TECHNICAL SPECIFICATION

CERAMIC FIBER MODULE INSULATION

FOR FURNACES MB11-5M

DATE: 01 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 1 OF 5

TABLE OF CONTENTS

Section Title Page No.

1. GENERAL ......................................................................................................................................1
1.1 Scope..............................................................................................................................................1
1.2 KBR Documents, Codes and Industry Standards ..........................................................................1
1.3 Module Design ................................................................................................................................1
1.4 Module and Batten Strip Density and Compression.......................................................................2
1.5 Module Anchorage..........................................................................................................................2
1.6 Module Installation .........................................................................................................................3
2. TESTING AND INSPECTION ........................................................................................................3
2.1 Testing ............................................................................................................................................3
2.2 Inspection........................................................................................................................................4

1. GENERAL

1.1 Scope

This Specification, KBR Purchasing Standards MB2-1PS and SDR-2MB-5 cover the requirements for the
design, manufacture, purchase, and testing of proprietary ceramic fiber module insulation and anchoring system
for furnaces. Exceptions to this Specification, if any, and abbreviations are in accordance with KBR Technical
Standard MB15-1TS. (Note: KBR will be referred to as the Purchaser.)

1.2 KBR Documents, Codes and Industry Standards

The following documents are referenced herein and form part of the order. Additional KBR documents, when
applicable, will be listed in the Requisition. Applicable dates of issue for codes and industry standards shall be
as indicated in the KBR Technical Standard MB15-1TS.

KBR DOCUMENTS
MB2-1PS, “Purchasing Requirements for Furnace Materials, Components and Equipment”
MB15-1TS, “General Furnace Specification”
SDR-2MB-5, “Supplier Data Requirements – Refractories"

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM C177, "Steady State Heat Flux Measurements and Thermal Transmission Properties by Means of
the Guarded Hot Plate Apparatus"
ASTM C892, “High-Temperature Fiber Blanket Thermal Insulation”

1.3 Module Design

a. The module supplier shall pre-engineer layout and manufacture of the modules to conform to special
requirements of the inquiry.

b. Modules shall be maximum of 12 inch (300 mm) x 12 inch (300 mm) except in areas where the use of
larger modules has previously been approved by Purchaser.

c. Monolithic modules made with blown fiber require pre-approval by Purchaser. Maximum shop content shall
meet the requirements of ASTM C892. The chemical composition of the fiber shall include a minimum 15%
zirconia content.

d. Service (operating) temperatures shall be 2400oF (1315oC) for cracking furnaces and 2200oF (1204oC) for
reformer furnaces and as specified on the Purchaser design drawing for other types of furnaces.
 TECHNICAL SPECIFICATION
CERAMIC FIBER MODULE INSULATION
FOR FURNACES MB11-5M

DATE: 01 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 2 OF 5

e. Maximum Module Thermal Conductivity as follows:

TABLE I Module Thermal Conductivity

Maximum Module Thermal Conductivity at Temperatures
Btu›in/hr›ft2›oF (W/m›K)
MODULES
500oF 1000oF 1500oF 2000oF
(260oC) (538oC) (815oC) (1093oC)
Folded Modules 9 lb/ft3
0.56 (0.08) 0.92 (0.13) 1.82 (0.26) 2.80 (0.40)
(144 kg/m3) density
Monolithic Modules 12 lb/ft3 (192 kg/m3)
0.50 (0.07) 0.96 (0.14) 1.66 (0.24) 2.45 (0.35)
density
Monolithic Modules 15 lb/ft3 (240 kg/m3)
0.49 (0.07) 0.84 (0.12) 1.43 (0.20) 2.19 (0.31)
density

f. No batten strips shall be used in the arch section unless the Purchaser’s pre-approved mechanical securing
pin is incorporated in the design.

g. Modules shall be designed for a 100 ft/sec (30m/s) flue gas velocity as a minimum and at higher velocity, if
specified in the Purchaser Order. For "SCORE" Technology Furnaces, the Z neck shall be designed for a
minimum flue gas velocity of 150 ft/sec (45 m/s) with an abrasion resistant coating on corbels. Specific
consideration for the anchoring system shall be made to ensure integrity of the corbel modules.

h. Maximum shrinkage shall be less than 2%.

1.4 Module and Batten Strip Density and Compression

1.4.1 The minimum density of the compressed module shall be 9 lb/ft3 (144 kg/m3) for modules other than
monolithic modules. Monolithic modules shall have a minimum density of 12 lb/ft3 (192 kg/m3) and 15 lb/ft3
(240 kg/m3) at peep doors.

1.4.2 The pre-engineered design of a complete insulation system shall provide uniform compression of
minimum 25% for all except monolithic types of modules and batten strips. Batten strips shall have a minimum
50% compression. Thickness tolerance of blanket shall be considered in determining the minimum
compression.

1.4.3 Module joints filled with batten strips shall not exceed 1.5 inch (40 mm) in thickness and 5 feet (1500 mm)
in length. The use of greater thickness shall be approved by the Purchaser. Width of batten strips shall be
same as module thickness.

1.5 Module Anchorage

1.5.1 Type and Dimensions

a. All modules shall have a minimum of 2 support beams.

b. Minimum stud diameter shall be 5/16 inch (8 mm).

c. A 3/16 inch thick x 1 1/2 inch x 1 1/2 inch (5 mm x 40 mm x 40 mm) stud back-up plate shall be provided for
all studs. All stud to back-up plate welds shall be torque tested to 90% of its yield strength.

d. All back-up plates shall be square with studs located perpendicular in the center of the plate.

e. Stud layout shall be pre-engineered on centers shown on Figure 1.

 TECHNICAL SPECIFICATION
CERAMIC FIBER MODULE INSULATION
FOR FURNACES MB11-5M

DATE: 01 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 3 OF 5

1.5.2 Material of anchorage hardware

a. All back-up plates shall be carbon steel.

b. All studs shall be 304H stainless steel.

c. All module hardware shall be designed in accordance with Table II of this Specification.

d. All hardware shall be designed for 1% creep in 100 000 hours.

TABLE II
MODULE HARDWARE
Design Temperature Material

Below 1000oF (538oC) Stainless Steel

Over 1000oF (538oC) "H" Grade Stainless Steel

o o
Between 1200 F (649 C) and
304 H Stainless Steel.
1500oF (816oC)
Above 1500oF (816oC) To be approved by Purchaser

1.6 Module Installation

All back-up plates shall be fillet welded along two opposite sides to the casing plate on pre-engineered
locations. Modules shall then be located on studs and secured with a locknut. Special tools, if required, shall
be included as part of the supply.

2. TESTING AND INSPECTION

2.1 Testing

2.1.1 Frequency

a. The following tests are required as a minimum for the ceramic fiber modules in "as installed" condition, in
accordance with ASTM C892.

1. Density – Three (3) tests per batch or run or three (3) tests per day, whichever is greater.

2. Thermal Conductivity per ASTM C177 – One (1) test per order for major material (Note 1).

b. The following tests are required as a minimum for the ceramic fiber blanket used for modules, batten strips
or for any other purpose, in accordance with ASTM C892 and manufacturers standard.

1. Shot Content – Three (3) tests per batch or run or three (3) per day, whichever is greater.

2. Chemical Composition Analysis to quantify Major Constituents – one (1) test per 5000 modules with
one (1) test minimum.
 TECHNICAL SPECIFICATION
CERAMIC FIBER MODULE INSULATION
FOR FURNACES MB11-5M

DATE: 01 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 4 OF 5

3. Chemical Composition Analysis for chlorides – one (1) test.

Note 1: Thermal Conductivity test may be waived if the supplier can produce documentation to support
successful testing of the material within the past twelve (12) months prior to the issue of the Purchase Order.

2.2 Inspection

The inspector representing the Purchaser shall have entry at all times, while work on the contract of the
Purchaser is being performed, to all parts of the works that concern the manufacture of the material ordered.
The manufacturer shall afford the inspector all reasonable facilities to ensure that the material is being furnished
in accordance with this specification. All required tests and inspection shall be made at the place of
manufacture prior to shipment unless otherwise specified and will be conducted to avoid unnecessary
interference with the work operation.
 TECHNICAL SPECIFICATION
CERAMIC FIBER MODULE INSULATION
FOR FURNACES MB11-5M

DATE: 01 APR 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 5 OF 5

FIGURE 1