REF.

N° F-431
PRODUCTION MANAGEMENT REV. N° 1
CHANGE N/A
OPERATIONAL PROCEDURES DATE 01/12/20
SHEET 1 OF 9

REFRACTORY APPLICATION
PROCEDURE .

CONTROLED COPY No.

NO CONTROLED COPY No. 01

INVOLVED
AUTHORIZATIONS
AREAS

AUTHORIZE
REV. DATE MADE: SIGN: REVIEWED SIGN: SIGN: ÁREA ÁREA
D
ING.M. ING.M.
0 12-Junio-2018
PACHECO GARCIA
ING.M. ING.M.
1 01-Dic-2020 GPE
PACHECO GARCIA

GIN

GAC

GPY

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REF. N°
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TABLE OF CONTENTS

Scope & general comments………………………………………………….…3

Qualification of installation procedure and crew / installers …………..………4

Refractory materials and storage……………………………..……….……….4

General requirements……………………………………………………………5

Application of poured refractories (casting)……………………………………6

Curing of castable refractories………………………………………………..…7

Sampling and testing during installation………………………………………. 7

Inspection………………………………………….………………………………9

Repairs to refractory lining……………………………………………………….9

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This procedure covers the refractory application on Furnaces BA-61001,

BA-62001, BA-61002, BA-62002, BA-61003 and BA-62003, applicable in
Modules of convection and stacks in these equipments.

1. SCOPE
1.1 This procedure shall be used in accordance with API-560-Fired-Heaters and
API 936.
1.2 Shall perform all refractory installation work in accordance with supplier
datasheets
1.3 All units shall be in S.l (metric)
1.4 The purpose of this Procedure is to define the requirements for refractory,
Materials, handling, installation, drying, curing, testing, inspection and repair
work if any.
1.5 The refractory installation contractor is responsible for providing a finished
refractory lining to the specified density, thickness, and uniform composition
that will perform in service to the ability proven in previous use and test data,
in conformance with the prequalification and test on samples based on API
936.
1.6 The general guidelines of this procedure are minimum care and quality
requirements. The installation contractor is expected to utilize his expertise in
refractory installation.
1 .7 The contractor shall be responsible for the maintenance of records of the
refractory used (by manufacturer's batch number and date) and required, per
shift, of samples that will be send to independent lab tests and recording of the
results.
2. APPLICABLE DOCUMENTS
- Datasheets of manufacturer. Kaolite 2300 LI.
- API 936 4th Edition.
- API-560.
-
3. RESPONSIBILITY AND AUTHORITY
3.1 MANUFACTURING MANAGER
- To supervise the correct application of this procedure.

3.2 QUALITY MANAGER

- Prior and during application of refractory will be checked the guidelines of this
procedure and datasheets of the product.
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4. PROCEDURE
4.1 QUALIFICATION OF INSTALLATION PROCEDURE AND CREW /
INSTALLERS.
4.1.1 Contractor shall check all materials upon receipt at the site
of installation for damage such as broken bags, moisture
infiltration, etc., to assure the refractory containers (bags,
drums, etc.) as marked are material specified (Kaolite
2300 LI), and that the refractory is the specific mix for the
intend method of application (Casting), all in accordance
with Datasheet of material requested.
4.1.2 Prior to starting refractory installation, inspection shall
verify that 5% random bend test of the anchors has been
performed and recorded.
4.1.3 Bagged refractory shall have the batch date checked prior
to mixing to confirm that the material has not passed the
manufacturer 's recommended shelf life.
4.1.4 Castable which show signs of having set (lumps or
hardness throughout) prior to mixing shall be rejected,
regardless of shelf life or expiration date.
4.1.5 A qualification of the contractor personnel is required by
End User qualified inspector, in accordance with API 936
4th Edition paragraph 8.3.2

5. REFRACTORY MATERIAL AND STORAGE.

5.1.1 The material manufacturer’s instructions for storage, handling,
and shipment of materials shall be met. Shipment of refractory
should be scheduled to ensure that it is installed within its
specified shelf life. Material which has been longest in storage
shall be used first.
5.1.2 Refractory materials hall be stored with protection from extreme
weather conditions and exposure to sun. In winter, plastic
moldable refractory materials may freeze and must be thawed
before use. This is done by removing only the outside
packaging, not the foil, and storing in a warm place. Thawing
may take several days; the material is ready when it can easily
be formed by hand.
5.1.3 All hydraulic setting refractory materials shall be protected from
moisture absorption during shipment and storage. Air-tight,
moisture-tight polyethylene bags shall be used when specified
by the supplier.

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5.1.4 Refractory that shows signs of having set, ie. Hard or

unbreakable lumps in the dry mixture prior to installation shall
be rejected and be removed from the job site.
5.1.5 Fractional part from previous jobs as well as damaged bags
shall also be removed from the job site.
5.1.6 Refractory materials, except dated castable refractory
materials, shall be protected to withstand ocean transit and
extended periods of storage at the jobsite for a minimum period
of 18 months. Materials shall be protected to safeguard against
all adverse environments, such as humidity, moisture, rain,
dust, dirt, sand, mud, salt, air, salt spray, and sea water.
5.1.7 A material qualification is required, in conformance with API 936
4th Edition, paragraph 8 (Cold crushing Strength, PLC and
Density), a report must be emitted for each lot of product before
shipment.

6. GENERAL REQUIREMENTS.
6.1 The recommended procedures from a manufacturer of a proprietary material
for water rates, mixing, placing and curing shall be followed unless:
6.1.1 Site conditions dictate some modifications to obtain the
desires results.
6.1.2 The installations contractor has demonstrated through
previous experience that his recommended changes will
produce a superior in place product.
6.1.3 Deviations in the manufacturer's recommended
procedures shall be submitted to client in writing.
Acceptance of the contractor's recommended changes by
client do not relieve the contractor of his responsibility and
liability for the completed lining.
6.2 Clean Water used for mixing or preparation of the refractory components
wetting of surfaces to be lined and for water spray during curing shall be
potable and shall have low chloride content (50 ppm maximum).
6.3 Each team of mixer operations, shall prepare either a standard shape (12”
x 4” x 4”), plywood or metal, where will be poured for inspections and keep
the records for each batch applied, Contractor test samples shall be stored
to set and dry, these samples must be per shift per crew, these samples will
be sent to the lab for testing in accordance with API 936 paragraph 8.4.

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7. APPLICATION OF POURED REFRACTORY.

7.1 Preparation.
7.1.1 As refractory are normally supplied in moisture proof bags
and are mixed with water on site and poured in place. The
amount of water to be added depends on the type of the
castable and the consistency required during installation.
The minimum amount of castable to be mixed shall be one
bag and larger mixes shall be made using a whole number
of bags. No partial bag should be used.
7.1.2 Where the steel casing does not completely surround the
refractory surface, forms are necessary. Forms should
have a relatively rigid, stable, smooth surface, be water
resistant, and be greased or coated with concrete mold
release agent.
7.1.3 Forms shall be kept in place for the curing period to
provide support and retain moisture within the castable.
Their design shall allow removal without damage to the
refractory. Forms shall be sealed when jointed to prevent
loss of water or material.
7.1.4 The preferred mixer for poured castable is a pan mixer
(mortar mixer).

7.1.5 Temperature of the air and shell at the installation site

shall be maintained between 10°C to 32°C (API 936,
paragraph 9.5.1).
7.2 Installation.
7.2.1 The lining shall be applied in narrow areas, starting at the
bottom and working upward.
7.2.2 Each batch of the mixer shall be cast over the full
thickness and evenly distributed.

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7.2.3 Once application has started it shall proceed without

intervals until the entire scheduled lining has been
completed.
7.2.4 If an unavoidable interruption occurs, the wet ending of the
lining shall be cut back at an angle to the surface to
provide a slight "keyed" effect when the final material is
cast. All material ahead of the cut shall be discarded.
7.2.5 When casting horizontal areas without molds, the finished
surface shall be levelled off with a scraper or screed only;
slurry shall not appear after finishing the surface.
7.2.6 As the work progresses, the refractory shall be checked
for final thickness and any deficiencies shall be corrected
immediately. A screened finish is all that is required;
smoothing, floating or troweling shall be avoided.

7.3 Specific method of refractory installation for Superheater, Boiler (6”

thick of refractory installation) and wedge modules. (4 thick of inches
refractory installation), including the header boxes.
7.3.1.1 The surface that will be casted with refractory
concrete, needs to be free of loose debris and getting
SSPC SP7 / NACE No.4 / ISO 8501-1 Sa 1 (Light
Blast Cleaning) level of surface preparation.
7.3.1.2 Clean and open all anchors in accordance with
drawing 30-10-32 F (60° to 90°), enough to have 1” of
the anchor embedded into the refractory concrete.
7.3.1.3 The wall X and Y, must be settled in a leveled jig,
divided in a 1.5 mts x 1.5 mts grid that will be installed
(keep in mind that is required a 3” gap for field
installation), 1 square 1.5 mts x 1.5 mts full and next
empty, until finishing the odd number squares
proceed with pairs numbers squares.
7.3.1.4 In each boundary between this odd and pair squares,
is necessary a “joint”, to preserve the insulation
capabilities of the complete set, a “step” formed with
dimensions of half thickness in vertical and half
thickness in horizontal position.
7.3.1.5 A set of samples is requested for lab testing, in
accordance with API 936, the dimensions is 12” x 4”
x 4”.

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7.4 CURING OF CASTABLES REFRACTORIES.

7.4.1 The purpose of curing a castable refractory is to prevent
the loss of water through evaporation needed by the
refractory binder to develop its strongest hydraulic bond.
7.4.2 Surface temperatures must be maintained between 10-
32°C for 24 hours during curing (API 936 paragraph
9.13.1).
7.4.3 Apply fine mist of water spray, frequency of spraying is
determined by factors such as ambient temperature,
humidity, air circulation, etc. In general, the surface must
not be allowed to dry during the first 24 hours after
refractory placement.
7.4.4 After the 24-hour cure period, an additional 24 hours of air
drying is mandatory before handling or application of any
heat to the refractory.
7.5 SAMPLING AND TESTING DURING INSTALLATION.
7.5.1 A set of samples (12” x 4” x 4”) per shift and crew is
obtained during the casting of concrete, same samples will
be sent to the lab for testing in accordance with table 4,
type of test “for other services” (Cold Crushing Strength,
Permanent Linear change and Density).
7.5.2 The lab will obtain the necessary specimens for requested
in this table 4 (API 936), including copy of QC sheet.
7.5.3 Each sample shall be clearly marked with APPLICATOR'S
code numbers for that Day/shift/crew and for sequence of
production. Each code shall be unique, and traceable to
the locations where refractory has been applied by that
crew during that shift.
7.6 INSPECTION.
7.6.1.1 Visual inspection of complete surface of concrete
after curing step. the lining shall be inspected for
cracks. Random surface cracking up to 2 mm wide,
not more than the full refractory thickness in depth,
and not exceeding an average spacing of 300 mm is
acceptable. Areas containing cracks wider than 2 mm
or any crisscross. (intersecting) cracks are
considered defective and shall be repaired.
7.6.2 Visual, dimensional, and quality inspection of expansion
joints shall be made.

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8. HAMMER TESTING.
8.1.1 The type of inspection is generally referred to as a
Hammer test. It involves the practice of striking the lining
over its entire area with a ball point machinist hammer
having a recommended weight of 450grams.
8.1.2 Hammer testing will indicate whether or not a lining is
homogeneous. An experienced ear will determine, in more
detail, faults which might cause a lining to collapse such
as voids eliminations etc.
9. REPAIRS TO REFRACTORY LINING.
9.1 If inspection reveals defective areas as previously defined greater than 150
mm x 150 mm, the full thickness of the defective concrete layer must be
removed for a minimum area that include 3-4 anchors.
9.2 Care must be taken in the removal of the faulty material that the surrounding
sound lining is not damaged
9.3 The removal of the refractory concrete should progress at a small angle to
the shell and the periphery of any repair be located mid-way, between
anchors.
9.4 The area being repaired should be cleaned of all loose concrete and debris
and the adjacent sound material thoroughly wetted before any new concrete
is installed.
9.5 Only the same concrete as originally employed should be used for
replacement and wherever possible, especially in large areas the same
installation method as was originally used.

10. Dryout “by Others”.

F. SGC-01.1 Rev. 1
 Thermal Ceramics

Kaolite® LI Monolithics up to 2600°F (1427°C)

Datasheet Code US: 3-14-103 SDS: 103 / 153

Product Description Instructions for Using

Kaolite 2000-LI is a lower density cast/gun 2000°F (1093°C) Casting
monolithic traditionally used to reduce the amount of
supporting furnace steel work required and provide more Highest strength is obtained with monolithic refractory by
insulation with a thinner lining. using the least amount of clean mixing water that will allow
thorough working of material into place by vibrating. A
Kaolite 2300-LI and Kaolite 2300-LI Gun are 2300°F mechanical mixer is required for proper placement (paddle-
(1260°C) low iron, lightweight monolithics which type mortar mixers are best suited). Mix for 6 minutes to
incorporates a high-purity binder for applications where achieve a good ball-in-hand consistency. Place material
hydrogen or reducing atmospheres are present. Kaolite within 30 minutes after mixing.
2300-LI AHR Gun has additional alkali hydrolysis resistance
Gunning
capability due to its special high purity formulation.
Kaolite 2500-LI and Kaolite 2500-LI Gun are low iron, Use suitable gunite equipment. The gun grade material
lightweight monolithics that contains intermediate purity should be pre-dampened uniformly with approximately:
calcium- aluminate cement. Total iron oxide contents of Kaolite 2000-LI Gun 9-12%
0.9% enables use where hydrogen or reducing
atmospheres are present. Its low thermal conductivity and Kaolite 2300-LI Gun 7-9%
density produces the most economical 2500°F (1371°C) Kaolite 2300-LI AHR Gun 5-7%
insulating monolithic on a per cubic foot basis.
Kaolite 2500-LI Gun 6-8%
Kaolite 2600-LI and Kaolite 2600-LI Gun are low iron
2600°F (1427°C) designed especially for use in petrochemical Kaolite 2600-LI Gun 6-8%
applications. They incorporate a cement of sufficient purity for
by weight of clean water in a mechanical mixer before
low iron content and high-intermediate temperature strengths.
placing into gun. This will reduce rebound and dust. Add
Features required water at nozzle for effective placement. Suggested
air pressure at the nozzle is 20 to 35 psi.
• Light weight and low thermal conductivity reduce both
the quantity of heat storage and heat transfer producing Precautions
significant savings in furnace fuel consumption
Store bagged monolithics in a dry place, off the ground and
• Lower densities reduce the amount of supporting when possible with the original shrink wrapping intact.
furnace steelwork required and provide more insulation Normal shelf life is 12 months if properly stored.
with a thinner lining
Watertight forms must be used when placing material. All
Applications porous surfaces that will come in contact with the material
must be waterproofed with a suitable coating or membrane.
• Backup insulation in two component linings in For maximum strength, cure 24 hours under damp
petrochemical process units conditions before initial heat-up. Keep freshly placed
• Hot face lining in ductwork from waste heat recovery monolithic warm during cold weather, ideally between 50°F
boilers and process unit and 80°F until wet curing is completed. New monolithic
installation must be heated slowly the first time.
• F.C.C.U. linings - regenerator.
Freshly placed lightweight monolithic are prone to a
• Hydrogen or reducing atmosphere linings deteriorating condition called alkali hydrolysis when they are
• Radiant section in steam flood generators. kept in a non-dried state for a sustained period of time.
Under these conditions, the monolithic should be force-dried
• Hydrogen or reducing atmosphere linings. soon after placement to help retard the possible
deterioration effects. Kaolite 2300-LI AHR Gun has special
• Steam flood generator convection sections and target alkali hydrolysis resistance, especially when used in
walls combination with Kaoseal AHR Blue coating in place of a
typical curing compound.

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02/2016
 Thermal Ceramics

Kaolite® LI Monolithics up to 2600°F (1427°C)

Kaolite Kaolite Kaolite Kaolite Kaolite Kaolite Kaolite
Monolithic Product Name
2000-LI 2300-LI 2300-LI Gun 2500-LI 2500-LI Gun 2600-LI 2600-LI Gun
Material Class Crystalline Silica
Material method of installation cast/gun cast gun cast gun cast gun
Physical Properties
Temperature use limit, °F 2000 2300 2300 2500 2500 2600 2600
Temperature use limit, °C 1093 1260 1260 1371 1371 1427 1427
Placement, average lb to place 1 ft3 38 61 62 70 71 83 84
Placement, average kg to place 1 m3 18 28 29 31 32 38 38
Pounds per bag, lb 20 40 40 50 50 50 50
Pounds per bag, kg 9 18 18 23 23 23 23
Shelf life, months 12 12 12 12 12 12 12
Water, %, recommended
casting by vibrating 78-90 46-54 - 38-47 - 29-35 -
Density, ASTM C 134, pcf
dried 24 hrs @ 220°F 36-47 62-73 63-74 72-83 72-83 85-96 85-96
fired @ 1500°F 31-42 55-66 56-67 65-76 65-76 79-89 79-89
Density, ASTM C 134, kg/m3
dried 24 hrs @ 104°C 577-753 993-1169 1010-1186 1154-1330 1154-1330 1362-1538 1362-1538
fired @ 816°C 513-657 881-1057 897-1073 1041-1218 1041-1218 1250-1410 1250-1410
Modulus of Rupture, MOR, ASTM C 133, psi
dried 24 hrs @ 220°F 60-120 120-200 120-200 175-275 175-275 250-400 300-500
fired 5 hrs @ 1500°F 55-110 110-200 110-225 125-250 125-250 250-350 225-400
fired 5 hrs @ temperature use limit, °F 75-150 150-250 150-300 200-350 250-400 400-800 500-900
Modulus of Rupture, MOR, ASTM C 133, MPa
dried 24 hrs @ 104°C 0.41-0.83 0.83-1.38 0.83-1.38 1.21-1.90 1.21-1.90 2.07-3.45 2.07-3.44
fired 5 hrs @ 816°C 0.38-0.76 0.80-1.38 0.80-1.55 0.86-1.72 0.86-1.72 1.38-2.41 1.72-2.76
fired 5 hrs @ temperature use limit, °C 0.52-1.03 1.03-1.72 1.03-2.07 1.38-2.41 1.72-2.75 2.75-5.52 3.45-6.21
Cold crushing strength, CCS, ASTM C 133, psi
dried 24 hrs @ 220°F 225-400 350-600 350-600 600-1200 600-1200 850-1600 950-1700
fired 5 hrs @ 1500°F 175-350 350-900 350-900 550-1100 550-1100 900-1600 950-1700
fired 5 hrs @ temperature use limit, °F 200-375 400-1000 400-1000 800-1400 700-1300 1200-2000 1100-2000
Cold crushing strength, CCS, ASTM C 133, MPa
dried 24 hrs @ 104°C 1.55-2.76 2.41-4.13 2.41-4.13 4.14-8.28 4.14-8.28 5.86-11.03 6.55-11.7
fired 5 hrs @ 816°C 1.21-2.41 2.41-6.21 2.41-6.21 3.79-7.59 3.79-7.59 6.20-11.0 6.55-11.7
fired 5 hrs @ temperature use limit, °C 1.38-2.59 2.76-6.89 2.76-6.89 5.52-9.65 4.83-8.97 8.28-13.79 7.58-13.79
Permanent Linear Shrinkage, ASTM C 113, %
dried 24 hrs @ 220°F (104°C) 0 to -0.2 0 to -0.2 0 to -0.2 0 to -0.2 0 to -0.2 0 to -0.2 0 to -0.2
fired 5 hrs @ 1500°F (816°C) -0.6 to -1.3 -0.1 to -0.55 -0.2 to -0.6 -0.1 to -0.4 -0.2 to -0.5 -0.1 to -0.4 -0.2 to -0.5
fired 5 hrs @ temperature use limit, °F (°C) -1.5 to -3.0 -1.0 to -2.0 -1.0 to -2.0 -0.5 to -1.5 -0.5 to -1.5 -0.5 to -1.5 -0.5 to -1.5

Compliance data sheets for specific applications or job requirements are available upon request. The values given herein are typical average values obtained in accordance
with accepted test methods and are subject to normal manufacturing variations. They are supplied as a technical service and are subject to change without notice. The data
contained herein should not be used for specification purposes. Check with your Morgan Advanced Materials office to obtain current information.

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 Thermal Ceramics

Kaolite® LI Monolithics up to 2600°F (1427°C)

Chemical Analysis, % weight basis after firing
Alumina, Al2O3 30 40 37 44 41 47 45
Silica, SiO2 46 38 42 36 39 36 38
Ferric Oxide, Fe2O3 1.4 0.9 0.9 0.9 0.9 1 1
Titanium Oxide, TiO2 1 1.4 1.4 1.4 1.4 1.5 1.8
Calcium Oxide, CaO 16 18 (10) 17 (9) 17 (11) 16 (11) 13 (10) 13 (10)
Magnesium Oxide, MgO 0.5 0.2 0.2 0.2 0.2 0.2 0.2
Alkalies as Na2O and K2O 4.5 1.2 1.2 1 1 0.8 0.8
Thermal Conductivity, BTU•in/hr•ft2, per ASTM C201
Mean Temperature @ 500°F 1.1 1.48 1.48 1.76 1.76 2.7 2.9
1000°F 1.3 1.62 1.62 1.95 1.95 2.9 2.9
1500°F 1.5 1.77 1.77 2.15 2.15 3 3
2000°F - 1.90 1.90 2.36 2.36 3.2 3.2
Thermal Conductivity, W/m•K, per ASTM C201
Mean temperature @ 260°C 0.14 0.21 0.21 0.25 0.25 0.39 0.42
538°C 0.19 0.23 0.23 0.28 0.28 0.42 0.42
815°C 0.22 0.26 0.26 0.31 0.31 0.43 0.43
1093°C - 0.28 0.28 0.34 0.34 0.46 0.46

Compliance data sheets for specific applications or job requirements are available upon request. The values given herein are typical average values obtained in accordance
with accepted test methods and are subject to normal manufacturing variations. They are supplied as a technical service and are subject to change without notice. The data
contained herein should not be used for specification purposes. Check with your Morgan Advanced Materials office to obtain current information.

www.morganthermalceramics.com