API TR 977-2018 ASTM C704 Test Variability Reduced to Allow Further Optimization of Erosion-resistant Refractories for Critical Oil Refining Applications (FIRST EDITION).pdf

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1、ASTM C704 Test Variability Reduced to Allow Further Optimization of Erosion-resistant Refractories for Critical Oil Refining ApplicationsAPI TECHNICAL REPORT 977FIRST EDITION, FEBRUARY 2018Special NotesAPI publications necessarily address problems of a general nature. With respect to particular circ

2、umstances, local,state, and federal laws and regulations should be reviewed.Neither API nor any of APIs employees, subcontractors, consultants, committees, or other assignees make anywarranty or representation, either express or implied, with respect to the accuracy, completeness, or usefulness of t

3、heinformation contained herein, or assume any liability or responsibility for any use, or the results of such use, of anyinformation or process disclosed in this publication. Neither API nor any of APIs employees, subcontractors,consultants, or other assignees represent that use of this publication

4、would not infringe upon privately owned rights.API publications may be used by anyone desiring 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 connectio

5、n with this publication and hereby expressly disclaims any liability or responsibility for loss 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 p

6、roven, sound engineering and operatingpractices. These publications are not intended to obviate 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 any

7、one from using any other practices.Any manufacturer marking equipment or materials in conformance 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

8、 do in fact conform to the applicable API standard.Classified areas may vary depending on the location, conditions, equipment, and substances involved in any givensituation. Users of this Technical Report should consult with the appropriate authorities having jurisdiction.Users of this Technical Rep

9、ort should not rely exclusively on the information contained in this document. Soundbusiness, scientific, engineering, and safety judgment should be used in employing the information contained herein.API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and prop

10、erly train andequip their employees, and others exposed, concerning health and safety risks and precautions, nor undertaking theirobligations to comply with authorities having jurisdiction.Where applicable, authorities having jurisdiction should be consulted.Work sites and equipment operations may d

11、iffer. Users are solely responsible for assessing their specific equipmentand premises in determining the appropriateness of applying the Technical Report. At all times users should employsound business, scientific, engineering, and judgment safety when using this Technical Report.All rights reserve

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13、hington, DC 20005.Copyright 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 anythin

14、gcontained in the publication be construed as insuring anyone against liability for infringement of letters patents.Questions concerning the interpretation of the content of this publication or comments and questions concerning theprocedures under which this publication was developed should be direc

15、ted in writing to the Director of Standards,American Petroleum Institute, 1220 L Street, NW, Washington, D.C. 20005. Requests for permission to reproduce ortranslate all or any part of the material published herein should also be addressed to the director.Generally, API standards are reviewed and re

16、vised, reaffirmed, or withdrawn at least every five years. A one-timeextension of up to two years may be added to this review cycle. Status of the publication can be ascertained from theAPI Standards Department, telephone (202) 682-8000. A catalog of API publications and materials is publishedannual

17、ly and updated quarterly by API, 1220 L Street, NW, Washington, D.C. 20005.Suggested revisions are invited and should be submitted to the Standards Department, API, 1220 L Street, NW,Washington, D.C. 20005, standardsapi.org.iiiContentsPage1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . .

18、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Referenced Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Terms and Definitions . . . . . . . . .

19、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Continuing Drive for More Erosion-resistant Cyclone Linings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Abrasion Testing-History . . . . . . . . . . . . . . . .

20、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.1 The Standard ASTM Test, ASTM C704 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.2 Consensus of Strengths and Weaknesses of the Test Procedur

21、e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105.3 Strengths and Weaknesses of the ASTM C704 Test Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Evaluation of Potential Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22、 . . . . . . . . . . . . . . . . 127 Changes to Procedure Defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Round Robin Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23、. . . . . . . . . . . . . . . . . 138.1 Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138.2 Laboratories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148.3 Protocol for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Results Compared Between the 2015 Round Robin and 1999 Round Robin . . .

25、. . . . . . . . . . . . . . . . . 159.1 1999 Ruggedness Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159.2 2015 Ruggedness Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26、. . . . . . . . . . . . . . . . . . . 1610 Conclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1811 What is Next? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Bibliography. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Figures1 ASTM C704 Testing Machine . . . . . . . . . . . . . . . . .

28、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Example of FCCU Cyclone Pair Showing Key Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 FCC Unit Showing Key Components . . . . . . . . . . . . . . . . . . . . . .

29、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 New Machined Stainless Steel Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Survey Events Determining FCCU Turnaround Timing Outside of Planned Maintenance.

30、 . . . . . . . . . . . . 86 Samples of FCCU Cyclone Lining Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Tables1 Developments Leading to the Introduction of ASTM C704 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31、 . . . 102 ASTM C704 Standard Actions and Modifications Since 1972 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Precision Statistics for Abrasion Resistance: Research Report RR:C08-1019 . . . . . . . . . . . . . . . . . . . . . 164 Castable Abrasion Loss, cm3. . . . . .

32、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Glass Plate Abrasion Loss, cm3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17vASTM C704 Test Variability Reduce

33、d to Allow Further Optimization of Erosion-resistant Refractories for Critical Oil Refining Applications 1 Scope 1.1 This technical report documents the results of a joint project conducted by the API CRE Subcommittee on Refractory Materials (SCRM) and the ASTM C08 Committee to improve the reproduci

34、bility of the ASTM C704/C704M, 2015 Edition, Standard Test Method for Abrasion Resistance of Refractory Materials at Room Temperature. Erosion-resistant refractories are used in many oil refining applications, such as fluid catalytic cracking units (FCCUs), to resist the wearing effects of solids pa

35、rticles (5 m to 100 m is typical) circulating at elevated velocities 30 ft/s to 200 ft/s (9 m/s to 61 m/s) in a high-temperature process environment 900 F to 1400 F (482 C to 760 C). 1.2 This technical report also reviews the drivers for continuing improvement in erosion-resistant refractories and t

36、he role of ASTM C704/C704M for the selection and installation quality control of refractories used in these installations. This report documents changes made to the setup and procedures to improve the reproducibility of the test. These changes are designed to achieve this end, while providing a roug

37、h equivalency consistent with historical data before the changes were made. These results are validated by extensive international round robin and ruggedness testing and are reported herein. 2 Referenced Documents API 936, Refractory Installation Quality ControlInspection and Testing, Monolithic Ref

38、ractory Linings and Materials (2014) API TR 978, Monolithic Refractories: Manufacture, Properties, and Selection API TR 979, Applications of Refractory Lining Materials API TR 980, Monolithic Refractories: Installation and Dryout ASTM C704/C704M 1, Standard Test Method for Abrasion Resistance of Ref

39、ractory Materials at Room Temperature (2015). ASTM C1036, Standard Specification for Flat Glass ASTM E691-09, Standard Practice for Conducting an Interlaboratory Study to Determine the Precision of a Test Method 3 Terms and Definitions 3.1 abrasion resistance The ability to withstand the effects of

40、eroding particles for an extended period without the significant loss of material or other damage. Often referred to as “erosion resistance” in fluid solids units, such as FCC units, which is technically incorrect, but commonly understood in refining jargon. EXAMPLE Ability of a refractory lining in

41、 an FCCU transfer line to retain thickness when exposed to circulating catalyst in the process stream. NOTE For refractory materials, abrasion resistance is measured in the form of eroded volume loss in accordance with ASTM C704/C704M. 1ASTM International, 100 Barr Harbor Drive, PO Box C700, West Co

42、nshohocken, Pennsylvania, 19428-2959. 2 API TECHNICAL REPORT 977 3.2 air pressure gauges Control devices used in an ASTM C704/C704M test to measure and allow for better control of the pressure of the motive air used to accelerate the blasting particles to create the test conditions. 3.3 ASTM C704 te

43、sting machine ASTM-specified machine shown in Figure 1. Refractory sample is eroded by a controlled grit blasting using No. 36 silicon carbide (SiC) grit at a specified feed rate, duration, and air pressure, using the specified machined block nozzle at a distance of 8 in. (203 mm) from nozzle tip to

44、 sample surface. Figure 1ASTM C704 Testing Machine 3.4 casting The application of wet mixed castable refractory by placing (possibly with the aid of vibration), pouring, or rodding. Key: 1. refractory sample 2. grit feed system 3. inlet air line 4. pressure regulator 5. air-line pressure gauges 6. m

45、achined block nozzle 7. vacuum gauges 8. box cabinet with door 9. exhaust line 10. box pressure monometer 1 234677559 8 10TEST VARIABILITY REDUCED TO ALLOW FURTHER OPTIMIZATION OF EROSION-RESISTANT REFRACTORIES FOR CRITICAL OIL REFINING APPLICATIONS 3 3.5 catalyst A substance that causes or accelera

46、tes a chemical change without being permanently affected by the reaction. EXAMPLE The catalyst circulated between reactor and regenerator vessels in the FCC process. 3.6 compliance datasheet A list of mechanical and chemical properties for a specified refractory material that are warranted by the ma

47、nufacturer to be met if and when the product is tested by the listed procedure in accordance with API Standard 936. 3.7 cyclones (of FCCUs or fluid coking units) Components, usually internal, used for inertial (momentum) separation of particulate solids from flue or product gas. Cyclones can be in m

48、ultiple stages, including an inlet, barrel, cone, dust pot, dip leg, and outlet crossover, as illustrated in Figure 2. Figure 2Example of FCCU Cyclone Pair Showing Key Components 3.8 density The mass of a unit volume of a substance, usually expressed in kilograms per cubic meter (kg/m3), grams per c

49、ubic centimeter (gm/cm3), or pounds per cubic foot (lb/ft3). 4 API TECHNICAL REPORT 977 3.9 erosion of refractories The mechanical wearing away of the surfaces of refractory bodies in service by the washing action of moving liquids or gasses such as molten slags or high-velocity particles. In the case of moving solid particles, this is more correctly termed “abrasion.” 3.10 erosion resistance (as it applies to ASTM C704/C704M test results) Volume of refractory loss, measured in cubic centimeters, after abrading the surface of a test specimen with 2.2 lb (1000 gm) of SiC grit,