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1、MANUAL REFRACTORY BRICKS AND SHAPES DEP 44.24.90.31-Gen. October 1994 (DEP Circular 18/95 has been incorporated) DESIGN AND ENGINEERING PRACTICE USED BY COMPANIES OF THE ROYAL DUTCH/SHELL GROUP This document is confidential. Neither the whole nor any part of this document may be disclosed to any thi
2、rd party without the prior written consent of Shell Internationale Petroleum Maatschappij B.V., The Hague, the Netherlands. The copyright of this document is vested in Shell Internationale Petroleum Maatschappij B.V., The Hague, the Netherlands. All rights reserved. Neither the whole nor any part of
3、 this document may be reproduced, stored in any retrieval system or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright owner. PDF created with pdfFactory Pro trial version PREFACE DEP (Design and
4、Engineering Practice) publications reflect the views, at the time of publication, of: Shell International Oil Products B.V. (SIOP) and Shell International Exploration and Production B.V. (SIEP) and Shell International Chemicals B.V. (SIC) The Hague, The Netherlands, and other Service Companies. They
5、 are based on the experience acquired during their involvementwith the design, construction, operation and maintenance of processing units and facilities, and they are supplemented with the experience of Group Operating companies. Where appropriate they are based on, or reference is made to, nationa
6、l and international standards and codes of practice. The objective is to set the recommendedstandard for good design and engineeringpractice applied by Group companies operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any other such facility, a
7、nd thereby to achieve maximum technical and economic benefit from standardization. The information set forth in these publications is provided to users for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condi
8、tion at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual operating companies to adapt the information set forth in DEPs to their own environment and requirements. When Contractors or Manufacturers/Suppliers use DEPs they shall be solely responsible for th
9、e quality of work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Principal will expect them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the DE
10、Ps. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal or its technical advisor. The right to use DEPs is granted by SIOP, SIEP or SIC, in most cases under Service Agreements primarily with companies of the Royal Dutch/Sh
11、ell Group and other companies receiving technical advice and services from SIOP, SIEP or SIC. Consequently, three categories of users of DEPs can be distinguished: 1)Operating companies having a Service Agreement with SIOP, SIEP, SIC or other Service Company. The use of DEPs by these Operating compa
12、nies is subject in all respects to the terms and conditions of the relevant Service Agreement. 2)Other parties who are authorized to use DEPs subject to appropriate contractual arrangements. 3)Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or
13、2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards. Subject to any particular terms and conditions as may be set forth in specific agreements with users, SIOP, SIEP and SIC disclaim any liabil
14、ity of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof. The benefit of this disclaimer shall inure in all respects
15、 to SIOP, SIEP, SIC and/or any company affiliated to these companies that may issue DEPs or require the use of DEPs. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of SIOP and SIEP, be d
16、isclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of SIOP and SIEP
17、. The copyright of DEPs vests in SIOP and SIEP. Users shall arrange for DEPs to be held in safe custody and SIOP or SIEP may at any time require information satisfactory to them in order to ascertain how users implement this requirement. All administrative queries should be directed to the DEP Admin
18、istrator in SIOP. NOTE: In addition to DEP publications there are Standard Specifications and Draft DEPs for Development (DDDs). DDDs generally introduce new procedures or techniques that will probably need updating as further experience develops during their use. The above requirements for distribu
19、tion and use of DEPs are also applicable to Standard Specifications and DDDs. Standard Specifications and DDDs will gradually be replaced by DEPs. DEP 44.24.90.31-Gen. October 1994 Page 2 PDF created with pdfFactory Pro trial version TABLE OF CONTENTS 1.INTRODUCTION .4 1.1SCOPE 4 1.2DISTRIBUTION, I
20、NTENDED USE AND REGULATORY CONSIDERATIONS4 1.3DEFINITIONS 4 1.3.1General definitions.4 1.3.2Specific definitions .5 1.4CROSS-REFERENCES 5 2.USE AND CLASSIFICATIONS OF SHAPED REFRACTORY MATERIALS 6 2.1USE OF SHAPED REFRACTORY MATERIALS .6 2.2CLASSIFICATIONS OF SHAPED REFRACTORY MATERIALS 6 2.2.1Shape
21、d insulating refractory materials.6 2.2.2Dense shaped refractory materials6 2.2.3Special compositions .7 2.2.4Acid-resistant refractory materials .7 3.QUALITY ASSURANCE/QUALITY CONTROL8 4.DESIGN.9 4.1DESIGN PARAMETERS .9 4.2TYPES OF LINING 9 4.3SELECTION OF SHAPED REFRACTORY MATERIALS 10 4.3.1Burner
22、s11 4.3.2Furnaces12 4.3.3Sulphur Recovery Units (SRUs) 13 5.SUPPLY 14 5.1MANUFACTURE OF REFRACTORY MATERIALS. 14 5.2REFRACTORY SHIPMENT AND STORAGE14 6.TRANSPORT OF BRICK-LINED EQUIPMENT 15 7.INSTALLATION OF REFRACTORY BRICK CONSTRUCTIONS 16 7.1GENERAL16 7.2TEMPERATURE CONTROL DURING INSTALLATION 16
23、 7.3BRICKED CONSTRUCTIONS.16 7.4ANCHORS.17 8.INSPECTION, MAINTENANCE AND START-UP.18 8.1INSPECTION .18 8.2MAINTENANCE.19 8.3START-UP AND OPERATION 19 9.REFERENCES 20 FIGURES22 APPENDICES APPENDIX 1SPECIFICATION FOR SHAPED REFRACTORY MATERIALS . 24 1.APPLICATION 24 2.SCOPE.24 3.DOCUMENTATION 24 4.SPE
24、CIFICATION OF SHAPED REFRACTORY MATERIALS 25 APPENDIX 2SPECIFICATION FOR SAMPLING AND TESTING OF SHAPED REFRACTORY MATERIALS28 1.INTRODUCTION 28 DEP 44.24.90.31-Gen. October 1994 Page 3 PDF created with pdfFactory Pro trial version 2.DOCUMENTATION 28 3.SAMPLING AND DIMENSIONAL INSPECTION OF SHAPED
25、MATERIALS .28 DEP 44.24.90.31-Gen. October 1994 Page 4 PDF created with pdfFactory Pro trial version 1.INTRODUCTION 1.1SCOPE This DEP, which is a revision of the DEP of the same number dated December 1982, covers the design, supply and installation of insulating, dense, special composite and acid-
26、resistant refractory bricks and special (pre-formed) shapes. This revision includes integration of the technical developments since the last revision and a change in format from a Technical Specification to a Manual. The intention of the change of format is to provide in one document the recommended
27、 engineering practice supported with guidance and explanations. Refractory bricks and shapes are often used in combination with monolithic refractory materials of similar compositions. For these monolithic refractory applications, reference is made to DEP 64.24.32.30-Gen. and DEP 30.48.60.34-Gen., w
28、hich should be read in conjunction with this DEP. Non-refractory acid-resistant bricks and tiles are excluded from the scope of this DEP, but are covered by DEP 30.48.60.33-Gen. 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorised by SIPM, the distribution of this
29、document is confined to companies forming part of or managed by the Royal Dutch/Shell Group, and to Contractors nominated by them (i.e. the distribution code is “C“, as defined in DEP 00.00.05.05-Gen.). This DEP is intended for use in oil refineries, chemical plants, gas plants, supply/marketing ins
30、tallations and exploration and production facilities. If national and/or local regulations exist in which some of the requirements may be more stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requ
31、irements will be acceptable as regards safety, economic and legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the requirements of this document which is considered to be necessary in order to comply with national and/or local regulations. The Principal may t
32、hen negotiate with the Authorities concerned with the object of obtaining agreement to follow this document as closely as possible. 1.3DEFINITIONS 1.3.1General definitions The Contractor is the party which carries out all or part of the design, engineering, procurement, construction and commissionin
33、g for a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor. The Manufacturer/Supplier is the party which manufactures or supplies equipment and services to perform the duties specified by the Contractor. The Principal is the party which initia
34、tes the project and ultimately pays for its design and construction. The Principal will generally specify the technical requirements. The Principal may also include an agent or consultant, authorised to act for the Principal. The word shall indicates a requirement. The word should indicates a recomm
35、endation. DEP 44.24.90.31-Gen. October 1994 Page 5 PDF created with pdfFactory Pro trial version 1.3.2Specific definitions The Applicator is the party which applies the refractory linings specified by the Contractor. The term bricks includes both bricks and special shapes. The term refractory mater
36、ials/products/linings includes dense, insulating, acid-resisant and/or special composite refractory materials. 1.4CROSS-REFERENCES Where cross-references to other parts of this DEP are made, the referenced section number is shown in brackets. Other documents referenced by this DEP are listed in (9).
37、 DEP 44.24.90.31-Gen. October 1994 Page 6 PDF created with pdfFactory Pro trial version 2.USE AND CLASSIFICATIONS OF SHAPED REFRACTORY MATERIALS 2.1USE OF SHAPED REFRACTORY MATERIALS The design and application of refractory linings is required to protect equipment (such as radiant and convection se
38、ctions of furnaces including burners, waste heat boilers, flue ducts and fluidised bed installations) from process conditions. Refractory linings are used to: enclose a space in which processes take place at high temperatures, giving protection to the steel enclosure and the environment. Examples: f
39、urnaces, kilns, (fluid bed) incinerators, waste heat boilers, ducts, steel stacks. be placed in installations in which solids or gases are processed at high temperatures. Examples: reactors, strippers, regenerators. Refractory materials need to have: resistance to high temperatures and temperature f
40、luctuations; chemical/mechanical resistance against those substances which come in contact with the refractory material, e.g. gases, slag, etc.; sufficient mechanical strength to be part of the construction of the installation and to withstand loads during maintenance operations. The specifications
41、to obtain satisfactory service from refractory materials depend strongly on the location(s) where they are to be used. A substantial investment in refractory products designed to handle high temperatures and destructive operations can be lost by inadequate design or careless construction/installatio
42、n. All shaped (insulating, dense, special composite or acid-resistant) refractory materials are classified in terms of the chemical and mineralogical nature of the main constituents according to ISO 1109, as follows: high alumina products(Group HA), fireclay and low fireclay products(Group FC and LF
43、), siliceous and silica products(Group SS and SL). NOTE: Siliceous and silica products are rarely used in refinery equipment. 2.2CLASSIFICATIONS OF SHAPED REFRACTORY MATERIALS Refractory bricks are divided into four sub-groups: 2.2.1Shaped insulating refractory materials Insulating refractory materi
44、als are manufactured from base refractory materials, fired and with a total porosity of at least 45% determined in accordance with ISO 5016. NOTE:This definition stems from the fact that thermal insulating products all have a low thermal conductivity and a small thermal capacity, properties which ar
45、e related to the total porosity of the product. The bulk density, which for a given product is directly linked with porosity, can therefore be chosen as a criterion for classification. 2.2.2Dense shaped refractory materials Dense refractory materials are manufactured from base refractory materials w
46、ith a total porosity of less than 45% and with a pyrometric cone equivalent (P.C.E.) of at least 1500 C. The main constituents are alumina silicates. DEP 44.24.90.31-Gen. October 1994 Page 7 PDF created with pdfFactory Pro trial version In the manufacturing process the method of bonding and the pro
47、cess of shaping the materials define to a great extent the ultimate properties of refractory bricks and shapes. A distinction may therefore be drawn between, plastic, semi-dry and dry formed products. 2.2.3Special compositions Special compositions are mainly manufactured from refractory base materia
48、ls other than the alumina silicategroup, i.e. basic compositions(magnesia), siliconcarbide and zirconium silicate used for special applications. 2.2.4Acid-resistant refractory materials Acid-resistant materials are manufactured from refractory base materials and comply with the classification criter
49、ia of refractory products defined in ISO 1109. The classification is based on ISO 10080, with respect to resistance against sulphuric acid and apparent porosity of the refractory material. DEP 44.24.90.31-Gen. October 1994 Page 8 PDF created with pdfFactory Pro trial version 3.QUALITY ASSURANCE/QUALITY CONTROL The required properties of the refractory bricks are specified in Appendix 1. Sampling and testing requirements are specified in Appendix