Engineering Standard

SAES-N-100

30 January 2007

Refractory Systems
Heat Transfer Equipment Standards Committee Members
Anizi, Salamah Salem, Chairman
Bagawi, Jamil Jarallah, Vice Chairman
Hamam, Ibrahim Hassan
Fernandez, Gabriel Thomas
Gahtani, Moraya Saif
Dossary, Musfir Abdullah
Rumaih, Abdullah Mohammad
Naffaa, Mahmoud Youniss
Moore, Mark Andrew
Anezi, Mohammed Ali

Saudi Aramco DeskTop Standards

Table of Contents
1
2
3
4
5
6
7
8
9
10

Scope............................................................. 2
Conflicts and Deviations................................. 2
References..................................................... 2
Definitions...................................................... 4
Responsibilities.............................................. 6
Design............................................................ 6
Physical Properties........................................ 9
Metallic Components................................... 10
Refractory Systems...................................... 11
Refractory Installation.................................. 12

Previous Issue: 30 November 2004 Next Planned Update: 30 January 2012

Revised paragraphs are indicated in the right margin
Primary contact: Anizi, Salamah Salem on 966-3-8746139
CopyrightSaudi Aramco 2007. All rights reserved.

Page 1 of 16

Document Responsibility: Heat Transfer Equipment

Issue Date: 30 January 2007
Next Planned Update: 30 January 2012

SAES-N-100
Refractory Systems

Scope
1.1

This standard establishes the minimum mandatory requirements for the design
and selection of refractory systems for pressure vessels, boilers, process heaters,
heat exchangers, flare tips, sulfur recovery unit equipment and piping.

1.2

Refractory selections shall be limited to castable refractory systems, refractory

ceramic fiber (RCF) systems, and fireclay brick systems.

1.3

The requirements detailed in this standard are aimed at standardizing refractory

systems used in Saudi Aramco facilities.

1.4

For equipment and refractory systems not covered by this standard, the Saudi
Aramco Engineer is to 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 new and
existing refractory systems.

Conflicts and Deviations

2.1

Any conflicts between this standard and other applicable Saudi Aramco
Engineering Standards (SAESs), Materials System Specifications (SAMSSs),
Standard Drawings (SASDs), or industry standards, codes, and forms shall be
resolved in writing by the Company or Buyer Representative through the
Manager, Consulting Services Department of Saudi Aramco, Dhahran.

2.2

Direct all requests to deviate from this standard in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager, Consulting Services Department of
Saudi Aramco, Dhahran.

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, unless otherwise noted.
3.1

Saudi Aramco References

Saudi Aramco Engineering Procedure
SAEP-302

Instructions for Obtaining a Waiver of a

Mandatory Saudi Aramco Engineering
Requirement
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Document Responsibility: Heat Transfer Equipment

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Next Planned Update: 30 January 2012

SAES-N-100
Refractory Systems

Saudi Aramco Engineering Standards

SAES-A-112

Meteorological and Seismic Data for Plant Design

SAES-N-110

Installation Requirements-Castable Refractories

SAES-N-120

Installation Requirements-Extreme Erosion

Resistant Refractories

SAES-N-130

Installation Requirements-Fireclay Bricks

SAES-N-140

Installation Requirements-Refractory Ceramic

Fiber

Saudi Aramco Materials System Specification

32-SAMSS-022

Manufacture of Components for Flare Systems

Saudi Aramco Standard Drawings

AB-036395

Refractory Ceramic Fiber Modulus Installation

Details

AB-036396

Hexsteel Details

AC-036397

Anchoring Details for Castable Refractories

AB-036400

Refractory Ceramic Fiber Layered Blanket and

Blanket/Boards Installation Details

AB-036914

Support Details at Nozzles and Manways for

Castable Refractories

Commentary Note:
The Saudi Aramco Drawings listed above and referenced in this standard shall be
used 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

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Document Responsibility: Heat Transfer Equipment

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Next Planned Update: 30 January 2012

SAES-N-100
Refractory Systems

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
Refractories

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

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

Definitions
Anchors: "V" or "Y" shaped hardware that supports and holds castable refractory in
place.
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.

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Document Responsibility: Heat Transfer Equipment

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Next Planned Update: 30 January 2012

SAES-N-100
Refractory Systems

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/ft 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.
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.
Plastic Refractory: A pre-mixed, phosphate-bonded refractory material.
Refractory Ceramic Fibers (RCF): Fibers made from melting alumina/silicate in an
electric furnace.
RCF Manufacturer: The company that manufactures RCF products from raw
materials and that designs RCF systems.
Refractory Manufacturer: The company that manufactures refractory products other
than RCF from raw materials.

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Document Responsibility: Heat Transfer Equipment

Issue Date: 30 January 2007
Next Planned Update: 30 January 2012

SAES-N-100
Refractory Systems

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.
Saudi Aramco 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. For RCF, the vapor barrier consists
of a metal foil imbedded in RCF and high temperature coating on the shell.
Vibration Casting: Castable installation technique where by refractory is mixed with
water and placed in a formed enclosure with the aid of which causes the refractory to
become "fluid like" and thereby flow and consolidate to the desired shape of the formed
enclosure.
5

Responsibilities
5.1

The Design Engineer 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. As a minimum, the drawings
shall include anchorage design including spacing and orientation, refractory
thicknesses, all materials, surface preparation, and welding details.

5.3

The RCF Manufacturer is responsible for the complete design of an RCF

system, in accordance with the specifications supplied by the Design Engineer.

Design
6.1

General
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.

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Document Responsibility: Heat Transfer Equipment

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Next Planned Update: 30 January 2012

SAES-N-100
Refractory Systems

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.

6.1.2 Section 9 of this standard details the minimum design requirements for
refractory systems to be specified by the Design Engineer.
6.1.3

The Design Engineer shall review and approve the Equipment

Manufacturer's and RCF 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 Consulting Service Departments Welding
Specialist, or a representative designated by the Consulting Services
Department.

6.1.5

The continuous-use temperature of hydraulic-setting castable refractory

materials shall be a minimum of 95C above the maximum service
temperature of the equipment for hot face layer. For back-up layer, the
continuous-use temperature shall be a minimum of 165C above the
calculated temperature of the back-up layer.

6.1.6

The continuous-use temperature of RCF materials shall be a minimum of

150C 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 determined by the Design Engineer. 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/m (80 lb/ft):
Kcr = (% hydrogen X 0.01) + 1.0.

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Next Planned Update: 30 January 2012

2)

SAES-N-100
Refractory Systems

For refractory materials with dry bulk densities above 1280 kg/m
(80 lb/ft) up to and including dry bulk densities of 1920 kg/m
(120 lb/ft):
Kcr = (% hydrogen X 0.0025) + 1.0.

6.2

Minimum Lining Requirements

6.2.1

6.2.2

6.2.3

6.2.4

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.

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.

Dual Layer Castable Linings

1)

This type of refractory lining shall consist of a layer of an

insulating back-up of 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.

Extreme Erosion-Resistant Castable Linings

1)

This type of extreme erosion-resistant refractory shall not have an

erosion loss that exceeds 6 cm after firing at 815C, 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.

Extreme Erosion-Resistant Plastic Castable Linings

This type of extreme erosion-resistant refractory shall satisfy the same
erosion resistance as required for extreme erosion-resistant castable
linings.

6.2.5

Refractory Ceramic Fiber (RCF) Linings

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Next Planned Update: 30 January 2012

6.3

SAES-N-100
Refractory Systems

1)

This type of refractory system consists of a vapor barrier coating,

metal foil, attachment studs, locking devices, and one or more
layers of RCF lining.

2)

RCF designs shall be limited to, the layered blanket ("wallpaper")

type, blanket/board type or the moduled type.

3)

The spray-on and wet blanket types of RCF designs shall only be
used with the prior approval of the Saudi Aramco Engineer.

4)

Layered blanket and blanket/board designs shall be used up to a

hot-face temperature of 1090C.

5)

Module designs shall be used when the hot-face temperature is

above 1090C.

6)

For layered blanket systems, the top two layers shall have a density
of 129 kg/m (8 lb/ft). The bottom layers shall have a density of
97 kg/m (6 lb/ft).

7)

For blanket/board systems, the top two layers shall have a density
of 129 kg/m (8 lb/ft). The bottom layers shall have a density of
97 kg/m (6 lb/ft).

8)

Module construction shall be of the pre-compressed, folded blanket

("soldier") type and shall be manufactured from RCF blanket
material of 129 kg/m (8 lb/ft) density prior to compression.

9)

Selection of RCF system installations shall be subject to the

maximum velocity limits of Table 1.

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 outside casing surface design temperatures shall be determined in

accordance with the criteria below:
The values of ambient air temperatures shall be in accordance with
SAES-A-112, corresponding to the average annual temperature, in still
air, for the specific site location.

Physical Properties
7.1

General
7.1.1

The use of refractory materials containing asbestos is strictly prohibited.

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Next Planned Update: 30 January 2012

7.2

SAES-N-100
Refractory Systems

7.1.2

The Design Engineer shall specify properties that are necessary and
sufficient to meet the design requirements of this standard.

7.1.3

The physical properties for castable refractories shall be in accordance

with the Saudi Aramco refractory types as specified in this standard.

Design Data for Castable Refractories

7.2.1

The physical properties to be specified on data sheets and used in design

calculations shall be in accordance with values specified in Table 2 of
the Data for Castable Refractory.

7.2.2

The Saudi Aramco Materials System (SAMS) catalog provides a

complete physical, chemical and service descriptions. These
descriptions include maximum continuous use temperature, bulk density,
cold crushing strength, modulus of rupture (MOR), linear change,
average thermal conductivity, and maximum erosion loss.

7.2.3

The generic descriptions that are detailed in SAMS are to be used for the
purchase of all castable refractories, including DC (Direct Charge) orders
and all projects. Table 2 lists the SAMS stock numbers (S/N) per Saudi
Aramco Refractory Type.

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 dual-layer linings for the support of 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 AC-036397.

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

Anchors for all types of RCF linings shall be welded to equipment.

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Next Planned Update: 30 January 2012

8.2.6
8.3

SAES-N-100
Refractory Systems

For details of anchors for RCF linings refer to AB-036395 and

AB-036400.

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

8.4

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 AB-036396.

Nozzles and Manways

Details of nozzle and manway openings in refractory lined pressure vessels and
piping shall be in accordance with AB-036914.

8.5

8.6

Metallic Fiber Reinforcement (Needles)

8.5.1

Unless otherwise specified in this standard, the density of metallic fiber

reinforcement shall be 80 kg/m (5 lb./ft).

8.5.2

Metallic fiber reinforcement shall be manufactured from melt extracted

material, approximately 0.5 mm in thickness and approximately 25 mm
long.

"S" Bars
"S" bars shall be used only for the support of extreme erosion-resistant
refractory.

Refractory Systems
9.1

The refractory systems for specific equipment shall be in accordance with the
requirements in Table 3, "Mandatory Refractory Systems".

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10

SAES-N-100
Refractory Systems

9.2

The types of castable refractory material that are specified in Table 3 are the
Saudi Aramco Refractory Standard Type.

9.3

Complete generic descriptions corresponding to the Saudi Aramco refractory

type are detailed in SAMS.

Refractory Installation
Refractory systems shall be shop and/or field installed in accordance with the
procedures as detailed in the following standards:

30 January 2007

SAES-N-110

Installation Requirements-Castable Refractories

SAES-N-120

Installation Requirements-Extreme Erosion Resistant

Refractories

SAES-N-130

Installation Requirements-Fireclay Bricks

SAES-N-140

Installation Requirements-Refractory Ceramic Fiber

Revision Summary
Revised the "Next Planned Update". Reaffirmed the contents of the document and
reissued with no other changes.

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Next Planned Update: 30 January 2012

SAES-N-100
Refractory Systems

Table 1 RCF Installation

RCF System

Velocity Limits

Blanket

Less than 9 m/sec

Modules

Up to 18 m/sec

Blanket/Board

Up to 24 m/sec

Table 2 Design Data for Castable Refractory

Type of Castable Refractory [1][4]
Bulk Density kg/m
(lb/ft) Cured and
Dried at 815C
Cold Crushing Strength
kg/cm (lb/in) after
firing at 815C
MOR after firing at
815C kg/cm (lb/in)
Permanent Linear
Change
Thermal Conductivity K
value in W/m.C
(Btu-in/ft.F.Hr)
at 260C
at 540C
at 815C
Max. Continuous
Use Temperature
Notes:

[1]

880 (55)
[2]

1120 (70)
[3]

880 (55)
[3]

1280 (80)
[3]

2080 (130)
[2]

2240 (350)
[2]

2720 (170)
[2]

2720 (170)
[2]

2720 (170)
[2]

20 (300)

21 (300)

31 (300)

105 (1500)

525 (7500)

350 (5000)

560 (8000)

560 (8000)

350 (5000)

20 (300)

7 (100)

12 (180)

25 (350)

70 (1000)

98 (1400)

86 (1200)

105 (1500)

70 (1000)

-1.5%

-0.5%

-1.2%

-0.2%

-0.1%

-0.2%

-0.1%

-0.4%

-0.2%

0.21 (1.50)
0.25 (1.70)
0.26 (1.80)

0.18 (1.30)
0.20 (1.40)
0.23 (1.60)

0.35 (2.47)
0.38 (2.63)
0.40 (2.79)

0.40 (2.80)
0.42 (1.95)
0.44 (3.10)

0.24 (1.70)
0.23 (1.65)
0.26 (1.80)

0.95 (6.30)
0.97 (6.90)
1.08 (7.70)

1.56 (10.8)
1.41 (9.8)
1.40 (9.7)

1.61 (11.5)
1.75 (12.5)
1.96 (14.0)

1.61 (11.5)
1.75 (12.5)
1.96 (14.0)

1095C

980C

1540C

1200C

1215C

1315C

1700C

1650C

1705C

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.

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SAES-N-100
Refractory Systems

Table 3 Mandatory Refractory Systems

Equipment
(Specific Notes)

Operation
Condition

FCCU-regenerator shell,
heads and plenum
chamber
FCCU-U-bends,
Y-sections, standpipes,
other external catalyst
transfer lines
FCCU-Regenerator
cyclones (1)

760C mild erosion

oxidizing atmosphere

Anchors
(Material, Sizes
and Types)
Type 304H, 6 mm
diameter, V-type.

510-750C extreme
erosion, oxidizing or
reducing atmosphere.

Type 304H, 6 mm
diameter V-type.

760C extreme
erosion, oxidizing
atmosphere.

25 mm, 14 gage Type

304H hexsteel, or S
bars.

FCCU-reactor cyclones
(1)

550C extreme
erosion, oxidizing
atmosphere.

25 mm, 14-gage Type 304H or 410S hexsteel,

or S bars.

FCCU-flue gas lines

760C oxidizing
atmosphere, heavy
erosion on elbow and
medium erosion on
straights.
760C medium
erosion, oxidizing
atmosphere.
510-760C severe
erosion.
260-760C acidic
water.

Type 304, 6 mm
diameter, V-type.

FCCU-steam generator
FCCU-slide valves (2)
FCCU-seal ports (3) (4)

Naphtha reformersreactors wall lining

550C hydrogen rich

atmosphere.

Hydrogen-plants waste
heat boilers and transfer
lines

840C hydrogen rich

astmosphere.

High alumina ceramic

ferrules, 125 mm long on
inlet tubesheet.
25 mm 13 gage, Type
304H hexsteel.
Immersion Lining:
a) No anchors required
b) V-type anchors.
c) Type 304, 6 mm
diameter, V-type 75
mm long.
Above immersion level:
Type 304, 6 mm
diameter, V-type, 75 mm
long.
Type 304, 6 mm
diameter on a 225 mm
square pattern.

Two component lining:

Type 310, 500 mm long,
V-type.
Shroud lining:
Incoloy 800, shrouds.

Refractory Material
(Type, Weight % of Needles
and Application Method)
Type-D, medium weight heat
insulating, 5% weight Type 304
needles. Gunnited.
Type F, erosion resistant, heat
insulating, 3-% weight Type
304 needles. Vibration cast or
gunnited (if diameter permits).
Type H or I, extreme erosion
resistant hexsteel or use 3%
weight Type-304 needles with S
bars. Handpacked.
Type H or I, extreme erosion
resistant 25 mm thick in hexsteel
or use 3% weight Type 304
needles in S bars. Handpacked.
Elbows: Type-F, erosion
resistant insulating with 3-%
weight Type 304 needles.
Gunnited.
Type E (fused silica) 125 mm
thick with 3% weight Type 304
needles. Cast.
Type H or I erosion resistant
25 mm thick. Handpacked.
Immersion level:
a) 3 mm thick vapor barrier.
b) 25 mm thick acid resistant
refractory. (Saureisen's type
54LW or equal)
c) Type E with 3% weight Type
304 needles. Gunnited.
Above immersion level:
Type E. Gunnited.
Type B (low iron), insulating 100
mm thick, 5% weight Type 304
needles. Shroud supports and
vapor stops required to minimize
gas bypassing. Gunnited.
Two component lining:
1) Type G, erosion resistant
(hot face), 3% weight type
310 needles. Vibration cast
or gunnited.
2) Type B, insulating (back up),
5% weight type 304 needles.
Vibration cast or gunnited.
Shroud lining:
Type B (low iron), insulating
cast.

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Equipment
(Specific Notes)

Operation
Condition

Hydrogen-plants furnaces
(3)

1090C low erosion,

oxidizing atmosphere.

Sulfur plants-reaction
furnace (3) (8)
Sulfur plants-thermal
oxidizer(3) (9)

1540C oxidizing
atmosphere.

Fired heater radiant

section or boiler furnace
(3) (5) (6)
Fired heater convection
section

980 - 1310C
oxidizing atmosphere,
mechanical and
thermal spalling.
Up to 980C.

SAES-N-100
Refractory Systems
Anchors
(Material, Sizes
and Types)
Walls: sectionally
supported wall anchors
or manufacturer's design.
Ceiling:
Manufacturter's design.

Tubesheet: ceramic
ferrules, aluminized
anchors or Two Part
Hexagonal Ferrule
Design
Shell & Front end: Type
310, 6 mm diameter, Vtype on a 225 mm
square pattern.
Side walls and roof:
manufacturer's design
Type 310 minimum.

Floor: Type 304, 6 mm

diameter, V-type on a
225 mm square pattern.

Fired heaters and boilersstacks (3)

Flare tips (6)(7)(8)

315 - 815C mild

erosion, some
mechanical and
thermal spalling.
315 - 1090C mild
erosion, some
mechanical and
thermal spalling.

Type 304, 3 mm
diameter, V-type.

3 mm diameter, V-type
anchors or coiled wire (7)

Refractory Material
(Type, Weight % of Needles
and Application Method)
Walls RCF.
Ceiling: Type A insulating, 5%
weight Type 304 needles,
gunnited
Floor: High duty firebrick
(unmortared) (hot face), Type C
(back up). Cast.
Tubesheet: Type G, erosion
resistant poured or Two Part
Hexagonal Ferrule Design
Shell & Front end: 90% alumina
brick (hot face) with Type C
backup. Cast or gunnited.

Side walls and roof: 3 mm thick

vapor barrier on casing, RCF,
type A or type D insulating.
Convection section Type A or D
insulating, with optional 5%
weight Type 304 needles,
gunnited or RCF (up to 80 ft/sec
gas velocity).
Floor: High duty fireclay brick
laid dry (hot face). Type A
insulating (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.
3 mm thick vapor barrier on shell
and breaching. Type A or D
insulating thickness with optional
5% weight type 304 needles.
Both sides, one shot lining, Type
G, 5% weight needles, Type
310. Cast or gunnited (if
accessible).

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 Saudi Aramco Engineer's Approval.

Page 15 of 16

Document Responsibility: Heat Transfer Equipment

Issue Date: 30 January 2007
Next Planned Update: 30 January 2012

SAES-N-100
Refractory Systems

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 175C 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). For fuels with a higher sulfur content, refer to AB036395 and AB-036400.

(6)

The anchor materials for flare tips shall be specified in accordance with 32-SAMSS-022.

(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

Page 16 of 16