SAES-N-100 pDF – Refractory Systems

This article is about SAES-N-100 which is about Refractory Systems and download SAES-N-100 PDF for Mechanical and Insulation Engineers, supervisors and project managers, Mechanical QCs, Insulation QC Supervisors. This is saudi aramco standards of Heat Transfer Equipment Engineering based on international codes and standards and useful for Mechanical and Insulation Engineering knowledge to get job as engineers, QC Supervisors and QC managers, Engineering managers and technicians.

SAES-N-100 pDF Download

SAES-N-100

Refractory Systems

SAES-N-100 is a standard that establishes the minimum mandatory requirements for the design and selection of refractory systems used in pressure vessels, boilers, process fired heaters, heat exchangers, flare tips, sulfur recovery unit equipment, and piping in Saudi Aramco facilities.

According to this standard, the refractory selections are limited to three types: monolithic refractory systems, refractory ceramic fiber (RCF) systems, and refractory brick systems. The purpose of this standard is to standardize the use of refractory systems within Saudi Aramco facilities.

If there are equipment or refractory systems that are not covered by this standard, it is recommended to consult with the Saudi Aramco Engineer for guidance on the applicability of this standard.

Furthermore, this standard can be attached to and made a part of purchase orders, ensuring compliance with the specified requirements. It covers both the design requirements and material selection for new and existing refractory systems.

Industry Codes and Standards

American Society for Testing and Materials (ASTM) is a widely recognized organization that develops and publishes voluntary consensus standards for various industries. In the context of refractory systems, the following ASTM standards are relevant:

1. 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.
2. ASTM C24: Standard Test Method for Pyrometric Cone Equivalent (PCE) of Fireclay and High Alumina Refractory Materials.
3. ASTM C113: Standard Test Method for Reheat Change of Refractory Brick.
4. ASTM C133: Standard Test Methods for Cold Crushing Strength and Modulus of Rupture of Refractories.
5. ASTM C134: Standard Test Methods for Size, Dimensional Measurement, and Bulk Density of Refractory Brick and Insulating Firebrick.
6. ASTM C182: Standard Test Method for Thermal Conductivity of Insulating Firebrick.
7. ASTM C201: Standard Test Method for Thermal Conductivity of Refractories.
8. ASTM C704: Standard Test Methods for Abrasion Resistance of Refractory Materials at Room Temperature.
9. ASTM C892-10: Standard Specification for High-Temperature Fiber Blanket Thermal Insulation.

The American Petroleum Institute (API) also provides relevant standards for refractory installation quality control guidelines and inspection and testing. The specific standard related to refractory installation is API STD 936.

These industry codes and standards ensure proper testing, performance evaluation, and quality control of refractory materials and linings used in various applications, including pressure vessels, boilers, fired heaters, and more.

Refractory System Design

In the design of refractory systems, several considerations need to be taken into account. Here are the key points outlined in the standard:

6.1 General:

• The design and selection of refractory systems should consider factors such as allowable shell metal temperatures, ambient conditions, outside casing temperatures, maximum service temperatures, velocities of flue gases or fluids, composition of flue gases and fluids, abrasive particles in flue gases and fluids, casing or shell pressure, pressure fluctuations, and optimum heat conservation.
• Section 9 of the standard provides the minimum design requirements for refractory systems specified by the Refractory Designer.
• The Refractory Designer is responsible for reviewing and approving detail drawings.
• The maximum service temperature limit of the refractory material selected should be a minimum of 95°C above the material layer design hot face temperature.
• The increase in thermal conductivity of refractory materials in hydrogen-rich gases compared to air should be determined by the Refractory Designer.
• Minimum thermal coefficient correction factors for increased thermal conductivity due to hydrogen pressures are provided based on the percentage of hydrogen and dry bulk densities of the refractory materials.

6.2 Minimum Lining Requirements:

• Single-Layer Castable Linings: Consist of a single layer of castable refractory for thermal insulation and/or mechanical resistance. The minimum thickness, unless specified otherwise, should be 50 mm with support from anchors or 19 mm when erosion-resistant and supported by hexsteel or “S” bars.
• Multi-Layer Castable Linings: Consist of one or more layers of back-up refractory lining covered by a denser refractory layer on the hot face for thermal insulation and/or mechanical resistance. The minimum thickness of the hot face layer should be 75 mm.
• Extreme Erosion-Resistant Refractory Linings: Should have an erosion loss not exceeding 4 cm³ after firing at 815°C, as per ASTM C704. They should not be used for heat insulation.
• Refractory Ceramic Fiber (RCF) Linings: Consist of a coating, vapor barrier, attachment studs, locking devices, and one or more layers of RCF lining. Different RCF designs, such as layered blanket, blanket/board, or moduled types, can be used. The specific use of spray-on and wet blanket types requires prior approval. Layered blanket and blanket/board designs have temperature limitations and should not be used above 982°C. The selection of RCF system installations should comply with the maximum velocity limits specified in Table 1.

These guidelines ensure the appropriate design and selection of refractory systems for various equipment and applications.

FAQs about SAES-N-100 pDF Download

Read Also:

SAES-N-004 PDF Download – Design and Installation of Building Thermal Envelop

SAES-N-001 PDF Download – Basic Criteria, Industrial Insulation