API 982:Guide to Refractory Lining Inspection and Repair
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8 January, 2025
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10:33 am
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Introduction
Refractory linings are essential components in various high-temperature refinery equipment. They provide thermal insulation and protect the equipment from extreme conditions. API 982 outlines industry best practices for inspecting and maintaining these linings, ensuring safety and efficiency.
What is API 982?
API 982 is a recommended practice (RP) that provides guidelines for the installation, inspection, and repair of refractory linings used in refinery equipment. This includes, but is not limited to:
- Fluid Catalytic Cracking Units (FCCUs)
- Reforming Units
- Fired Heaters
- Incinerators
- Sulfur Recovery Units
- Boilers
- Flue Gas Stacks
- ETC…..
Inspection and Assessment of Refractory Linings
API 982 emphasizes the importance of regular inspections to identify potential problems and ensure the integrity of refractory linings. Several inspection methods are recommended:
- 1.Visual Inspection: A thorough visual examination of the lining to identify cracks, spalling, or other visible damage.
- 2.Remote Visual Inspection: Using cameras or other remote devices to inspect areas that are difficult to access.
- 3.Rope Access Inspection: Utilizing trained rope access technicians for inspections in challenging locations.
- 4.Infrared Thermal Imaging: Detecting hot spots or temperature variations that may indicate lining deterioration.
- 5.Hammer Testing: Assessing the soundness of the lining by tapping it with a hammer and listening for changes in sound.
Inspection and Test Plan (ITP)
API 982 recommends developing a comprehensive Inspection and Test Plan (ITP) to ensure that inspections are conducted systematically and effectively. The ITP should outline the scope of inspections, the methods to be used, and the frequency of inspections.
Understanding Refractory Lining Degradation
To properly assess and address refractory lining issues, API 982 provides valuable resources:
- Refractory Lining Degradation Mechanism Matrix: This matrix outlines the various ways refractory linings can degrade. It helps identify the root causes of damage, such as chemical attack, thermal shock, or mechanical stress. Understanding the cause is crucial for selecting the right repair strategy.
- Annex A (Informative): This annex provides further details on specific refractory lining defects and degradation mechanisms. It expands on the matrix by offering information on:
- Refractory Lining Defects: Descriptions and illustrations of common defects like cracks, spalling, erosion, and disintegration.
- Mechanical Degradation Mechanisms: In-depth explanations of how mechanical forces, like impact and abrasion, can damage refractory linings.
By utilizing these resources, inspectors and engineers can make informed decisions about repairs and preventative measures.
Key Benefits of API 982
- Enhanced Safety: Regular inspections and proper maintenance help to prevent catastrophic failures that can result in injuries or fatalities.
- Improved Efficiency: Identifying and addressing refractory lining issues early can prevent costly downtime and production losses.
- Extended Equipment Life: Proper maintenance can extend the life of refinery equipment, reducing the need for costly replacements.
- Industry Best Practices: API 982 provides a standardized approach to refractory lining inspection and repair, ensuring consistency and quality.
Conclusion
API 982 is an essential resource for anyone involved in the inspection, maintenance, and repair of refractory linings in refinery equipment. By following the guidelines outlined in this RP, refineries can ensure the safety and efficiency of their operations.
| Component | Unit | Types of Lining Systems : with( / ) Dual Layer Hot face and backup layer | Degradation Mechanisms |
|---|---|---|---|
| Vessel Sidewalls | _ | Castable—Medium Weight | Spalling,Excessive Cracking,Overheating,Chemical Attack on Hot Face |
| Cyclones | _ | Castable—Abrasion Resistant Insulating ; Castable—Dense Erosion Resistant or High Alumina | Abrasion (erosion),Spalling,Anchor Failure Corrosion,Thermal Shock |
| Plenums | _ | Castable—Abrasion Resistant Insulating;Castable—Dense Erosion Resistant or High Alumina/Castable—Light Weight Insulating | Abrasion (erosion),Spalling,Excessive Cracking,Hot Gas Bypassing |
| Strippe | _ | Castable—Medium Weight ; Castable—Abrasion Resistant Insulating | Abrasion (erosion); Spalling |
| Slide Valves | Solid Fluid Unit, Including Fluid Catalytic Cracking (FCCU | Castable—Abrasion Resistant Insulating ; Castable—Dense Erosion Resistant or High Alumina/Castable—Medium Weight | Abrasion (erosion) ; Spalling ; Excessive Cracking ; Overheating ; Chemical Attack on Hot Face ; Anchor Failure Corrosion ; Thermal Shock ; Hot Gas Bypassing |
| Transfer Lines | _ | Castable—Abrasion Resistant Insulating | Abrasion (erosion) ; Spalling ; Excessive Cracking ; Overheating ; Chemical Attack on Hot Face ; Anchor Failure Corrosion ; Thermal Shock ; Hot Gas Bypassing |
| Air Preheater | _ | Castable—Light Weight Insulating ; Castable—Medium Weight ; Brick—Firebrick ; Brick—Insulating Firebrick ; Plastic Refractory | Spalling ; Excessive Cracking ; Overheating ; Thermal Shock |
| Orifice Chamber | _ | Castable—Medium Weight ; Castable—Abrasion Resistant Insulating ; Castable—Dense Erosion Resistant or High Alumina | Abrasion (erosion) ; Spalling ; Excessive Cracking |
| Overhead Line | _ | Castable—Abrasion Resistant Insulating ; Castable—Dense Erosion Resistant or High Alumina/Castable—Light Weight Insulating | Abrasion (erosion),Spalling,Excessive Cracking,Hot Gas Bypassing |
| Distributors | _ | Castable—Abrasion Resistant Insulating ; Castable—Dense Erosion Resistant or High Alumina | Abrasion (erosion),Spalling,Excessive Cracking,Hot Gas Bypassing ; Anchor Failure Corrosion |
| Floor | # | Castable—Light Weight Insulating/Brick—Insulating Firebrick ; Brick—Firebrick/Castable—Light Weight Insulating ; Castable—Medium Weight/Castable—Light Weight Insulating , Brick—Firebrick/Insulation Block ; Castable—Medium Weight | Spalling; Excessive Cracking ; Overheating ; Thermal Shock |
| Radiant Sidewall | Fired Heaters | Brick—Firebrick/Castable—Light Weight Insulating ; Brick—Firebrick/Insulation Block , Ceramic Fiber—Blanket , Ceramic Fiber—Modules ; Castable—Medium Weight/Castable—Light Weight Insulating | Abrasion (erosion) ; Spalling ; Excessive Cracking ; Overheating ; Thermal Shock |
| Arch Bullnose | # | Castable—Abrasion Resistant Insulating/Castable—Light Weight Insulating | Abrasion (erosion); Spalling ; Overheating ; Excessive Cracking |
| Convection Section | # | Castable—Medium Weight ; Castable—Light Weight Insulating | Abrasion (erosion) ; Spalling ; Excessive Cracking ; Chemical Attack on Hot Face |
| Header Boxes | # | Ceramic Fiber—Blanket | Abrasion (erosion) ; Spalling ; Excessive Cracking |
| Breechings - Line Flue Gas - Lines and Stack | # | Castable—Light Weight Insulating ; Castable—Medium Weight (55pcf) | Abrasion (erosion) ; Spalling ; Excessive Cracking |
| Radiant Floor | ? | Brick—Firebrick/Brick—Insulating Firebrick ; Brick—Firebrick/Castable—Light Weight Insulating ; Castable—Medium Weight/Castable—Light Weight Insulating ; Brick—Firebrick/Insulation Block ; Castable—Medium Weight ; Castable—Medium Weight/Insulation Block , Ceramic Fiber—Expansion Joints | Abrasion (erosion) , Spalling , Overheating , Excessive Cracking , Thermal Shock |
| Radiant Sidewall | ? | Ceramic Fiber—Blanket ; Ceramic Fiber—Blanket/Ceramic Fiber—Modules ; Castable—Light Weight Insulating/Brick—Insulating Firebrick ; Insulation Block/Brick—Insulating Firebrick ; Castable—Medium Weight ; Ceramic Fiber—Expansion Joints | Spalling,Excessive Cracking, Overheating, Anchor Failure Mechanical , Anchor Failure Corrosion , Thermal Shock |
| Arch Bullnose | Ethylene Furnaces | Castable—Medium Weight ; Castable—Abrasion Resistant Insulating ; Insulation Block/Castable—Abrasion Resistant Insulating ; Ceramic Fiber—Blanket/Ceramic Fiber—Modules ; Ceramic Fiber—Blanket ; Ceramic Fiber—Expansion Joints | Abrasion (erosion),Spalling , Excessive Cracking , Overheating , Anchor Failure Corrosion , Thermal Shock |
| Convection Section | ? | Castable—Light Weight Insulating ; Castable—Medium Weight | Abrasion (erosion) , Spalling , Excessive Cracking , Thermal Shock |
| Header Boxes - Breechings - Line Flue Gas - Lines and Stack | ? | Castable—Light Weight Insulating , Castable—Medium Weight , Ceramic Fiber—Blanket , Ceramic Fiber—Expansion Joints | Abrasion (erosion) , Spalling , Excessive Cracking , Anchor Failure Corrosion |
| Bussel Ports | £ | Castable—Dense Erosion Resistant or High Alumina | Abrasion (erosion),Spalling, Excessive Cracking, Overheating , Thermal Shock |
| Combustion Chamber | CO Furnace | Brick—Firebrick/Castable—Light Weight Insulating ; Brick—Firebrick/Brick—Insulating Firebrick ; Castable—Dense Erosion Resistant or High Alumina/Castable—Light Weight Insulating | Spalling, Excessive Cracking ,Thermal Shock |
| Tube Section | £ | Brick—Firebrick/Castable—Light Weight Insulating ; Brick—Firebrick/Brick—Insulating Firebrick ; Castable—Dense Erosion Resistant or High Alumina/Castable—Light Weight Insulating | Abrasion (erosion) ; Spalling ; Excessive Cracking , Overheating |
| Radiant Sidewall | $ | Brick—Firebrick/Castable—Light Weight Insulating ; Castable—Medium Weight ; Brick—Insulating Firebrick/Ceramic Fiber—Blanket &/o (Ceramic Fiber—Expansion Joints) ; Ceramic Fiber—Blanket ; Ceramic Fiber—Modules | Excessive Cracking , Overheating , Chemical Attack on Hot Face , Anchor Failure Mechanical , Anchor Failure Corrosion |
| Viewports | $ | Castable—Medium Weight ; Brick—Insulating Firebrick ; Ceramic Fiber—Modules | Spalling,Excessive Cracking, Overheating , Thermal Shock |
| Radiant Floor and Heat Shield | Reforming Furnaces for Hydrogen and Syngas Production Flue Gas Zones | Brick—Firebrick/Brick—Insulating Firebrick ; Brick—Firebrick/Castable—Light Weight Insulating ; Castable—Medium Weight/Castable—Light Weight Insulating ; Brick—Firebrick/Insulation Block ; Castable—Medium Weight | Excessive Cracking |
| Tunnel Walls | $ | Brick—Firebrick & (Ceramic Fiber—Expansion Joints) | Spalling, Excessive Cracking |
| Arch Roof and Bullnose | $ | Castable—Abrasion Resistant Insulating/Castable—Light Weight Insulating ; Ceramic Fiber—Modules | Anchor Failure Mechanical , Anchor Failure Corrosion |
| Convection Section | $ | Castable—Light Weight Insulating , Castable—Medium Weight , Castable—Medium Weight/Castable—Light Weight Insulating ; Castable—Medium Weight12Insulation Block | Spalling, Excessive Cracking |
| Header Box and Breech | $ | Castable—Light Weight Insulating ; Castable—Medium Weight ; Ceramic Fiber—Blanket | Spalling, Excessive Cracking |
| Collection Headers and Transfer Line | $ | Castable—Dense Erosion Resistant or High Alumina/Castable—Light Weight Insulating ; Castable—Dense Erosion Resistant or High Alumina/Castable—Medium Weight ; Castable with Alloy Shroud Facing with sealed attachment/s to shell./Castable—Medium Weight | Spalling, Excessive Cracking , Chemical Attack on Hot Face, Chemical Attack from Condensing Acid , Thermal Shock , Hot Gas Bypassing |
| Secondary Reformer/ Pre-reformer | $ | Castable—Dense Erosion Resistant or High Alumina/Castable—Light Weight Insulating | Spalling, Excessive Cracking , Chemical Attack from Condensing Acid , Thermal Shock , Hot Gas Bypassing |
| Heat Exchangers | $ | Castable—Dense Erosion Resistant or High Alumina/Castable—Light Weight Insulating; Castable with Alloy Shroud Facing with sealed attachment/s to shell. | Spalling, Excessive Cracking , Hot Gas Bypassing |
| Reaction Furnace Cylinder | % | Brick—Dense High Alumina/Castable—Light Weight Insulating ; Brick—Dense High Alumina/Brick—Insulating Firebrick | Spalling, Chemical Attack on Hot Face , Anchor Failure Mechanical , Thermal Shock |
| Tubesheet | % | Castable—Dense Erosion Resistant or High Alumina | Spalling, Overheating , Thermal Shock , cracking of ceramic ferrules |
| Condenser | Sulfur Recovery Units | Castable—Medium Weight ; Castable—Abrasion Resistant Insulating ; Brick—Firebrick | Spalling ; Excessive Cracking , Chemical Attack on Hot Face , Chemical Attack from Condensing Acid, Anchor Failure Mechanical , Anchor Failure Corrosion |
| Incinerator | % | Brick—Dense High Alumina/Castable—Light Weight Insulating; Brick—Dense High Alumina/Brick—Insulating Firebrick | Overheating, Chemical Attack on Hot Face, Anchor Failure Mechanical |
| Sulfur Pit | % | Castable—Medium Weight; Brick—Firebrick | Chemical Attack on Hot Face, Chemical Attack from Condensing Acid, Anchor Failure Mechanical, Anchor Failure Corrosion, Thermal Shock |
| Sidewall and Bottom Heads | Catalytic Reforming Reactors | Castable—Light Weight Insulating ; Castable with Alloy Shroud Facing with sealed attachment/s to shell/Castable—Medium Weight | Overheating |
| Top Head | Catalytic Reforming Reactors | Castable—Medium Weight | Spalling, Excessive Cracking, Overheating,Anchor Failure Mechanical |
| Calciners | Coke Calcining and Combustion | Brick—Dense High Alumina/Brick—Insulating Firebrick ; Brick—Dense High Alumina/Castable—Medium Weight ; Brick—Insulating Firebrick/Castable—Medium Weight ; Brick—Dense High Alumina ; Castable—Dense Erosion Resistant or High Alumina | Abrasion (erosion), Spalling, Excessive Cracking,Overheating,Chemical Attack from Condensing Acid, Anchor Failure Mechanical, Anchor Failure Corrosion |
| Combustors | Coke Calcining and Combustion | Brick—Dense High Alumina/Brick—Insulating Firebrick ; Brick—Dense High Alumina/Castable—Medium Weight ; Brick—Insulating Firebrick/Castable—Medium Weight | Abrasion (erosion), Spalling, Excessive Cracking,Overheating,Chemical Attack from Condensing Acid, Anchor Failure Mechanical, Anchor Failure Corrosion |
| Gasifier | Coke Calcining and Combustion | Brick—Dense High Alumina/Brick—Insulating Firebrick ; Brick—Dense High Alumina/Castable—Medium Weight ; Brick—Insulating Firebrick/Castable—Medium Weight | Abrasion (erosion), Spalling, Excessive Cracking,Overheating,Chemical Attack from Condensing Acid, Anchor Failure Mechanical, Anchor Failure Corrosion |
| Stacks | General | Castable—Light Weight Insulating ; Castable—Medium Weight ; Brick—Firebrick , Brick—Insulating Firebrick | Spalling,Excessive Cracking, Anchor Failure Corrosion, Thermal Shock |