Refractory Ceramic Fiber - Design and Installation - PDFYAR - Engineering Notes, Documents & Lectures

1. SCOPE………………………………………………………………………………..2. REFERENCES
3. DEFINITIONS
4. GENERAL ……………………………………………………………………………5. DESIGN
6. WELDING
7. STORAGE AND HANDLING………………………………………………..8. SURFACE PREPARATION
9.
INSTALLATION
9.1 General …………………………………………………………………………9.2
Installation of Vapor Barrier
9.3 Modular Construction
9.4
Veneering with RCF ………………………………………………………..
9.5
Anchors
9.6
Layered Blankets and Blanket Board Construction
10.
INSPECTION AND REPAIRS …………………………………………………
10.1 General
10.2
Inspection of Anchors and Supports
10.3 Repairs……………………………………………………………………………
FIGURE
1 Soldier Course Installation with Single Batten Strip
2 Soldier Course Installation with Double Batten Strip
3 Doors…………………………………………………………………………………..4 Burner Blocks
5 Soldier Course Module Installations Around Corners
6 Corner Modules………………………………………………………………….7
Joint Construction Between Dense Refractory and Modules
8 Veneering Module Installation
9 Veneering Module Anchor Installation……………………………………10 Corner Details, Layered Blanket Systems
11 Corner Details in Blanket / Board Systems
12 Tie-In of Blanket to Dense Refractory ………………………………………13 Use of Speed Clips
14 Layered Blanket Anchor Placement, Joint Construction
15
Blanket / Board Anchor Placement Joint Construction………………..
16 Covering Anchor Ends
17
Installation of Cuplock Washers
18
Blanket Installations ………………………………………………………………18A. Lap Joint Method
18B. Staggered Joints
19 Butt Joint Method for Blanket / Board Systems………………………..
TABLE
I Anchor Material Temperature Limits, Clean Fuel (< 0.5% Sulfur)
II Anchor Material Temperature Limits, Dirty Fuel (> 0.5% Sulfur)
III Maximum Anchor Spacing ‘X’ …………………………………………………

1. Scope
1.1 This standard is for the design, installation, testing, and inspection of refractory ceramic fiber (RCF)
systems.
1.2 This standard is for the installation of new RCF systems and the repair of existing RCF systems.
2. References
Reference is made in this standard to the following documents. The latest issues, amendments and
supplements to these documents shall apply unless otherwise indicated.
SABIC Engineering Standards (SES)
N02-S01 Refractories – Application and Selection
American Society of Mechanical Engineers (ASME)
Section IX Welding and Brazing Operators
Steel Structures Painting Council (SSPC)
SP 1 Solvent Washing
SP 3 Power Tool Cleaned
SP 7 Brush Blasting
3. Definitions
For the purpose of understanding this standard, the following definitions apply:
Anchors. The hardware that holds RCF modules and blankets in place.
MSDS. Material Safety Data Sheets for refractory material, supplied by RCF manufacturers.
Parquet Installation. An installation method for RCF modules where the layers are oriented perpendicular
to each module.
RCF Modules. Modules made from RCF material, including boards, blankets and straps.
Refractory Ceramic Fibers (RCF). Fibers made from melting aluminosilicates in an electric furnace.
Refractory System. A lining system that is designed to resist high temperatures, hot gases, and the
action of erosive materials. Components comprise anchors, reinforcement, vapor stops, and refractory
materials needed for complete installation.
Soldier Installation. An installation method for RCF modules where the layers are oriented
uni-directionally.
Vapor Barrier. A high-temperature coating that is applied to the shell of equipment to protect the steel
from condensing corrosive gases.
Veneering. The application of RCF materials over existing refractory castable or brick linings.
4. General
4.1 Ceramic fibers are made by spinning or air-blowing molten minerals into fibers or filament, followed by
rapid quenching. They consist primarily of alumina and silica, with small amounts of other oxides and
additives. Fiber properties are dependent on the composition, microstructure and manufacturing process.
4.2 Fibers formed by melt spinning are usually longer and stronger. Air blowing produces shorter fiber, but
with less shot content. Shot is a form of fiber particle or bead, and is a defect in the manufacturing process.
4.3 The following variables in the fiber manufacturing process affect the temperature rating, strength and
durability of the ceramic fiber:
a. Bulk density. Usually dense fiber masses perform better at higher temperatures and in harsher
environments.

b. Shot content. The higher the shot content, the lower the strength and durability in the fiber mass.
c. Fiber diameter. Smaller fiber diameter yields a more insulating material. Most fibers are between
1 and 3 micron in diameter.
4.4 Most commercially available ceramic fibers can be classified into two groups based on their
compositions and microstructure:
a. Alumina-silica fibers. Maximum continuous service temperature is related to alumina content,
with a maximum of around 1260 °C for 60 percent alumina fibers in a blanket application. Addition of
zirconia or chromic oxides can increase the service temperature to approximately 1315 °C.
b. Polycrystalline fibers. Fiber with higher alumina or zirconia content. Higher service temperature is
achieved by addition of chromic oxide, or other oxides, as a stabilizer; increasing the alumina content;
and pre-crystallizing the fiber.
4.5 Ceramic fibers used as insulation material are manufactured into two forms: ceramic fiber blanket
(CFB) and ceramic fiber module (CFM). Ceramic fiber modules are fabricated by either folding the fiber
blankets in a compressed manner, or holding them together in log, pleat, edge-grain, or layered forms.
Both blanket and module are fabricated to certain sizes and thicknesses for various applications.
4.6 Operating temperatures for fibers are usually limited by shrinkage, caused by thermal sintering,
viscous creep, and crystallization. At high temperature (>1090 °C), silica partially converts to cristobalite,
an allotropic form of silica. Extent of reaction is a function of time and temperature, and results in
devitrification, causing fiber to shrink and become friable.
4.7 Ceramic fibers have the following chemical properties:
a. Ceramic fiber products are inert to oil and water. Thermal and physical properties are restored
after drying.
b. Hydrogen, carbon monoxide, and hydrocarbons can attack silica in the fiber, causing
embrittlement, shrinkage and loss of strength
c. Vanadium and other alkalis found in heavy fuel oil react with alumina-silica fiber above 870 °C
d. Sulfur in the fuel can cause devitrification of the fiber hot face layer, and can form sulphuric acid
in the presence of water vapor, attacking casing if casing temperature drops below acid dew point
4.8 Any conflicts between this standard, SES and industry standards, engineering drawings and contract
documents shall be resolved at the discretion of SABIC.
5. Design
5.1 The equipment manufacturer shall prepare detailed engineering drawings of refractory system. The
drawings shall include details of the anchorage design, refractory thicknesses, materials, surface
preparation, and welding details.
5.2 When evaluating fiber, the following shall be considered:
a. Temperature limitation of the fiber blanket or modules
b. Linear shrinkage rate
c. Composition and properties, especially resistance to the attack from sulfur, vanadium, alkalies,
carbon monoxide, hydrogen, hydrocarbons and their compounds formed in the combustion process
d. Thermal conductivity
5.3 Selection of fiber grade and density will depend on hot face, cold face, and interface temperatures of
the lining, and overall lining thickness. For calculation of temperature profiles, see SES N02-S01.
5.4 Ceramic fiber material shall not be installed in turbulent areas, around burners, high velocity zones, or
in a location where vibration can cause tearing and sagging of the fiber material. For those locations,
castable or bricks shall be used.

6. Welding
6.1 Refractory anchor welding shall be in accordance with the requirements of ASME Section IX,
paragraph QW-180.
6.2 Refractory anchors, stud supports, and vapor stops for the support of RCF modules shall be made
with the shielded metal arc (SMAW), gas tungsten arc (GTAW), or stud welding processes, and shall be
welded all around. Stud welding shall only be used on non pressure components.
6.3 Refractory installer shall prepare and submit detailed welding procedure specifications and
performance qualification records to SABIC for review and approval prior to welding.
6.4 Refractory anchorage, including anchors, studs, supports, edging bars, and similar items shall not be
welded within 50 mm of circumferential and longitudinal seams of pressure vessels and piping.
6.5 If equipment is to be post weld heat treated, anchors shall be welded prior to heat treatment.
7. Storage and Handling
7.1 Prior to placement, RCF modules shall be protected from water and moisture.
7.2 Materials shall be stored off the ground and shall be covered with tarps to protect against water or
moisture damage.
7.3 Containers shall be protected from mechanical damage for example tears and rips.
7.4 RCF manufacturer’s precautions, as specified on the MSDS, shall be strictly followed.
8. Surface Preparation
8.1 Surfaces shall be clean, dry, and free from oil, grease, weld slag, rust and mill scale prior to installation
of refractory.
8.2 If specified in the purchase order, shells and casings of equipment to be lined shall be solvent cleaned
in accordance with SSPC SP 1.
8.3 Shells and casings that were previously coated, or are rusty, shall be brush-blasted in accordance
with SSPC SP 7 or power-tool cleaned in accordance with SSPC SP 3.
8.4 Before installing veneering modules onto existing refractory, defective areas shall be removed. The
surface shall be free of dirt and dust, and glazed areas shall be sandblasted to ensure a good bond
between refractory and mortar. Large holes shall be filled with mortar.
9. Installation
9.1 General
9.1.1 RCF manufacturer shall supply the materials, installation drawings, and installation instructions for
the complete installation of RCF modules.
9.1.2 Refractory installer shall prepare a complete installation procedure, and install refractory system in
accordance with the requirements of this standard, and the specific requirements of RCF manufacturer
and the equipment manufacturer. The installation procedure shall be approved by SABIC prior to
installation.
9.2 Installation of Vapor Barrier
9.2.1 Steel casing shall have a vapor barrier of coal tar-epoxy or SABIC approved equivalent.
9.2.2 The manufacturer’s instructions shall be followed for the application of the vapor barrier.
9.2.3 Prior to coating, anchors shall be covered with sheaths to prevent blocking of the threads.
9.2.4 The vapor barrier shall be sprayed or brush applied to a dry film thickness of 1.5 to 3 mm
(1/16 – 1/8 in).

9.2.5 Refractory material shall be installed as soon as the vapor barrier is dry to the touch.
9.3 Modular Construction
9.3.1 Modules shall be installed using the uni-directional with batten strip (soldier) method. See Figure 1.
9.3.2 Batten strips shall be single-folded for service temperatures up to 1090 °C (2000 °F) and
double-folded for service temperatures above 1090 °C. See Figures 1 and 2.
9.3.3 RCF modules shall be installed in accordance with RCF manufacturer’s installation drawings and
Figures 3 to 7.
9.3.4 RCF modules around doors shall be oriented such that the outside modules are perpendicular to the
door frame, as shown in Figure 3.
9.3.5 Joints between RCF modules and castable refractory shall be packed with a folded batten strip and
shall be sealed with mortar. See Figure 7.
9.4 Veneering with RCF
9.4.1 The installation of RCF veneering over brick or castable refractory shall be in accordance with RCF
manufacturer’s instructions and Figures 8 and 9.
9.4.2 Only the parquet method of installation shall be used for veneering.
9.4.3 When modules with anchors are specified, the anchors shall be mortared into the existing refractory
to a depth of 40 – 50 mm (11
/2 – 2 in). The end of the anchor shall be protected with moldable RCF. See
Figure 9 and 16, and Tables I and II.
9.4.4 When the mortar used to apply the modules is dry, the seams between modules shall be pounded
out.
9.5 Anchors
9.5.1 The materials for anchors shall be in accordance with Tables I and II.
9.5.2 The layout of anchors shall be in accordance with RCF manufacturer’s detailed drawings, or as
shown in Figures 14 and 15.
9.5.3 In Figure 14 the maximum anchor spacing (X) along the length of the blanket shall be as given in
Table III.
9.5.4 Anchors shall be oriented in the same direction, so that locking washers will be oriented alike when
locked in place.
9.5.5 Ends of anchors and cuplocks shall be covered to protect them from oxidation, sulfur attack or
thermal shock, as shown in Figures 16 and 17.
9.6 Layered Blankets and Blanket Board Construction
9.6.1 Maximum operating temperature shall be 1090 °C (2000 °F).
9.6.2 Blankets and blanket boards shall be installed in accordance with RCF manufacturer’s installation
drawings and Figures 10 to 12.
9.6.3 Speed clips may be used to retain layers below the hot face. See Figure 13. They shall not be used
within 75 mm (3 in) of the hot face when using ceramic cuplocks.
9.6.4 The lap joint method with staggered joints shall be used for the installation of blankets. See
Figures 18A and 18B.
9.6.5 The butt joint method shall be used for the installation of blanket boards. See Figure 19.
9.6.6 A layer of vapor barrier made of stainless steel type 304 foil 50 microns thick shall be bonded to or
laid against one face of an intermediate back up layer of ceramic fiber blanket, 40 to 50 mm from casing.
Seams in the foil, and the points where studs penetrate the foil, shall be sealed using a sealant compatible
to the lining system.

10. Inspection and Repairs
10.1 General
10.1.1 Any refractory that is found to be defective due to construction damage shall be totally removed tthe full thickness of the layer and shall be relined to comply with this standard.
10.1.2 The method of repair shall be in accordance with the original installation procedure.
10.1.3 Where needed, additional refractory anchors shall be installed.
10.2 Inspection of Anchors and Supports
10.2.1 A minimum of three trial anchors shall be welded on the same material composition and thicknesthat is used on the heater shell material.
10.2.2 These trial anchors shall be hit with a hammer, bent a minimum of 15° from vertical, and then
straightened back to vertical. If there are no visual signs of cracking, the production welding can begin.
10.2.3 Production welding shall use the same welding parameters that were used during the trial.
10.3 Repairs
10.3.1 The method of repair shall be in accordance with the original installation procedure.
10.3.2 Where needed, additional anchors shall be installed.

Figure 1
Soldier Course Installation with Single Batten Strip