NIOEC-SP-45-14(0)

DOCUMENT CODE NO. OF PAGES: 8

PLAN/PRJ/SUB UNIT PHASE DISCIPLANE DOCUMENT TYPE SERIAL NO. REV. NO. DATE
NIOEC 000 EG ME SP 4514 A0 JULY, 2005

NATIONAL IRANIAN OIL REFINING & DISTRIBUTION COMPANY

NATIONAL IRANIAN OIL ENGINEERING
& CONSTRUCTION COMPANY

NIOEC SPECIFICATION
FOR

PROCEDURE FOR REFRACTORY LINING

FIRST EDITION

JULY, 2005

THIS SPECIFICATION IS THE PROPERTY OF NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY. IT IS CONFIDENTIAL AND ALL
RIGHTS RESERVED TO THE OWNER. NEITHER WHOLE NOR ANY PART OF THIS DOCUMENT MAY BE DISCLOSED TO ANY THIRD PARTY,
REPRODUCTED, STORED IN ANY RETRIEVAL SYSTEM OR TRANSMITTED IN ANY FORM OR BY ANY MEANS WITHOUT THE PRIOR WRITTEN
CONSENT OF THE NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY
JULY, 2005 NIOEC-SP-45-14(0)
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REVISION INDEX
REV. REV. REV. REV.
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
PAGE PAGE PAGE PAGE

1 26 51 76
2 27 52 77
3 28 53 78
4 29 54 79
5 30 55 80
6 31 56 81
7 32 57 82
8 33 58 83
9 34 59 84
10 35 60 85
11 36 61 86
12 37 62 87
13 38 63 88
14 39 64 89
15 40 65 90
16 41 66 91
17 42 67 92
18 43 68 93
19 44 69 94
20 45 70 95
21 46 71 96
22 47 72 97
23 48 73 98
24 49 74 99
25 50 75 100

NOTES:
1) THIS SHEET IS A RECORD OF ALL REVISIONS TO THIS SPECIFICATION.
2) REMARKS RELATED TO EACH REVISION SHOW A BRIEF DESCRIPTION. THESE REMARKS SHALL BE
INTERPRETED IN CONJUNCTION WITH THE REVISED TEXT MARKED BY REVISION NUMBERS.
3) WHEN APPROVED EACH REVISION SHALL BE CONSIDERED AS A PART OF THE ORIGINAL
DOCUMENT.
4) NUMBER OF PAGES EXCLUDES THIS SHEET AND THE COVER SHEET.

1
0 JULY 2005 M.R.F./A.K. M.H. ZAKER M.R. FARZAM M.A.A. SAJEDI
REV. DATE PREPARED CHECKED APPROVED AUTHORIZED
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CONTENTS: PAGE NO.

0. INTRODUCTION......................................................................................................................2
1. SCOPE.........................................................................................................................................2
2. REFERENCES ...........................................................................................................................2
2.1. Equivalent to IPS Standard...............................................................................................3
3. UNITS..........................................................................................................................................3
4. DEFINITIONS & TERMINOLOGY.......................................................................................3
5. ADDENDUM TO IPS STANDARD (IPS-C-TP-352) .............................................................4

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0. INTRODUCTION

To satisfy the requirements of this NIOEC Specification, relevant sections of Iranian Petroleum
Standard IPS-C-TP-352 about refractory lining with the modifications as specified herein after
shall be strictly followed.
Articles 1 through 4 of this document replace entirely the related articles in the referenced IPS
Standard.

1. SCOPE

- This procedure pertains to materials, application, curing inspection and thermal drying of
refractory linings for fired heaters, boilers, incinerators, vessels and the evaluation through
compressive strength tests of insulating refractories which are field installed.
- This Specification includes requirements for preparation of material for use, application,
drying or curing, transportation, installation, repair of lining and inspection of lined parts.
- It applies to equipment fabricated in metal or concrete and in both bonded and loose linings.
- Requirement for design and fabrication of the equipment, the state of preparation necessary
for the surface to be lined and thickness of lining shall be according to NIOEC-SP-45-07

2. REFERENCES

Throughout this Specification the following dated and undated standards/codes are referred
to. These referenced documents shall, to the extent specified herein, form a part of this
Specification. For undated references, the latest edition of the referenced document
(including any supplements and amendments) applies. For dated references, the edition cited
applies.
The applicability of changes in dated references that occur after the cited date, shall mutually
be agreed upon by NIOEC and the Vendor/Contractor.

ASTM (AMERICAN STANDARDS FOR TESTING AND MATERIALS)

C-71 "Standard Terminology Relating to Refractories"
C-93 "Test Methods for Cold Crushing Strength and Modulus of Rupture
of Insulating Fire Brick"
C-133 “Test Methods for cold crushing strength and modulus of rapture of
insulating firebrick”.
C-268 "Preparing and Curing refractory Concrete Test Sample"
C-309 “Liquid membrane forming compounds for curing concrete”.
C-860 “Practices for determining and measuring consistency of refractory
concretes”.
C-862 “Practice for preparing refractory concrete specimens by casting”.
C-865 “Practice for firing refractory concrete specimens”.

IPS (IRANIAN PETROLEUM STANDARDS)

IPS-E-TP-350 “Engineering Standard for Lining”

IPS-C-TP-352 “Construction Standard for Lining”

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IPS-C-TP-101 “Construction Standard for surface preparation”

NIOEC-SP (NIOEC SPECIFICATIONS)

NIOEC-SP-00-10 “NIOEC Specification for units”

NIOEC-SP-45-07 “NIOEC Specification for Refractory Linings”
NIOEC-SP-80-02 “NIOEC Specification for Painting”

SIS (SWEDISH STANDARD)

SIS 05 59 00 "Rust Levels of Steel Structure and Quality Levels for Preparation of
Steel Surface for Rust Protecting Paints"

2.1. Equivalent to IPS Standard

Substitute the following IPS Standards as referred to throughout IPS-C-TP-352 to relevant

NIOEC's Specifications as follows:
IPS Standard Relevant NIOEC Specification

IPS-E-TP-350 NIOEC-SP-45-07
IPS-C-TP-352 NIOEC-SP-45-14
IPS-C-TP-101 NIOEC-SP-80-02

3. UNITS

International System of units (SI) shall be used in accordance with NIOEC-SP-00-10, Unless
otherwise specified.

4. DEFINITIONS & TERMINOLOGY

4.1 “Employer” means: “National Iranian Oil Engineering & Construction Company”.
(NIOEC)

4.2 “Purchaser” means: “National Iranian Oil Engineering & Construction Company”. When
quoted in this Specification as part of a direct purchase order by NIOEC and “Contractor”
where this Specification is part of Contract Documents.

4.3 “Vendor” means: The manufacturer's from which the equipment is to be purchased.

4.4 “Contractor” means: The party which carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility.

4.5 “Inspector” means: The inspector or engineer employed by the Purchaser and acting as
the Purchaser's representative, the inspector's or engineer's respective assistants properly
authorized and limited to the particular duties assigned to them, or the Purchaser acting as
the inspector.

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4.6 “Refractory” means: Non-metallic materials with chemical and physical properties
applicable for structures and system components exposed to environments above 538°C
(1000°F), ASTM-C-71.

5. ADDENDUM TO IPS STANDARD (IPS-C-TP-352)

This addendum revises the below listed articles of the referenced standard as follows:

17.1 General (Modification)

Add the following articles at the end of paragraph

17.1.7 Experience of Personnel

Only personnel who are thoroughly familiar and experienced in application of refractory
shall be employed in application of linings. Supervisors and foremen should have acted in
a supervisory category on at least two previous jobs. Skilled tradesmen such as
bricklayers and nozzle operators should have had at least one year's previous experience
of such work on jobs of a similar nature.

17.1.8 Steel anchors shall be furnished by the Vendor and installed by the Contractor unless
otherwise specified.

17.1.9 Prior to application of refractory, inspect all support anchors to make sure that anchors
are attached securely to metal surfaces. If visual inspection warrents, test anchor by
sharply striking the ends of the anchor with a light hammer. Properly fused welds give a
ringing sound; defective welds give a dull, flat sound. Any anchor indicated to be
unsatisfactorily welded shall be replaced and retested.

17.1.10 See NIOEC-SP-45-07 for details of types of anchors.

17.2.1.2 Mixing (Modification)

Add the following article at the end of paragraph

17.2.1.2.9 Check pneumatic gun to assure that refractory wheels are included.

17.2.2 Preparation of Surface to be lined (Modification)

Add the following sentences at the end of paragraph:

- Prepare the surface for the lining by thoroughly cleaning to remove all rust loose mill
scale or other foreign materials. All temporary field attachments shall be removed.
Surface to be lined shall be thoroughly sand blasted (Sa 2) with sharp, abrasive sand or
wire brushed to remove all unbounded scale, slag, rust, and other materials. All sand
blasting dust shall be removed before applying lining material. (see NIOEC-SP-80-02)

- Do not wash with water.

- The tube supports and other exposed structural items within the limits of the lining shall
be wrapped with several layers of tarred or deadening felt to prevent the concrete from
bonding to them.

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- Observation access and similar openings shall be fitted with sheet metal or wooden forms
slightly tapered and of such dimensions that they extend beyond the finished surface of
the concrete, and shall fit snugly into the openings. They shall be lightly coated with tar
or heavy grease to prevent bonding and shall not be removed until the concrete has
developed its final set.

- After these steps have been completed, the surface shall be inspected for cleanliness.

- All refractory shall be applied as per the Vendor’s detail application procedures approved
by the Purchaser.

17.3 Application Methods

17.3.3.1.4 Casting Process (Modification)
Add the following paragraphs at the end of article:

- Immediately prior to resuming lining application, the exposed surfaces of the

refractory, to which a bond will be made, shall be thoroughly wetted.

- When application is interrupted or concrete is discontinued, the concrete shall be cut

back to the steel platework with a steel trowel. This cut shall be made at locations
where the full thickness has already been applied. All material above the cut shall be
discarded.

- Other cements, lime, etc. shall not be added to any mixture. Tools used in mixing
and applying the refractory shall be kept clean and free of such substances.

- When the work is done during hot sunny weather the materials shall be stored in a
shaded place until ready for use.

- Care should be taken at time of ordering to ensure that recommended shelf life is
not likely to be exceeded before application.

17.3.3.2 Refractory gunning method (Modification)

Add the following paragraphs at the end of article:

t) All refractory materials shall be thoroughly dry mixed in a paddle or ribbon type
mixer before loading into gun chamber. Mixing on a concrete floor is not
permitted. Since the tendency to wash out the binder and segregation of particles
will occur. There is also the danger of contamination by foreign particles.

u) To reduce rebound and dust and increase the quality of the castable lining
due to reduction of stratification and increased uniformity. Refractory should be
predampened uniformly with just enough water added to the mixer to reduce
dusting to a satisfactory level. Water at this point should be introduced by means
of a fine spray to insure uniformity.

v) Mixer blades should be cleaned frequently during a day’s operation by striking

blades with a hammer to remove built up refractory. This waste should be
removed from mixer and discarded. Under no circumstances should this material
be loaded into gun.

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w) Water for mixing the refractory shall be cool, free of impurities and from a
chemical stand point good enough to drink. The water temperature shall not be
less than 5ºC.

17.3.3.3 Finishing of Castable Refractories (Addition)

Add the following articles:

17.3.3.3.1 The finished surface shall be reasonably smooth. This can be accomplished by
screeding excess material from the surface. However, excessive
troweling of the concrete shall be avoided. Screeding shall follow directly after
application and any deficiencies in thickness found during screeding shall be
immediately corrected by applying additional material, to prevent any laminations
occurring in the lining.

17.3.3.3.2 In places where the refractory is subject to abrasions, such as where soot
blowers are used in fired heaters and in incinerator stacks, an abrasion resistant
wash shall be used to protect the surface of the refractory

17.4. Curing and Drying (Modification)

Add the following articles at the end of paragraph

17.4.8 Freshly gunned hydraulic setting refractory linings may be cured with a fine water
spray using an atomizing (fog) nozzle for 24 hours after material has taken its initial set
(which generally occurs in about four hours) ,or when heat of hydration is first noted . If
curing is done in an ambient temperature below 15ºC (60ºF), curing time in excess of
24 hours is required.

17.4.9 Use of a liquid membrane forming curing compound is preferred .The liquid
membrane forming compound used shall be pigmented and shall meet the requirements
of ASTM-C-309, Type .2. Except that the loss of water shall not exceed 0.04 grams per
sq.cm. The pigmented curing compound shall be applied to the refractory surface as
soon as practicable after the disappearance of the sheen due to surface water. The curing
compound shall be applied to the refractory surfaces with a fine mist spray until it is no
longer absorbed.

17.4.10 After applying curing membrane, the lining shall be air dried for at least 24 hours by
circulation of warm air.

17.4.11 Curing with wet sacks spread on the surface of the lining shall not be permitted under
any circumstances.

17.4.12 Care shall be taken to prevent entrance of rain.

17.4.13 After the water curing, the lining shall be allowed to dry under ordinary atmospheric
conditions for as long as possible but not less than 72 hours.

17.4.14 When first placed in service, the temperature of the equipment shall be raised slowly
to gradually expel excess moisture.

17.8 Inspection and Test Methods

17.8.1(Modification)

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Add the following paragraphs at the end of article

- The Purchaser’s inspector shall make certain that the procedures outlined herein are
followed.

- Continuous observation shall be made by the Purchaser’s inspector, he shall check the
thickness of applied refractory with the use of a depth gauge immediately after
refractory has been applied, but under no circumstances after material has taken it’s
initial set. See attached sketch of depth gauge.

17.8.2.5 (Modification)
The whole paragraph shall be modified as follows
Samples shall be prepared and compression tested in 114 mm × 114 mm × 65mm test
samples, in accordance with ASTM C133, C860, C862, C865.

17.8.4 Sampling (Addition)

17.8.4.1 In addition to the pre-application tests outlined in article 17.8.2 of this Standard;
representative samples shall be taken of the mix during application.

17.8.4.2 A minimum of one test sample shall be taken cured for 24 hours and tested as
follows:

a) The first batch of refractory applied by each crew each day.

b) One for each stack lining.
c) As further required by NIOEC’s appointed inspector.

17.9 Minimum Compressive Strengths (Addition)

17.91 Refractory concrete tested in accordance with Specification NIOEC-SP-45-07 shall

develop a minimum compressive strength of 110 bar (1600psi) for material whose
density after drying at 104°C(220°F) for 18 hours is about 1360-1520Kg/m3 (85-
95lbs/ft3).

17.9.2 Should failure to meet minimum compressive strength occur in materials already
placed, further test specimens may be taken by coring to confirm condition of placed
material.

17.9.3 Lining placed for which cored samples have failed shall be removed and replaced.

17.9.4 Prior to thermal drying, test all refractory linings by striking with a ball peen hammer
300-500gm (10 to 16-oz) at approximately 30 cm. intervals. Any voids or dry filled
places will produce a dull sound. Such areas shall be chiseled out completely to steel,
and laterally to sound refractory material. The minimum area removed shall be
sufficient to expose at least three (3) anchors. The sides of the cut shall be tapered back
towards the vessel wall forming a keyed hole to form a stronger patch. Method of
repair, curing and retesting shall be in accordance with the original procedure for
installation. Cracks of any size are not acceptable at this stage.

17.9.5 After thermal dry-out per paragraph 10.0 a thorough visual examination shall be made
of all refractory surfaces. Small networks of cracks 1.5mm (1/16”) in width & 19mm

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(3/4”) deep are considered normal. Areas showing larger cracks shall be considered for
repair.

17.10 Thermal Dry-Out(Addition)

The Vendor shall submit thermal dry-out procedure for NIOEC's review and comment.
Detailed application procedures shall be approved by the Purchaser.