1、Monolithic Refractories: Installation and DryoutAPI TECHNICAL REPORT 980FIRST EDITION, APRIL 2018Special NotesAPI publications necessarily address problems of a general nature. With respect to particular circumstances, local,state, and federal laws and regulations should be reviewed.Neither API nor
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4、ng to do so. Every effort has been made by the Institute to assure theaccuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, orguarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for l
5、oss ordamage resulting from its use or for the violation of any authorities having jurisdiction with which this publication mayconflict.API publications are published to facilitate the broad availability of proven, sound engineering and operatingpractices. These publications are not intended to obvi
6、ate the need for applying sound engineering judgmentregarding when and where these publications should be utilized. The formulation and publication of API publicationsis not intended in any way to inhibit anyone from using any other practices.Any manufacturer marking equipment or materials in confor
7、mance with the marking requirements of an API standardis solely responsible for complying with all the applicable requirements of that standard. API does not represent,warrant, or guarantee that such products do in fact conform to the applicable API standard.All rights reserved. No part of this work
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9、ight 2018 American Petroleum InstituteForewordNothing contained in any API publication is to be construed as granting any right, by implication or otherwise, for themanufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anythingcontained in the publi
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13、 the publication can be ascertained from theAPI Standards Department, telephone (202) 682-8000. A catalog of API publications and materials is publishedannually by API, 1220 L Street, NW, Washington, DC 20005.Suggested revisions are invited and should be submitted to the Standards Department, API, 1
14、220 L Street, NW,Washington, DC 20005, standardsapi.org.iiiContentsPage1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Referenced Documents . . . . . . . . . . . . . . . . . . . .
15、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Terms and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Installation . . . . . . . . . . . . . . . . . . . .
16、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.2 Refractory Concrete
17、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.3 Plastic Refractories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Co
18、nstruction Details for Refractory Concrete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
19、5.2 Support Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295.3 Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20、. . . . . . . . . . . . . 305.4 Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305.5 Rebar and Metal Embedment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21、 . . . . . . . . . . . . . . . . . . . . 385.6 Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 Curing, Drying, and Firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386.1 General Drying/Firing Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386.2 Modes of Drying/Firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406.3 Refractory Concretes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406.4 Plastics and Ramming Mixes. . . . . . . . . . . . . . . . . . . . . . .
24、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487.1 Introduction . . . . . . . . . . . . . . . . . . . . .
25、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487.2 Failure Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487.3 Surface Preparation . . . . . . .
26、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497.4 Anchoring and Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507.5 Repair Materials . .
27、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507.6 Repair Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Biblio
28、graphy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Figures1 Hot Modulus Versus the Amount of Mixing Water for a Fireclay Castable with a Low-purity Cement . . . . . . . . . . . . . . . . .
29、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Flexural Strength of a Tabular Alumina, High-purity Cement Castable . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Typical Hand-held Reciprocating Rammer. . . . . . . . . . . . . . . . . . . . . .
30、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Short-handled Trimming Spade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Transmission of Force by the Rammer. . . . . . . . . . . . . . . . . . . . . . . . .
31、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Trimming a Plastic Refractory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 Construction Joints Being Added to Installed Plastic Refractory Lining. . . . . .
32、. . . . . . . . . . . . . . . . . . . . 258 Refractory Construction for Three-zone Pusher Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 Refractory Construction for Roof Anchor Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33、. . . . . . . 2710 Refractory Construction for Roof Section in Reheat Furnace (1 in. = 25.4 mm) . . . . . . . . . . . . . . . . . . . . 2811 Refractory Construction for Typical Burner Port (1 in. = 25.4 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2912 Typical V-clip Anchors . .
34、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3113 Typical Anchor Arrangement for V-clips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3214 Metal Roof Anch
35、ors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33vContentsPage15 Flexible Rotary Kiln Anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36、 . . . . . . . 3316 Wall Anchors for Monolithic Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3517 Refractory Roof Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37、. . . . . . . . . . . 3618 Typical Wall Seat Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3719 Hydration Reaction Products of Calcium Aluminates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38、. . . . . . . . 4120 Graph Showing Maximum Drying Rate for Phosphoric Bonded Refractories Occurs at Approximately 174 F (80 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Tables1 Dryout of Conventional Castable Refractories . .
39、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43viIntroductionThis report is the last in a series of three American Petroleum Institute (API) reports covering the use of refractoryconcrete (castables), plastics, and ramming mixes for applications for the h
40、ydrocarbon processing industry (HPI). Itscontent is complimented by the two other reports in this series: API TR 978, Monolithic Refractories: Manufacture, Properties and Selection API TR 979, Applications of Refractory Lining MaterialsThese API technical reports update and add to the original repor
41、ts written by Committee 547 of the AmericanConcrete Institute (ACI) in 1979 and 1989. The ACI reports are ACI 547.R-79, State-of-the Art Report: RefractoryConcrete and ACI 547.1R-89, State-of-the Art Report: Refractory Plastics and Ramming Mixes. Many of the figuresappearing in these three new API t
42、echnical reports are scanned images from the two ACI 547 reports, and are usedwith ACIs written permission. Even though the native files are no longer available, these figures were not redrawnbecause of their historical significance.ACI Committee 547 was organized in 1969 to provide a reliable and c
43、omprehensive source of information onmonolithic refractory technology. In subsequent years, participation in the ACI refractory technical community waned.At the same time, participation increased on the API committee that was drafting refractory content. The APIcommittee currently runs a certificati
44、on program for refractory practitioners based on API Standard 936, RefractoryInstallation Quality ControlInspection and Testing Monolithic Refractory Linings and Materials. To facilitate use ofthe updated content in the API certification program, ACI allowed API to use the material in the two above-
45、mentionedACI publications, which are no longer maintained by ACI. This enabled API to create new technical reports byupdating and adding to the material from the ACI reports. API formed the Vessel Refractory Task Group in the late 1980s with the objective of providing a standard for theinspection an
46、d application of quality controls for monolithic refractories used in refining applications. In response todemands for greater reliability and cycle life objectives, refiners had already developed their own companyspecifications for refractory installations for the highest-value applications, where
47、unit availability is critical. A cottageindustry of supporting quality control experts and inspectors evolved that has helped owners reduce this gap in thelast few decades. Up until that time, however, manufacturers and installers largely had little say in this development,and uniform industry stand
48、ards were never developed or adopted.To address this issue, a broad representation of all the stakeholders gathered as part of APIs spring and fall RefiningEquipment Standards Meetings. Addressing the standards gap and noting the many similarities in owner andequipment manufacturerdeveloped specific
49、ations, the API task force undertook the task of identifying useful industrypractices and/or negotiating to agreement best fits for standards application. APIs Refractory Installation QualityControl GuidelinesInspection and Testing Monolithic Linings and Material was first issued in 1996 as arecommended practice. After a number of subsequent revisions, it was approved as API Standard 936 in 2006, with acertification program that began in 2004.In addition to maintaining API Standard 936 and overseeing the certification program, the task force reorganized in2014 under the API Com
