The primary source of reliability is based on simple concepts which provide a refractory lining that is based on good engineering and industry practices for the particular application.
These concepts are:
- Specification of the Correct Materials
- Engineering and Design of the Refractory Lining
- Pre-qualification of the installation techniques and crew
- Installation – installation – installation
The design of refractory lining involved the application of good engineering practices that balance the operational aspects of the equipment with the critical elements required in the refractory lining. These elements include the balancing of the design of the anchoring / tie back systems, the thermal expansion, hot load deformation and the thermal profiles into the design of the refractory lining to accommodate issues related to abrasion, corrosion, thermal mechanical attack and strength issues caused by operation of the unit. The final result is the preparation of a refractory lining that incorporates the all aspects of the engineering and design that will provide a reliable refractory lining for the project.
The pre-qualification process is based on the API standard which includes all aspects of the installation process. Additionally, you must specify the pre-qualification and testing all personnel installing welded components based on relevant ASME or AWS standards prior to application. Remember that the refractory design is only as good as the installation, therefore the pre-qualification of personnel is one key aspect of the installation process.
Improper installation of the design is a primary cause for failure for many refractory lining. A simple process of planning the installation through the preparation of installation procedures, quality verification documentation, and site monitoring / audits to verify the correct implementation of the intended design goes a long way to the successful completion of any project.