163540)
Type F Erosion Resistant Insulating Castable (SAMS S/N 32163550)
Type G Hydraulic Setting Erosion Resistant Castable (SAMS S/N 32163560)
Type H Chemical Setting Extreme Erosion Resistant Castable (SAMS S/N 32163570)
Type I Chemical Setting Extreme Erosion Resistant Plastic (SAMS S/N 32163580)
[2] Density with Cast Insulation.
[3] Density with Gunnited Installation.
[4] Variation of ±10% to the values shown in the table are acceptable except for max. continuous use temperature the values shown are the
minimum.
Page 21 of 25
JERES-N-100
Rev. 1
Appendix C
Table 3 – Mandatory Refractory Systems

Anchors Refractory Material
Equipment Operation
(Material, Sizes (Type, Weight % of Needles
(Specific Notes) Condition
and Types) and Application Method)
For FCC refractory system,
refer to JERES-N-150
Naphtha reformers-reactors 550°C hydrogen rich Type 304, 6 mm diameter Type B (low iron), insulating 100
wall lining atmosphere. on a 225 mm square mm thick, 5% weight Type 304
pattern. needles. Shroud supports and vapor
stops required to minimize gas
bypassing. Gunnited.
Page 22 of 25
JERES-N-100
Rev. 1
Table 3 – Mandatory Refractory Systems (Cont’d)

Anchors Refractory Material
Equipment Operation
(Material, Sizes (Type, Weight % of Needles
(Specific Notes) Condition
and Types) and Application Method)
Sulfur plants-thermal Temperature <1430°C Type 310 stainless steel A single layer of 228 mm (9 in.)
oxidizer(3) (9) (10) V-anchors shall be used thick, 90 percent alumina firebrick
to support the castable. (Babcock and Wilcox SR 90, or
Anchor ends shall be equivalent) shall be used for the
located 38 mm from the inner layer of the thermal reactor to
hot inside surface of the protect it during short periods of
castable. V-anchors excessive temperature, and to
shall be supplied provide adequate mechanical
preferably bent to shape. keying strength between bricks.
They shall be annealed Lightweight castable (Harbison-
after bending. Anchors Walker LW No. 28, or equivalent),
shall not be bent after 115 mm thick (suitable for
welding in place. temperatures up to 1540°C) shall be
Anchors shall be 6 mm used for the outside refractory layer.
thick and spaced a
maximum of 300 mm
apart.
Sulfur plants-thermal 1540°C oxidizing Type 310 stainless steel V- 99 percent alumina firebrick for the
oxidizer(3) (9) (10) atmosphere. anchors shall be used to inner layer
support the castable. Lightweight castable (Harbison-
Anchor ends shall be Walker LW No. 28, or equivalent),
located 38 mm from the hot 115 mm thick (suitable for
inside surface of the temperatures up to 1540°C) shall be
castable. V-anchors shall used for the outside refractory layer.
be supplied preferably bent
to shape. They shall be
annealed after bending.
Anchors shall not be bent
after welding in place.
Anchors shall be 6 mm
thick, 225 mm square
pattern (maximum of 300
mm).
Sulfur plants-reaction Anchors shall be 3 mm (1/8 Refractory insulation of high-
furnace (3) (8) (10) in.) thick UNS R0556 alumina castable material (A. P.
Tubesheet (Haynes 556 or equivalent) Green, Greencast 97, or equivalent),
material. either poured or trowelled between
ferrules. Minimum insulation
thickness shall be 100 mm (4 in.).
Hydrogen-plants waste heat 840°C hydrogen rich Two component lining: Two component lining:
boilers (shall conform to atmosphere Type 310, 500 mm long, V- 1) Type G, erosion resistant (hot
ASME section I) and transfer type. face), 3% weight type 310
lines needles. Vibration cast or
Shroud lining: gunnited.
Incoloy 800, shrouds. 2) Type B, insulating (back up),
5% weight type 304 needles.
Vibration cast or gunnited.
Shroud lining:
Page 23 of 25
JERES-N-100
Rev. 1
Type B (low iron), insulating cast.

Waste heat boiler Cold end part 300°C Anchors shall be type Refractory lining 50mm minimum
and above AISI304 thickness
Hydrogen-plants furnaces (3) 1090°C low erosion, Walls: sectionally Walls: Contractor to propose for
oxidizing atmosphere. supported wall anchors or Company approval.
manufacturer’s design. Ceiling: Type A insulating, 5%
Ceiling: weight Type 304 needles, gunnited
Manufacturter’s design. Floor: High duty firebrick
(unmortared) (hot face), Type C
(back up). Cast.
Page 24 of 25
JERES-N-100
Rev. 1
Table 3 – Mandatory Refractory Systems (Cont’d)

Fired heater radiant section 980 - 1310°C oxidizing Side walls and roof: Side walls and roof: Contractor to
or boiler furnace (3) (5) (6) atmosphere, mechanical manufacturer’s design Type propose for Company approval.
Fired heater convection and thermal spalling. 310 minimum. Convection section Type A or D
section Up to 980°C. insulating, with optional 5% weight
Type 304 needles, gunnited
Floor: Type 304, 6 mm Floor: High duty fireclay brick laid
diameter, V-type on a 225 dry (hot face). Type A insulating
mm square pattern. (back up). Cast.
Divider walls super duty and high
duty fireclay brick laid with air set
mortar and expansion joints.
Burner blocks - super duty fireclays
or formed air set plastics.
Fired heaters and boilers- 315 - 815°C mild Type 304, 3 mm diameter, 3 mm thick vapor barrier on shell
stacks (3) erosion, some V-type. and breaching. Type A or D
mechanical and thermal insulating thickness with optional
spalling. 5% weight type 304 needles.
Flare tips (6)(7)(8) 315 - 1090°C mild 3 mm diameter, V-type Both sides, one shot lining, Type G,
erosion, some anchors or coiled wire (7) 5% weight needles, Type 310. Cast
mechanical and thermal or gunnited (if accessible).
spalling.
General Note:
Existing boilers, flare tips, and fired heaters (furnaces) which are refractory-lined with castable type refractories, shall be maintained and
repaired using the same refractory systems as specified by the original Equipment Manufacturer. Modifications to original design require Jubail
Export Refinery Engineer’s Approval.
Specific Notes:
(1) Hexsteel with Type H refractory shall be used for new installations, and “S” bars with Type I refractory shall be used for maintenance
repairs. Materials of hexsteel and “S” bars are to be the same material and Type as the equipment.
(2) Slide valve bodies are to be lined in accordance with the requirements for FCC standpipes.
(3) An asphaltic mastic coating rated to 175°C shall be used for a vapor barrier.
(4) Use a refractory material, which is resistant to acidic water.
(5) The anchor material specified is for clean fuel (less than 5% sulfur).
(6) The anchor materials for flare tips shall be specified in accordance with JERMS-F-3222.
(7) Unless otherwise specified by the Equipment Manufacturer, flare tips less than 600 mm nominal diameter shall not be internally lined.
(8) The minimum lining thickness shall be 50 mm
(9) Two layer refractory system
(10) Typical acceptable castable refractory lining material are:
Green Cast 94
Castolast G
Plicast 40
Resco RS 17 A
Towacast C-18
Restrictions: Fe2O3<6%, CaO<15%, Alkalis<2.5%
Page 25 of 25

JERES-N-100 Refractory Systems PDF

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

JERES-N-100 Refractory Systems PDF

Caricato da

Copyright:

Formati disponibili

Jubail Export Refinery

Revision Responsibility 03 February

Revision Revision Date Scope of Revision

1 03 February 2009 Revised to update paragraphs: 7.2.2 and 7.2.3

0 29 April 2008 Issued for bid package.

General revision for consistency with links, incorporated comments from

03 31 March 2008 Issue for Bid Package, only for review

02 23 January 2008 Revision links consistency, refractory limitations

01 03 May 2007 The first official JERES-N-100 is issued.

Section Contents Page

2 Conflicts, Deviations and Clarifications 4

5 Responsibilities and Documentation 9

11 Materials Pre-Shipment Testing 15

12 Claus Unit Special Requirements 16

13 Refractory Material Shipment 18

C Table 3 – Mandatory Refractory Systems 22

2 Conflicts, Deviations and Clarifications

3.1 Company References

Company Engineering Standards

JERES-N-110 Installation Requirements-Castable Refractories

Company Materials Specification

JERMS-F-3222 Manufacture of Components for Flare Systems

JERSD-N-0002 Hexsteel Details

3.2 Industry Codes and Standards

American Society for Testing and Materials

ASTM C20 Standard Test Methods for Apparent Porosity, Water

API STD 560 Fired Heaters for General Refinery Service

API RP 936 Refractory Installation Quality Control Guidelines-Inspection

ISO 1109 Refractory Products-classification of dense shape

ISO 10081-1 Basic Refractory Products-Classification Part1: Products

Company: Jubail Export Refinery.

Company Representative: A designated person from the Company or an assigned

4.2 List of Definitions

Modulus of Rupture (MOR): A measure of transverse or “cross-breaking” strength

5 Responsibilities and Documentation

6.1.5 The continuous-use temperature of hydraulic-setting castable refractory materials

6.1.6 The continuous-use temperature of RCF materials shall be a minimum of 150°C

6.1.7 The increase in the value(s) of thermal conductivity of refractory materials in

6.2 Minimum Lining Requirements

6.2.1 Single-Layer Castable Linings

2) Unless otherwise specified in this standard the minimum thickness of a single

6.2.2 Dual Layer Castable Linings

6.2.3 Extreme Erosion-Resistant Castable Linings

6.2.4 Extreme Erosion-Resistant Plastic Castable Linings

6.3 Fired Process Heaters

The design ambient air temperatures shall be in accordance with JERES-A-112,

7.1.1 The use of refractory materials containing asbestos is strictly prohibited.

7.2 Design Data for Castable Refractories

8.3.1 Hexsteel shall be the offset-lance, tight-clinched type.

8.3.6 For installation details of hexsteel, refer to JERSD-N-0002.

8.4 Nozzles and Manways

8.5 Metallic Fiber Reinforcement (Needles)

8.6 “S” Bars

JERES-N-110 Installation Requirements-Castable Refractories

11 Materials Pre-shipment Testing

Refractory purpose Test specimens per sample Sampling Frequency

Erosion plates 114x114x25mm

12 Claus unit, special requirements

Metallurgy shall be based on the maximum long-term temperature to which the

Maximum Permissible Anchor T° [°C], Material (1) (2)

Table A – Design Parameters for Castable Refractory.

o Cold crushing strength in accordance with ASTM C109 or C133.

Figure 1: Y-Anchor for Dual Layer Gunned Linning.