PELATIHAN BALAI BESAR KERAMIK

2019
REFRAKTORI API 936
Installation Setup - API 936
Scope of API 936
• Installation quality control guidelines for monolithic
refractory linings
• Designed to supplement owner specifications.
• Qualification of materials, equipment, and personnel
• Monitor and control applied refractory quality
• Installation and testing procedures
• Responsibilities

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 Refractory Lining Materials
Affect Unit Performance

•MATERIALS SELECTION
•APPLIED QUALITY
•SYSTEM DESIGN
STRONGLY
INFLUENCE

•EFFICIENCY
•RELIABILITY
•MAINTENANCE
Key Elements of Quality Control

• Documentation
• Material qualification
• Applicator qualification
• Installation monitoring
• As-installed testing
• Pre-dryout inspection
• Dryout monitoring
• Post dryout inspection
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Quality Control Elements
JOB SCOPE
DEFINED
DEFINE DESIGN DETAILS
SET QUALITY STANDARDS
AGREE ON EXECUTION PLAN

DOCUMENTION

MOBILIZE INSPECTOR
MATERIAL QUALIFICATION
APPLICATOR QUALIFICATION
INSPECTION MONITORING
INSTALLATION
"AS APPLIED" TESTING
TESTED PHYSICAL PROPERTIES MEET SPECIFIED CRITERIA

INSPECTION CONFIRMS APPLIED LININGS MEET SPECIFIED CRITERIA

INSPECTION MONITORING DRYOUT

INSPECTION CONFIRMS SUCCESSFUL DRIED OUT (OPTIONAL)

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Work Execution Documentation
Design Details:
•Lining products, thickness, method of application and extent of coverage.
•Anchor materials, geometry and layout.
•Surface preparation, welding procedures and anchor attachment integrity.
•Dimensions, concentration, type and metallurgy of fiber, if used.
Quality Standards:
•Physical property requirements
•Sampling procedures
•Required lining thickness tolerances and acceptance criteria
Execution Details:
•Installation and quality control procedures.
•Designation of responsible parties.
•Curing and dryout procedures. 7
Cooperating Parties in a Refractory
Installation
• manufacturer: supplies the refractory lining materials to be
installed in the equipment of the owner.
• contractor: installs refractory in the equipment of the owner.
• inspector: monitors refractory installation work being
conducted by the contractor and supplying material
manufacturer(s).
• heating contractor: dries out monolithic refractory linings
by heating.
• owner: The proprietor of equipment who has engaged one
or more parties to install or repair refractory in the
equipment. 8
Three Stages of Sampling and Testing
• material qualification: Pre-installation testing of refractory
materials in which production lots of refractories manufactured
for a specific installation are sampled and tested to confirm that
they meet specified physical property requirements.
• applicator qualification: Pre-installation simulation of
production work that is sampled and tested as well as visually
inspected to verify that application equipment and personnel are
capable of meeting specified quality standards.
• as-installed testing: Testing of refractory materials sampled from
the installation to confirm that they meet specified physical
property standards.

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Prequalification Tests
• Materials
• EROSION SERVICE:
1 sample per pallet or less from each Production Run
• OTHER SERVICE:
1 sample per 3 pallet or less from each Production Run
• Contractor Equipment/Personnel
• SIMULATE JOB
• EQUIPMENT AND PERSONNEL FOR JOB
• PRODUCTION BATCH OF MATERIAL
• INSPECTED AND TESTED PRIOR TO WORK START

• For Revision One frequency was:

• EROSION SERVICE: 1 sample per 2 tons or less
• OTHER SERVICE: 1 sample per 5 tons or less
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Contractor Responsibilities for Material
Qualification
• Arrange for testing at either an independent laboratory or the
manufacturer's plant
• Direct the work to assure that mixing techniques, water contents,
ambient temperatures, mix temperatures, and so on, adequately
represent those needed for production installation.
• Inform the owner of testing arrangements and timing so that the
owner may notify the inspector to witness or spot check the testing.

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Independent Laboratory Responsibilities
• Sampling, • Testing,
• Specimen preparation, • Documentation of results

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Contractor Responsibilities
• Advance agreement with the Owner on all installation details
• Execution of installation work, including quality assurance.
• Inspector verified documentation of installation records,
including:
• product/s being applied
• pallet numbers and location where applied
• installation crew members (designating nozzleman/gun operator when gunning)
• mixing and/or gunning equipment utilized
• fiber and water percentages
• mixing details including time, temperature and aging time (if gunned)
• location and identity of samples taken for installation quality control.
• Accountability for installed refractories meeting specified
standards
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Inspector Responsibilties
• Monitor qualification and production work conducted by
the manufacturer(s) and contractor to ensure compliance
with job specifications and agreed-to quality standards.
• Notify the owner and the contractor in a timely manner of
any work deficiencies or potential deficiencies based on
his or her monitoring of material qualifications and the
installation process.
• Make no engineering decisions contrary or in addition to
specified requirements.
• Submit conflicts between specified standards and
installed refractory quality to the owner for resolution.
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Inspector Responsibilties (Cont.)
• The inspector shall inspect and hammer test newly installed
linings before dryout and after dryout (when possible), and
report any anomalies to the owner.
• The inspector shall ensure that material and applicator
qualification test results are fully documented and the
contractor is provided with all applicable data for the materials
being installed.
• The inspector shall check and verify that accurate installation
records are being documented by the contractor.
• The inspector shall record all nonconformances and/or
potential problems to which the inspector has alerted the
contractor and owner.

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Quality Control Terminology
• production run: The quantity of refractory having the same formulation that is
prepared in an uninterrupted manufacturing operation.
• sample: That quantity of refractory taken from a single container or installation
sequence that is used to make a complete set of test specimens to determine
compressive strength, erosion resistance, density, linear change, and/ or any other
physical property determinations.
• specimen: Individual cubes, bars, or plate test pieces used for physical property
testing. Physical property test results for a sample are usually expressed as the
average of two or more specimens made up from the same sample.
• independent laboratory: A refractory testing facility not affiliated with the
manufacturer or contractor.
• Erosion Service: Installations of refractories in fluid solids units, such as transfer and
overhead lines, cyclone linings, and deflector shields, in which erosion resistance is a
determining feature of lining service life.
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Sample Forming Requirements for Material
Qualification
Type of Installation Preparation of Material Qualification Samples
Vibration Casting Vibration may be used in the forming of the test
specimens.
Pump Casting Poured into forms.
Hand Packing Hand packed.
Gunning Gunned or cast.
Alternatively specimens may be hand packed
subject to prior approval by the owner.
Plastic Formed using a mallet or handheld pneumatic
or rammer.
Ramming Mixes Specimen formation using a pneumatic or
ramming press as described by ASTM C1054, is
not permitted. 17
Qualifications of Refractory Inspector
• no commercial affiliations with the contractor or
manufacturer(s), unless otherwise agreed to by the
owner.
• working knowledge of applicable standards and terms.
• working knowledge of requirements defined in this
document, owner specifications and job specific
requirements outlined by the owner or manufacturer.

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Material Qualification Applicability
• Every refractory shall be applied within 4 months of initial
qualification tests, or 3 months of a succeeding qualification
test per the procedures herein. If the initial qualification period
is exceeded, the respective batch may be requalified.
Requalification permits usage for an additional 3 months after
each succeeding qualification test up to the manufacturer's
recommended shelf life.
• In the event a sample fails to meet specified results, it may be
retested. The retest shall be conducted using the same testing
facility and inspection, or at a different facility subject to the
owner's approval.

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Material Storage
• Refractory materials shall be stored in a weather-
protected area. Time limits for material qualification tests
shall set refractory shelf life. If the manufacturer's shelf life
recommendations are more stringent, the manufacturer's
restrictions shall apply.

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Gun Qualification Test Panel Requirements
• No nozzleman or gun operator
shall gun refractory materials
until they are qualified.
• > 24 in. x 24 in. (600 mm x 600
mm) with thickness and
anchors the same as the actual
installation job.
• Inclined 45 degrees above the
horizontal and supported on a
frame so that the panel's
midpoint is approximately 6 ft
(1.9 m) above ground level.
• Constructed with a removable
back for visual inspection of the
castable.
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Gun Qualification Sampling Requirements
GOOD
• The panel shall also be sectioned
and cut surfaces inspected for
voids, laminations, non-
uniformities, and rebound
entrapment.
• Sectioning or breaking of the
panel is permitted 18 hours after
completion of the panel unless
otherwise directed by the owner. NOT SO GOOD
• Test specimens shall be cut from
each panel and tested
• Satisfactory examination and test
results, will serve to qualify the
mixing and installation
procedures and the
nozzleman/gun operator teams.
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Casting Qualification Mock-up Requirements
• simulate the most difficult piece of the installation work or the
size/shape agreed to in the documentation phase
• simulate forming and placement procedures, installation of
refractory around nozzle protrusions, and fit-up tolerances if
work involves lining of sections to be fit-up at a later date.
• demonstrate general installation procedures, such as mixing,
handling/delivery to lining cavity and associated quality control
requirements.
• demonstrate the adequacy of vibration equipment and
attachment method of vibrators when vibration is to be used.
• cured for 12 hours minimum and then stripped of forms for
visual inspection only.
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Criteria for a Successful Casting Qualification
Mock-up
• The applicator shall not cast refractory linings until he or
she has completed a satisfactory mock-up test.
• Satisfactory examination and test results, will serve to
qualify the mixing and installation procedures as well as
mix water levels.
• Test specimens shall be prepared for materials sampled
from the mixes prepared for casting in the mock-up and
formed in molds using the same level of agitation as the
mock-up..
• The applied lining shall be homogeneous and free of
segregation and shall meet specified tolerances.
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Applicator Qualification: Contractor
Responsibilities
• Scheduling of Material Qualification Tests and delivery of
those materials and test results to the site.
• Scheduling and execution of work to qualify all equipment
and personnel needed to complete installation work,
including documentation and verification by the inspector.
• Preparation and identification of all testing samples and
timely delivery to the testing laboratory.
• Advance notification to the owner of the time and location
where work will take place so that this information can be
passed on to the inspector.
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 Applicator Qualification: Thin Layer, Erosion
Resistant Linings

• A test panel 12 in. x 12 in. x 3/4 or 1 in. (300 mm

x 300 mm x 20 or 25 mm), shall be packed by
each applicator
• Panel thickness shall be the same as the lining to
be installed. Mixing and application techniques
(e.g. pneumatic ramming, hand packing,
orientation sidewall or overhead) shall also be
the same as the installation.
• Hexmesh or hexalt anchoring system (as the case
may be) shall be attached to a backing plate such
that the backing plate may be removed and the
applied refractory lining examined from the
backside..

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Applicator Qualification: Thick Layer, Plastics
• A test panel shall be pneumatically ram packed by each
applicator using pneumatic ramming in a manner simulating the
actual installation (in other words, sidewall or overhead).
• The test panel shall be 24 in. x 12 in. (600 mm x 300 mm) with an
applied lining thickness and anchorage that are the same as the
actual installation. Anchors shall be attached such that the
backing plate may be removed and applied refractory examined
from the back side. The backing plate shall be coated with a
parting agent to facilitate removal from the applied refractory.
• No additional test specimens and testing are required as long as
material qualification results and applied refractory workability is
satisfactory.
• Satisfactory results will serve to qualify the equipment,
techniques, and applicator. No applicator shall ram pack
refractory materials until he or she has been qualified.
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Contractor Installation Responsibilities
• Advance agreement with the owner on all installation
details and as outlined in approved written execution plan.
• Execution of installation work, including preparation of as-
installed samples and timely delivery of those samples to
the designated test laboratory.
• Inspector verified documentation of installation records
• Accountability for installed refractories meeting specified
standards, including as-installed testing results and lining
thickness tolerance limits.

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MODULE 4 Q and A

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