Refractory Inspection: Prepared by Integrity Engineering

Refractory Inspection
Prepared By
Integrity Engineering
RasGas Integrity Engineering 1

A. Introduction
Refractory is extensively used in oil and gas industry especially for

equipment operating at elevated temperature.
Purpose: The ability to resist at high temperature environment.

 Minimize material degradation at high temperature.
 Corrosion protection to the shell
Common metals used for high temperature service are: *)
Carbon Steel and Low Alloy Steel: 370 C

Austenitic, iron base high temperature alloy: 540 C
Nickel base and cobalt base high-temperature alloys: 650 C
Refractory metal and alloys: 980 - 1540 C
*) Approx. value for “lower limit” of elevated-temperature behavior for several metal and alloys (Metals
Handbook Vol. 10)

A. Introduction.. (cont)
A.1.Form of Refractory:
 Bricks, preferred shapes, tile and block
 Castable (used for monolithic lining)
1. Castable ceramics
 Plastic, Ramming mixes.
 Refractory Ceramic fiber, Fiber
A.2. Refractory Function:

1. Contain process gases and solids
2. Support high temperature loads
3. Insulate

A.3.Refractory must resist:

: Heat
 Thermal shock
 Atmosphere
 Corrosion
 Erosion

A.4.What should I know about them
1. How are they supplied?

2. How do I select the right one?
3. How do I install them
4. How do I maintain and repair them

 A. Introduction.. (cont)
A.6.Refractory component
.
 A.6.1.Aggregates
1. Fire clay, bauxite
2. Alumina, silica, calcium oxides
3. Mullite zirconia’s, silicon carbide
4. Lightweight perlite, expanded fire clay, vermiculite
 A.6.2.Binder
1. Cement
2. Chemical
3. Ceramic
 A.6.3. Impurities
1. Iron
2. Titanium oxide
3. Lime (CaO)
4. Alkalis
 Sodium
 Potassium
 A.6.4. Additives
1. Set Retarders /accelerator
2. Deflocculates/flocculants
3. Plasticizers
4. Ultrafines (fumed alumina/silica)
5. Fibers (Metal/ceramic/organic

 A.7. Bricks, installed at

 Furnace wall
 Burner blocks
 Floor plates
 Roof tile
 Wear plate
 Catalyst product
 Advantages
 Predictable, pre-fired properties
 No preheat required
 Disadvantages
 High installation labor cost
 Special shape required
 Thick massive structures
 Thermal expansion provision required
 Expensive repair
 A.8.Plastic refractory
 Plastic consistency
 Unfired brick
 Tamp or ram to shape
 Components
 Plastic ball clay (10 to 20%)
 Alumina silica aggregate
 De-aired
 Failure of refractory while equipment in operation

 Hot spots on the metal shell
 On line refractory failure can be detected by applying
thermo chromic paint.
B. Type of Refractory
Monolithic lining
 Castable ceramic
Most commonly used of the mono lining mater It is refractory concrete contain both binder
and aggregate 60 to 80 % aggregate Binder hydraulic type Portland or Calcium Alumina
cement or chemically setting type silicate or phosphate. Mostly calc aluminates used
 How to place
 Casting
 Gunning
 Hand packing
To reinforce the monolithic lining additional of stainless steel fiber to promote fine cracks
during drying, and firing cycle rather than few large cracks
Gunning is applied mostly
Plastic refractory
 It is similar to unfired brick, which requires high temp or curing process to develop “ceramic
bonding” to become mechanically stable.
 Calcine clay plus binder or unfired clay 980 to create adequate ceramic bonding

 Refractory brick
 Good for chemical resistant apply and erosion as well thermal insulation.
 Chem. Resistant application is differ
 Chemical Resistance
 Lining to membrane
 Chemically resistance brick or tile
 Chemically Mortar or grout for joining bricks
 Insulation and erosion resistance

 Ceramic fiber
 Blanket
 Modules
 Paper
 Bulk fiber
 Board and shape
 Poor resistance to flow, perforated sheet material is used to prevent this.

C. Refractory Installation Method
 C.1.Castable Installation
 Hand Placement
 Vibration Casting /
 Pump casting / Self Flowing
 Guniting / Pneumatic ramming
 C.1.1 Hand Placement
 Mix with water and place
 Proper consistency
 Ball in hand
 Purity
 Temperature
 Water
 Concrete mixture
 Water ratio
 Aggregate type
 Grain sizing
 Suitable for ceramic fiber
 C.1.2. Vibration Casting
 Immersion Vibration
 C.1.3. Pump casting / Self Flowing
 Pre-mix and Pump (or pour)
 C.1.4 Guniting / Pneumatic ramming
 Blow through the hose, add water at nozzle
 Allentown gun Type
 Reed gun Type

D. Refractory Repair
D.1.Visual Inspection
Use small hammer to check the bonding of refractory to shell, mark the suspected area for
further inspection. Here are common type of failure:
 Surface corrosion
 Solid sulfur / process product accumulation,
 Loose segments, minor cracks
 Anchor Failure
 Anchor exposure
 Overheated steel exposure
D.2 Repair planning
 What caused this failure
 What is a suitable repair material
 How do we install the material
 How do we prevent future failure

 D.3.Type of Refractory Failure

 D.3.1.Structural
 Cracking
 Over heating
 Step thermal gradient
 Shrinkage/Expansion
 Repairing by filling open cracks and join with compressible
ceramic fiber
 Erosion
 High velocity particulates
 Location, at cyclone, catalyst transfer line, slide valve.
 Repairing by applying phosphate bonded high alumina

 D.3.2.Corrosive
 Potentially occurred in Incinerator
 High temperature 2800F
 Alkaline corrosion
 Thermal shock
 Unpredictable feed rate
 Corrosive Exposure
 CO, CO2, SO2
 Sulfates, chlorides
 D.3.2.Thermal
 Cause
 Rapid heat / Cool cycle
 Steep thermal gradient
 Flame impingement
 Air/steam quench
 Spalling
 Exceeding temp. limits


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What are the different forms that refractories can take?

What are the different forms that refractories can take?

What are the main functions of refractories?

What are the main functions of refractories?

Refractory Inspection

RasGas Integrity Engineering 1

Refractory is extensively used in oil and gas industry especially for

Purpose: The ability to resist at high temperature environment.

Carbon Steel and Low Alloy Steel: 370 C

RasGas Integrity Engineering 2

A.2. Refractory Function:

RasGas Integrity Engineering 3

A.3.Refractory must resist:

RasGas Integrity Engineering 4

A.4.What should I know about them

1. How are they supplied?

RasGas Integrity Engineering 5

RasGas Integrity Engineering 7

 A.7. Bricks, installed at

 Failure of refractory while equipment in operation

RasGas Integrity Engineering 10

RasGas Integrity Engineering 11

RasGas Integrity Engineering 12

RasGas Integrity Engineering 13

RasGas Integrity Engineering 14

 D.3.Type of Refractory Failure

RasGas Integrity Engineering 15

RasGas Integrity Engineering 16

RasGas Integrity Engineering 17

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