SAES-N-110 PDF – Castable Refractories Installation Requirements

This article is about SAES-N-110 which is about Castable Refractories Installation Requirements and download SAES-N-110 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-110 PDF Download

SAES-N-110

Castable Refractories Installation Requirements

Standard SAES-N-110 specifies the minimum mandatory requirements for the installation, testing, and inspection of castable refractory systems in various equipment and applications. Here are the key points outlined in the standard:

• The standard covers the installation of new castable refractory and the repair of existing castable refractory in pressure vessels, boilers, process fired heaters, heat exchangers, flare tips, sulfur recovery unit equipment, and piping.
• For equipment and refractory systems not covered by this standard, guidance from the Saudi Aramco Engineer should be sought to determine the applicability of this standard.
• The entire standard can be attached to and made a part of purchase orders to ensure compliance with the requirements.
• The standard ensures that the installation, testing, and inspection of castable refractory systems meet the minimum mandatory requirements for quality and performance.

By following this standard, Saudi Aramco aims to standardize the installation and maintenance practices for castable refractory systems to ensure their proper functioning and longevity in the specified equipment and applications.

Industry Codes and Standards

Steel Structures Painting Council (SSPC):

• SSPC SP 3: Power Tool Cleaning
• SSPC SP 7: Brush Blasting

American Petroleum Institute (API):

• API 936: Refractory Installation Quality Control Guidelines – Inspection and Testing Monolithic Refractory Linings and Materials

American Society of Mechanical Engineers (ASME):

• ASME SEC IX: Welding and Brazing Qualifications

American Society for Testing and Materials (ASTM):

• 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 C113: Standard Test Method for Reheat Change of Refractory Brick
• ASTM C133: Test Methods for Cold Crushing Strength and Modulus of Rupture of Refractories
• ASTM C134: Test Methods for Size and Bulk Density of Refractory Brick and Insulating Firebrick
• ASTM C860: Standard Practices for Determining and Measuring Consistency of Refractory Concretes
• ASTM C862: Practice for Preparing Refractory Concrete Specimens by Casting

These industry codes and standards provide guidelines and specifications for quality control, inspection, testing, welding qualifications, surface preparation, and material properties related to refractories, concrete, welding, and surface cleaning in various industrial applications.

Surface Preparation

Surface preparation is an important step in the installation of refractory materials. The following requirements are specified for surface preparation:

8.1 All surfaces: Prior to the installation of refractory, all surfaces must be clean, dry, and free from contaminants such as oil, grease, weld slag, and mill scale.

8.2 Metallic surfaces: For applications that do not require coating, metallic surfaces should be blasted according to the guidance provided by the Refractory Designer or Manufacturer.

8.3 Previously coated or heavily corroded surfaces: Surfaces that were previously coated with a vapor barrier or are heavily corroded should undergo brush blasting in accordance with SSPC SP 7. Brush blasting involves using abrasive materials to remove old coatings or heavy corrosion and prepare the surface for refractory installation.

8.4 Limited area cleaning: Surface cleaning in accordance with SSPC SP 3, which involves power tool cleaning, is acceptable only for limited areas such as spot grinding for repairs. This method can be used to clean specific areas that require attention but is not suitable for overall surface preparation.

These surface preparation requirements ensure that the surfaces are properly cleaned and prepared for the installation of refractory materials, promoting good adhesion and performance of the refractory lining.

Installation

The installation of castable refractory follows the guidelines and requirements outlined in the SAES-N-110 standard. Here are the key points related to the installation process:

9.1 General:

9.1.1 The application of castable refractory should be carried out according to the guidelines provided by the Refractory Manufacturer.

9.1.2 Test panels must be made before applying the castable refractory. These panels are used for testing procedures outlined in Section 11.

9.1.3 Surfaces that will be lined with refractory must be inspected and approved by a Refractory Inspector prior to installation.

9.1.4 The temperature of the backing surface during installation should be between 5°C and 37°C.

9.1.5 Ambient temperature during the curing period should be maintained between 10°C and 32°C to protect the linings from extreme conditions.

9.1.6 Installers should take necessary precautions to achieve the specified temperature limitations.

9.1.7 The liquid used to mix the refractory material must comply with the manufacturer’s guidelines.

9.1.8 Admixtures should not be used without approval from the manufacturer and review by the Saudi Aramco Engineer.

9.1.9 The liquid ratios specified by the Refractory Manufacturer should be followed.

9.1.10 The temperature of the liquid and refractory material should be controlled so that the mixed refractory is between 10°C and 25°C.

9.1.11 Piping and equipment should be adequately supported to prevent distortion during lining installation.

9.1.12 Threaded attachments on equipment should be protected during the application of the lining, without interfering with the lining process.

9.1.13 Equipment nozzle extensions should be protected to prevent refractory from bonding to them.

9.1.14 All openings in equipment should be closed by means that extend beyond the final thickness of the lining.

9.1.15 Refractory that has set prior to installation or is not used within the recommended time limits by the manufacturer should be rejected or discarded.

9.1.16 If refractory is installed in piping or vessel sections before they are welded together, a minimum gap of 100 mm at the ends of each section should be left unlined. At least one row of anchors should be left on each side of the weld.

9.1.17 In double-layer linings, the second layer should not be applied until the first layer has been cured. Precautions should be taken to prevent dehydration of the first layer.

9.1.18 Each type of refractory lining should be installed to its full thickness. If lining is applied in sections, the edges should be beveled to allow for keying of adjoining sections.

9.2 Installation of Anchors and Supports:

9.2.1 Anchors and T studs should be installed following the guidelines of AC-036397.

9.2.2 Details of nozzle and manway openings in refractory-lined pressure vessels and piping should be in accordance with AB-036914, with further review and modification as needed.

9.2.3 Hexsteel should be installed following the guidelines of AB-036396.

9.3 Mixing Refractory for Pneumatic Applications:

9.3.1 Refractory materials, when required to be mixed, should be done in a paddle type mixer.

9.3.2 Only full contents of refractory bags or drums should be placed in the mixer, fractional parts should not be used.

9.3.3 Dry gunning application method should be used, while shotcreting application requires approval from the Saudi Aramco Engineer.

9.3.4 When fiber reinforcement is added in the field, the fibers should be added to the mixer through

a wire mesh screen with approximately 12 mm openings to ensure proper fiber distribution.

These guidelines ensure proper installation of castable refractory, adherence to temperature and environmental conditions, and use of approved materials and techniques. It is important to consult the SAES-N-110 standard and refer to the Refractory Manufacturer’s guidelines for detailed instructions and specific requirements.

FAQs about SAES-N-110 PDF Download

Read Also:

SAES-N-100 PDF Download – Refractory Systems

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

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