Refractory Installation Quality Control—Inspection and Testing Monolithic Refractory Linings and Materials

API STANDARD 936

FOURTH EDITION, JUNE 2014

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Foreword

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iii

Important Information Concerning Use of Asbestos or Alternative Materials

Asbestos is specified or referenced for certain components of the equipment described in some API standards. It has been of extreme usefulness in minimizing fire hazards associated with petroleum processing. It has also been a universal sealing material, compatible with most refining fluid services.

Certain serious adverse health effects are associated with asbestos, among them the serious and often fatal diseases of lung cancer, asbestosis, and mesothelioma (a cancer of the chest and abdominal linings). The degree of exposure to asbestos varies with the product and the work practices involved.

Consult the most recent edition of the Occupational Safety and Health Administration (OSHA), U.S. Department of Labor, Occupational Safety and Health Standard for Asbestos, Tremolite, Anthophyllite, and Actinolite, 29 Code of Federal Regulations Section 1910.1001; the U.S. Environmental Protection Agency, National Emission Standard for Asbestos, 40 Code of Federal Regulations Sections 61.140 through 61.156; and the U.S. Environmental Protection Agency (EPA) rule on labeling requirements and phased banning of asbestos products (Sections 763.160-179).

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SAFETY AND HEALTH INFORMATION WITH RESPECT TO PARTICULAR PRODUCTS OR MATERIALS CAN BE OBTAINED FROM THE EMPLOYER, THE MANUFACTURER OR SUPPLIER OF THAT PRODUCT OR MATERIAL, OR THE MATERIAL SAFETY DATASHEET.

Contents

Page

1. Scope 1

2. Normative References 1

3. Terms and Definitions 1

4. Quality Control Elements 8

5. Responsibilities 8

   1. Owner 8

   2. Contractor 9

   3. Inspector 10

   4. Manufacturer 11

6. Inspector Qualifications 11

7. Materials 11

   1. Physical Property Requirements 11

   2. Storage 11

   3. Packaging and Marking 12

   4. Anchors 13

8. Qualification and Testing 13

   1. Testing and Test Procedures 13

   2. Preshipment Refractory Qualification Testing15

   3. Qualification of Installation Procedure and Crew/Installers 16

   4. Production (As-installed) Refractory Sampling and Testing 19

   5. Test Specimen Preparation 20

9. Installation/Execution 21

   1. Surface Preparation. 21

   2. Water Quality 22

   3. Water-contaminated Refractory 22

   4. Preparation for Lining Installation 22

   5. Application Temperature 23

   6. Gunning 23

1. Thin-layer Abrasion (Erosion) Resistant Linings 25

2. Thick-layer Plastic Linings 26

3. Metal Fiber Reinforcement 26

4. Organic Fibers 27

5. Interruption of Application 27

6. Curing 27

7. Repairs 28

1. Dryout 29

   1. Dryout Procedure 29

   2. Dryout Schedule 29

v

Contents

Page

Annex A (informative) Glossary 32

Annex B (normative) Refractory Compliance Datasheet 43

Annex C (informative) API Certification for Refractory Personnel 46

Bibliography 48

Figure

B.1 Sample Compliance Datasheet 45

Tables

1. Quality Control: Key Elements 8

2. Testing Machine Sensitivity and Loading Rate 14

3. Physical Properties and Acceptable Results for Testing of As-Installed Refractories 20

4. Required Number of Test Specimens per Sample 21

5. Dryout of Conventional Castable Refractories 30

B.1 Requirements for Compliance Datasheet Property Listings 44

C.1 Minimum Inspector Competencies 46

vi

Introduction

The purpose of this standard is to define the minimum requirements for the installation of monolithic refractory linings and to provide guidance for the establishment of quality control elements necessary to achieve the defined requirements.

vii

Refractory Installation Quality Control—Inspection and Testing Monolithic Refractory Linings and Materials

1. Scope

   This standard provides installation quality control procedures for monolithic refractory linings and may be used to supplement owner specifications. Materials, equipment, and personnel are qualified by the methods described, and applied refractory quality is closely monitored, based on defined procedures and acceptance criteria. The responsibilities of inspection personnel who monitor and direct the quality control process are also defined.

   
   

2. Normative References

   The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.

   
   

   ACI 547-79 1 (revised 1983, reapproved 1997), Refractory Concrete: Abstract of State-of-the-Art Report (out of print) ACI 547.1 R-89 (reapproved 1997), Report - Refractory Plastics and Ramming Mixes (out of print)

   ASTM C71 2, Standard Terminology Relating to Refractories

   
   

   ASTM C113, Standard Test Method for Reheat Change of Refractory Brick

   
   

   ASTM C133, Standard Test Methods for Cold Crushing Strength and Modulus of Rupture of Refractories ASTM C181, Standard Test Method for Workability Index of Fireclay and High-Alumina Plastic Refractories ASTM C704, Standard Test Method for Abrasion Resistance of Refractory Materials at Room Temperature ASTM C1054, Standard Practice for Pressing and Drying Refractory Plastic and Ramming Mix Specimens Harbison-Walker Handbook of Refractory Practices 3

   SSPC SP 3 4, Power Tool Cleaning

   
   

   SSPC SP 7/NACE No. 4, Brush-Off Blast Cleaning

   
   

3. Terms and Definitions

For the purposes of this document, the following definitions apply.

NOTE See Annex A for a glossary of additional refractory terms that are not referenced in this standard.

1. American Concrete Institute, 38800 Country Club Drive, Farmington Hills, Michigan 48332, www.aci-int.org.

2. ASTM International, 100 Barr Harbor Drive, West Conshohocken, Pennsylvania 19428, www.astm.org.

3. ANH Refractories, www.hwr.com/contact.

4. The Society for Protective Coatings, 40 24th Street, 6th Floor, Pittsburgh, Pennsylvania 15222, www.sspc.org.

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