PELATIHAN BALAI BESAR KERAMIK

2019
REFRAKTORI API 936
Installation Execution - API
936
Packaging Requirements
• Hydraulic bonded, castable
refractories:
• moisture-proof bags
• product name,
• batch number
• date of manufacture clearly shown.
• Bag weight shall be marked
• weight in the bag shall not deviate by
more that ± 2%.
• Chemical setting refractories
• heat-sealed plastic to assure vapor-
tight enclosure.
• Mechanical protection by cardboard,
rigid plastic, or metal outside
• batch number.
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Important Gunning Terms
Gunning: The application of monolithic refractories by means of air placement guns.

• gun operator: Individual in a dry • nozzleman: Individual at the point

gun operation who controls material
of application in a dry gun operation
who controls water addition via
charging, flow rate and air flow of water valve and material build up
the gunning machine. via maneuvering and positioning of
the outlet nozzle.
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Gunning Installation Requirements
• Pre-wet the refractory by mixing with water prior to
charging into the gun. Optimum amount and mixing of the
pre-wetted material shall be per the applicator qualification
testing.
• Gunning equipment shall provide a smooth and continuous
supply of water and material without causing laminations,
voids, or rebound entrapment.
• Shotboards or perpendicular edge cuts shall be used to
terminate work areas.
• When stoppages greater than 30 minutes are encountered
or initial set is determined by the inspector, only full
thickness lining shall be retained.
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Gunning Installation Requirements Cont.
• Start gunning at the lowest elevation, building up the lining
thickness gradually over an area of not more than 10 ft2 (1 m2)
to full thickness and working in an upward direction to minimize
the inclusion of rebound. Rebound material shall not be reused.
• Downhand gunning beyond 30 degrees below horizontal is
prohibited unless agreed to otherwise by the owner.
• Shot board height and depth gauges shall be used for thickness
measurement guides. After gunning and confirmation of
sufficient coverage, the refractory shall be trimmed (cut back)
with a serrated trowel or currycomb before initial set occurs.
• "Flashing" or interrupted build-up of lining thickness is not
permitted after initial set as defined by the surface being
exposed for more than 20 minutes or becoming dry to the touch.
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Important Gunning Terms
• pre-wetting: A technique used with dry gunning where a small
quantity of water is mixed into the dry refractory before charging into
the gun to reduce rebound and dust, and improve wetting of the
cement.
• rebound: Aggregate and/or cement which bounces away from a
surface against which refractory is being projected by gunning.
• shotboard: Temporary containments used in gunning which are set up
and secured against anchors to provide a firm surface on which to
make perpendicular cold joints at the termination of work areas.
• flash coat: A layer coat of refractory, usually gunned, which is applied
over refractory that has already been applied and allowed to set up.
• overspray: A cement-rich layer of refractory that deposits on exposed
surfaces around a gunning installation site from airborne, wetted
refractory dust generated by the gunning operation.
• cut-back: Pre-set refractory trimmed from the lining surface via a
cutting action to the final lining thickness dimension.
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Forming Requirements for Casting
• sufficiently strong to
Collapsible
support the hydraulic
head of wet refractory
Steel Form that it will retain and to
resist any mechanical
loads, such as vibration.
• waterproof and leak free.
• dimensional tolerances
shall meet specified
requirements.

• a release agent such as grease, form release, or wax shall be used to

facilitate stripping of the forms.
• newly applied lining shall cure per the manufacturer's recommendation
(minimum of 24 hours) before moving the piece or stripping the forms.
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Requirements for Vibration Casting

• Mixer capacity should be sufficient to facilitate placement with no more than 10 minutes
between successive mix batches.
• Two or more rotary vibrators shall be mounted externally on the equipment or component to
be lined.
• Vibrators shall have adequate force to move and consolidate the material being vibrated.
• Each vibrator shall be independently controlled to focus vibration and prevent segregation due
to over vibration.
• The method of vibrator attachment shall be subject to the owner's approval.

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Casting Terminology
• casting: The process of placing wet mixed refractory concrete by
pouring, pumping, rodding or vibrating.
• vibration casting: Castable installation technique whereby
refractory is mixed with water and placed in a formed enclosure
with the aid of vibration which causes the refractory to become
"fluid like" and thereby flow and consolidate to the desired shape
of the formed enclosure.
• pump casting: Castable installation technique in which refractory
is mixed with water and pumped through piping and/or hoses to a
site where it is poured from the outlet nozzle directly into a
formed enclosure.

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Requirements for Pump Casting

• mixer capacity shall be

sufficient to allow for
continuous pump operation
without stops and starts to
wait for material.
• submersion vibrators or
rodding may be used to aid
refractory flow and filling of
the formed enclosure.

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Installation of Air-setting Phosphate Bonded
Refractories
• Mixed in a rotating paddle mixer, such as
those manufactured by Hobart.
• The mixer shall have steel paddles and bowls.
Aluminum paddles and bowls shall not be
used due to their potential to react with the
acid component in the refractory.
• Mixing shall be in strict accordance with the
manufacturer's recommended procedures
using water levels determined during material
qualification testing.
• Adjustments in water levels are permitted
after application qualification tests, with
owner's approval.
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 Installation Requirements for
Heat-setting Plastic Refractories
• Plastic refractories shall be installed at the
manufact- ured consistency.
• Field water addition or reconditioning is not
permitted.
• Any reconditioning must be performed by the
manufacturer under controlled plant conditions,
and the reconditioned material shall be fully
requalified
• The manufacturer shall measure the workability
index on plastic refractories per ASTM C 181
seven days after manufacture and provide this to
the contractor.
• The manufacturer shall also provide the minimum
workability index for each plastic refractory
supplied, for suitable installation.
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Common Installation Requirements for
Air/Heat-setting Refractories for Thin-Layer,
Erosion Resistant Linings
• Refractory shall be applied using a handheld, reciprocating
pneumatic rammer, rubber mallet, and/or wood block as
demonstrated in applicator qualification tests.
• Refractory shall be fully compacted in and around the anchor
supports to form a homogeneous liningstructure free of voids
and laminations.
• Once consolidated, overfill shall be removed flush with the tops
of the hexmesh or hexalt anchors using a trowel or currycomb.
• The surface shall then be tamped, as necessary, to remove
imperfections such as surface tearing and pull away defects.
• Water slicking of the lining surface is not permitted. Water used
to clean and lubricate tools shall be dried off prior to use on the
refractory.
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Installation Requirements for Thick Layer,
Plastic
• Installed at the manufactured consistency. Field water addition
or reconditioning is not permitted.
• Refractory shall be removed from the container/plastic wrap
only when ready for application.
• Contents shall be placed on a clean surface for cutting and/or
separating precut slices. This work surface shall be maintained to
avoid contaminating fresh refractory with dried out material
from previous cutting or separating operations.
• Refractory shall be ram packed in successive handful-sized
clumps using a handheld, reciprocating pneumatic yammer, fully
consolidating each clump into a uniform mass and compacting
the material in and around the anchor supports to form a
homogeneous lining structure free of voids and laminations that
is greater than the desired lining thickness.
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Finishing Requirements for Thick Layer, Plastic
• Once placed and consolidated, the lining shall be trimmed
to the desired lining thickness using a trowel or currycomb.
• Cutback material may be reused if workability
characteristics are not diminished. Under no circumstances
shall dry or crumbly material be installed.
• The trimmed surface shall then be tamped, as necessary, to
remove imperfections such as surface tearing and pull away
defects.
• Water slicking of the lining surface is not permitted.

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Installation Terminology to Remember
• air-ramming: A method of forming refractory shapes, furnace hearths,
or other furnace parts by means of pneumatic hammers.
• hand packing: Castable installation technique whereby refractory is
placed by packing successive handfuls of material to the desired shape.
Refractory must be mixed at a consistency that is stiff enough for the
placed refractory to hold its shape, while at the same time wet and
sticky enough so that the lining formed is structurally homogenous.
• overlay: A layer coat of refractory, usually troweled on, which is
applied to an existing lining in an attempt to extend the lining life.
• shotcrete: Mortar or concrete projected at high velocity onto a
surface; also known as air blown mortar, pneumatically applied mortar
or concrete, blastcrete, sprayed mortar and gunned concrete.
• pallet: Quantity of refractory described by amount contained on a
shipping pallet.
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Requirements for Metal Fiber Reinforcement
• Metal fiber reinforcement shall be used only when specified by
the owner. Specific details of fiber dimensions, concentration,
and metallurgy shall be covered in documentation
• Fiber additions shall be uniformly dispersed in the castable
without agglomeration as follows:
1. Load castable into mixer and pre-mix.
2. Add pre-wet or mixing water.
3. Using a dispersing device, such as 1/2 in. (13 mm) hardware mesh, sieve
fibers into castable with mixer operating.
• Fiber concentrations typically range 1 - 4 wt percent with
effective diameters of 0.010 in. - 0.022 in. (0.3 mm - 0.6 mm) and
lengths 3/4 or 1 in. (19 mm or 25 mm).
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Organic Fiber Additives
• Used to facilitate moisture removal of refractory linings
during dryout
• May be used with owner approval.
• Fiber additions shall be performed during manufacture of
the castable or plastic refractory.

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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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Contractor Documentation Responsibilities
Inspector Verified Records of:
• 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.

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Applications Terminology: Fired Heaters
Convection Section: Breaching Section:
The section of a heat exchanger Enclosure in a heat exchanger furnace in
furnace downstream of the which flue gases are collected after the
radiant section that is closely last convection coil for transmission to
packed with tubes for optimum the stack or outlet ducting.
convective heat transfer.
Corbel:
A supporting projection of the
Arch:
face of a wall; an arrangement
A flat or sloped portion
of brick in a wall in which each
of a fired heater
course projects beyond the
radiant section Radiant Section: one immediately below it to
opposite the floor. The hottest section of a heat form a support, shelf, or baffle.
exchanger furnace near the
burners in which radiant heat
transfer is dominant.

Corbel

Burner 22
Brick Terminology
Shapes to remember
• wedge brick: A standard brick shape whose
thickness tapers along its length.
• arch brick: A standard brick shape whose
thickness tapers along its width.
• key brick: A standard brick shape whose
width tapers along its length.
• key: In furnace construction, the
uppermost or the closing brick of a curved
arch.

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Brick Terminology
• arch, flat: In furnace construction, a flat structure spanning an
opening and supported by abutments at its extremities; the arch
is formed of a number of special tapered brick, and the brick
assembly is held in place by their keying action. Also called a
jack arch.
• arch, sprung: In furnace construction, a bowed or curved
structure that is supported by abutments at the sides or ends
only, and which usually spans an opening or space between two
walls.
• arch, suspended: A furnace roof consisting of brick shapes
suspended from overhead supporting members.
• rise of arches: The vertical distance between the level of the
spring lines and the highest point of the under surface of an
arch.
• crown: A furnace roof, especially one which is dome-shaped;
the highest point of an arch.
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Brick Terminology
• burning (firing) of refractories: The final heat treatment in a kiln
to which refractory brick are subjected in the process of
manufacture, for the purpose of developing bond and other
necessary physical and chemical properties.
• sintering: A heat treatment which causes adjacent particles of
material to cohere, at a temperature below that of complete
melting.
• ceramic anchor: Fired refractory device that retains the
refractory lining in place.
• chemically-bonded brick: Brick manufactured by processes in
which mechanical strength is imparted by chemical bonding
agents instead of by firing.
• course: A horizontal layer or row of brick in a structure.
• expansion joint: A separation between adjoining parts of a
refractory lining which allows small expansive movements, such
as those caused by thermal changes.
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Brick Terminology
• firebrick: Refractory brick of any type.
• fireclay brick: A refractory brick manufactured substantially or entirely
from fireclay.
• insulating firebrick: A refractory brick characterized by low thermal
conductivity and low heat capacity.
• semi-silica fireclay brick: A fireclay brick containing not less than 72%
silica.
• low-duty fireclay brick: Fireclay brick which has a PCE not lower than
Cone 15, nor higher than 28 - 29.
• medium-duty fireclay brick: A fireclay brick with a PCE value not
lower than Cone 29 nor higher than 31 to 31-1/2.
• high-duty fireclay brick: Fireclay bricks which have a pyrometric cone
equivalent (PCE) not lower than Cone 31-1/2 nor above 32-1/2 to 33.
• superduty fireclay brick: Fireclay brick which have a PCE not lower
than Cone 33, and which meet certain other requirements as outlined
in ASTM C 27.
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MODULE 5 Q and A

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