Professional Documents
Culture Documents
MANUAL
PTS 30.48.60.12
AUGUST 2000
PREFACE
PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication,
of PETRONAS OPUs/Divisions.
They are based on the experience acquired during the involvement with the design, construction,
operation and maintenance of processing units and facilities. Where appropriate they are based
on, or reference is made to, national and international standards and codes of practice.
The objective is to set the recommended standard for good technical practice to be applied by
PETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemical
plants, marketing facilities or any other such facility, and thereby to achieve maximum technical
and economic benefit from standardisation.
The information set forth in these publications is provided to users for their consideration and
decision to implement. This is of particular importance where PTS may not cover every
requirement or diversity of condition at each locality. The system of PTS is expected to be
sufficiently flexible to allow individual operating units to adapt the information set forth in PTS to
their own environment and requirements.
When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the
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 PTS. 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 PTS rests with three categories of users :
1)
2)
3)
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users, PETRONAS disclaims any liability of whatsoever nature for any damage (including injury
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TABLE OF CONTENTS
1.
1.1
1.2
1.3
1.4
1.5
INTRODUCTION
SCOPE
DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS
DEFINITIONS
CROSS-REFERENCES
SUMMARY OF MAIN CHANGES SINCE PREVIOUS EDITION
2.
2.1
2.2
3.
3.1
3.2
3.3
4.
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5.
6.
6.1
6.2
6.3
6.4
6.5
6.6
LINING INSTALLATION
SURFACE PREPARATION FOR CONCRETE SURFACES
EXPANSION JOINTS
MEMBRANES
MORTARS
BRICKS AND TILES
JOINTLESS (FLOOR) SYSTEMS
7.
8.
QUALITY CONTROL
9.
10.
11.
REFERENCES
12.
BIBLIOGRAPHY
APPENDICES
APPENDIX 1
1.
INTRODUCTION
1.1
SCOPE
This PTS specifies requirements and gives recommendations for the design, installation,
testing and inspection of chemical-resistant linings for concrete structures used in the
petroleum, chemical and gas industries.
This PTS is a revision of the PTS of the same number dated May 1993 and has
incorporated PTS 30.48.60.33, which is now withdrawn. A summary of the main changes
since the previous edition of this PTS is given in (1.5).
Excluded from the scope of this PTS are rubber linings, for which reference is made to
PTS 30.48.60.10, and (acid-resistant) refractory bricks and shapes, for which reference is
made to PTS 44.24.90.31 Chemical-resistant linings for process equipment are covered by
PTS 30.48.60.13 Painting and coating systems are covered by PTS 30.48.00.31
This PTS principally covers ceramic types of lining materials (e.g. bricks, tiles and mortars)
and their underlying membranes, but also non-ceramic linings such as
synthetic-resin-based systems.
Chemical-resistant ceramic linings are used to protect concrete elements (such as floors
and gutters) against chemical attack. A combination of a ceramic lining and a membrane is
mostly used for this purpose. The membrane is designed to prevent penetration of
chemicals to the underlying concrete surface. The ceramic lining serves to protect the
membrane against chemical, mechanical and/or thermal loads (e.g. scaffolding, steam
cleaning).
It is not the intention of this PTS to provide detailed specifications for the various cases of
chemical attack. Each case shall be looked at individually and, based on these minimum
requirements, details shall be worked out and agreed between the Principal, the
Contractor, the Manufacturer and the Applicator, leading to a durable protection of concrete
structures against chemical attack under the particular conditions.
The specified properties shall be tested in accordance with internationally accepted
standards, or local standards if they exist. For convenience, specific standards are
mentioned in various cases.
For a further comparison of the chemical resistance between the materials, reference is
made to PTS 30.10.02.13
NOTE:
1.2
In various places in this PTS specific brands of products are specified. It is not intended to preclude the
use of other products; equivalent products may be used provided the Principal so approves.
1.3
DEFINITIONS
The Applicator is the party which applies the chemical-resistant linings specified by the
Contractor.
The Contractor is the party which carries out all or part of the design, engineering,
procurement, construction and commissioning 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 initiates 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 recommendation.
1.4
CROSS-REFERENCES
Where cross-references to other parts of this PTS are made, the referenced section
number is shown in brackets. Other documents referenced in this PTS are listed in (11).
1.5
2.
2.1
GENERAL
Concrete is a mixture of hydraulic cement and mineral aggregates, of which the cement is
the constituent in the mix most vulnerable to chemical attack. Because the concrete has a
relatively high open porosity and concrete surfaces become increasingly permeable over
time, attack on the underlying reinforcement becomes a major risk as well.
The alkaline character of the cement in the mix provides the concrete with a good
resistance against alkalis. However, if concrete is exposed to acids, acidic solutions or an
acid/alkaline condition, protection by means of a chemical-resistant lining may be required.
Concrete is resistant to most hydrocarbon solvents.
Structural and other steels not only have limited resistance against chemical loads, but are
often susceptible to various systems of stress corrosion cracking or embrittlement. Under
specific conditions special steels can be used for use with chemicals.
A chemical-resistant lining will, in general, consist of at least two lines of defence, i.e. a
membrane and a chemical-resistant lining. The optimal solution is bricks or tiles laid in a
synthetic resin-based mortar with a suitable membrane, but this type of construction is
expensive and should only be applied when justified.
Less expensive solutions, consisting of one or more layers of a synthetic-resin-based
system, either with or without a reinforcement, or full plastic-sheet membranes which are
mostly proprietary systems, can be applied but should be justified as well.
Where possible, alternative cheaper solutions, such as bricks or tiles laid in silicate-based
mortars, jointless protective layers, or a combination thereof should be used.
A well-prepared concrete surface is essential for the proper performance of chemicalresistant linings. The installation of these linings shall be carried out by specialised
contractors with skilled labour under stringent supervision. The installation shall be
completed with a suitable after-treatment.
Precautions shall be taken to avoid inadvertent outflow/disposal of chemicals (e.g.
hydrochloric acid used for cleaning dirty floors, "acidulation" of brick lining, etc.).
For an initial selection of a chemical-resistant lining Table 2-1 may be used as guidance.
For further and/or detailed comparisons or selections reference is made to
PTS 30.10.02.13
Chemical-resistant lining materials shall comply with Appendix 1 and PTS 30.10.02.13
2.2
SELECTION CRITERIA
The need for a chemical-resistant protection and the selection of the type of protection
required for the envisaged duty shall be based on:
Service/operating conditions or environment
- of prime importance are the nature, composition and temperature of the chemicals
against which a construction shall be protected. Exact knowledge is required of the
behaviour of these chemicals and the materials for which protection is required;
Existing (mechanical as well as chemical) load
- taking into account not only the present situation but also any future changes,
thereby avoiding expensive alterations;
Condition of construction/installation
- this often has a decisive influence on the costs. Each material or construction
requires greatly differing working conditions, e.g. temperature, dryness, ventilation,
material-specific required sequences, etc.;
Economics
- the most economical lining is the one which is adequately resistant to the loads that
arise and is quickly and cheaply applied, thus being likely to achieve the desired
service life;
Service life
- it is economically not justifiable to select protections which will outlive the
constructions they must protect. Sometimes it may be better to use a simple,
inexpensive application, even one requiring minor repairs, rather than more reliable
and sophisticated but costly applications;
Selection results
- besides the above criteria, thorough consideration should be given to specific site
and operational conditions, and the required safety margins within which operations
and/or the effectiveness of the protection can vary;
Types of chemical-resistant material
- in general terms as low, medium (normal) and high protection, or as types (in
ascending order), e.g. impregnation, sealing, coatings, fillers, synthetic resin screeds,
tiles in various types of mortars, including possible combinations.
Alkalis
Sulphates
+
+
+
+
+
+1] (+)
+
+
+
+
(+)
-
+
+ 1]
+
+
+
+
+
+
+
-
+
+
+
+
+
+
+
+
+
- + 1] (+) +
+
+
+
- + 1] +
+
+
+
- + 1] +
+
+
+
+
(+) +
+
(+) (+)1] (+) +
3]
+
(+)
(+)
+
(+)
3]
(+)
(+)
+
+
+
+
+
+
+
+
+
+
+
+
+
+
-
+
+
+
+
+
-
+
+
+
+
+
-
Poly-isobutylene sheet
Cold-cured epoxy
Mortar/coating based on:
Phenol-furfuraldehyde resin
Phenol-formaldehyde resin
Furane resin
Epoxy resin
Polyester resin
Sodium silicate
Potassium silicate
]
2
+ Resistant
NOTES:
up to up to
30% 50%
+
+
+
-
Esters
Phenols
Ketones
Alcohols
Protective membranes:
Asphaltic bitumen
Aliphatic
+
+
Mineral oils
+
+
+
Aromatic
+
+
+
Chlorinated
(+)
Chlorides
Hydrocarbons
Other salts
Potable
Brackish
Sea
Water
Table 2-1:
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
(+)
(+)
(+)
(+)
+
+
+
+
(+)
-
+
+
+
(+)
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
(+)
(+)
+
+
+
+
+
+
+
+
+
+
+
+
+
+
(+) (+)
(+) +
(+) +
+
+
- Not resistant
Sodium and potassium silicate cements are not resistant to ammonium fluoride and sodium
bicarbonate.
Although concrete has a certain degree of chemical resistance (4.2) it should be treated as
a substrate to be protected. The selection of the type of concrete shall be primarily based
on structural considerations, with its chemical resistance as a bonus.
3.
3.1
MEMBRANES
3.1.1
General
The following materials should be used as membranes for concrete structures:
asphaltic bitumen;
thermoplastic materials;
thermosetting materials.
Acid-resisting brick lining for floors, and bottoms of pits (e.g. neutralisation pits) or vessels
and trenches shall be provided with membranes which can sustain mechanical loads.
NOTE:
3.1.2
3.1.3
Thermoplastic membranes
Unless otherwise specified, only thermoplastic membranes based on polyisobutylene shall
be used. Polyisobutylene sheet lining provides a good liquid-tight membrane. It shall be
adhesive-bonded to the substrate and the joints shall be sealed either by an adhesive or by
fusion welding; vulcanisation is not required.
Polyisobutylene only has a fair resistance against hydrocarbon solvents.
NOTE:
3.1.4
Thermoplastic membranes are generally too rigid to accommodate irregularities of the concrete
substrate, unless they are used as "false form work".
Thermosetting membranes
For specific chemical conditions a synthetic resin-based membrane shall be used (with or
without a fibre reinforcement).
An optimum chemical resistance may be obtained by selection of an appropriate synthetic
resin.
3.2
3.2.1
3.2.2
Silicate-based mortars
Silicate-based mortars are commonly used for the construction of acid-resistant brick
linings.
If contact with sulphuric acid is expected, potassium silicate-based mortar is preferred to
sodium silicate-based mortar (see notes).
NOTES:
1. Under these conditions the sodium sulphate, formed in the sodium silicate mortar, crystallises with
an increase in volume due to the release of crystallisation water. Potassium sulphate, on the other
hand, crystallises without increase of volume.
2. Halogen-containing silicate-based mortars may, in contact with strong acids, produce hydrofluoric
acid which would attack the substrate in direct contact with it. For such conditions, halogen-free
silicate-based cements have been developed.
3. The porosity of silicate-based mortars, which is between 7% and 16% depending on the type, is a
major disadvantage and therefore they shall not be used as a membrane.
4. Silicate-based mortar may be used as a bedding material, applied on an asphaltic bitumen
membrane. The joints between brick and tiles should then be sealed with a synthetic resin-based
mortar.
Mildly alkaline media can be tolerated at ambient temperature after careful "acidulation" of
the mortar. Alternating acid and alkaline service, however, cannot be tolerated.
Silicate-based mortars have only slight resistance against erosion, especially from flowing
hot water, steam or alkali. Washing out of mortar from the joints may occur. The use of
other types of mortar, mainly synthetic-resin-based, shall then be considered for jointing
and laying the bricks.
A properly mixed fresh mortar reacts readily and cures even when air is excluded. During
reaction and curing the mortar remains soluble and shall be protected against rain or other
possible wash-out by water.
Silicate mortars do not adhere to rubber membranes.
3.2.3
Synthetic-resin-based mortars
Synthetic-resin-based mortars are commonly used for the construction of acid-resistant
brick linings. They cure as a result of a chemical reaction between the synthetic resin and a
curing agent. They adhere very well to a rubber membrane.
The main types are filled phenolic, furane, polyester and/or epoxy-resin-based cements.
Phenolic-resin-based mortars, when properly applied, are erosion resistant and free of
pores. They can be used both as a membrane and for embedding and sealing the joints
between bricks or tiles. The modified phenolic-resin-based mortars provide excellent
resistance against both acidic and alkaline conditions and have good resistance against
mildly oxidising solutions.
In general the properties of furane-resin-based mortar resemble those of mortars based on
phenol resin, but curing at high temperatures is not required to obtain full chemical
resistance. The furane-resin-based mortars have good chemical resistance. If a filler such
as graphite is added, resistance against hydrofluoric acid is also obtained.
Furane-resin-based mortars are erosion resistant and free of pores when properly applied.
Polyester-resin-based mortars have good chemical and erosion resistance.
Epoxy-resin-based mortars can be used for continuous floors and for embedding and
sealing purposes. An outstanding characteristic of epoxy-resin-based mortars is their very
good adhesion. For their application on a concrete substrate no pre-treatment other than
proper surface cleaning is necessary.
3.3
3.3.1
General
Bricks and tiles are manufactured to standard sizes which shall be used whenever possible
to save costs.
Tiles used for floors, trenches and neutralisation pits shall be at least 30 mm thick.
For walls in pump houses, etc. glazed, split tiles or similar shall be used. The minimum
thickness of the tiles should be 20 mm.
Bricks and tiles shall have a roughened, non-glazed surface finish or split dove-tailed
grooves that optimise adhesion of the mortar at the faces to be embedded.
Some acid-resistant bricks have low resistance against penetration of liquids and/or gases,
as against high thermal conductivity and consequently often good thermal shock
resistance. Attention shall be paid to their open porosity particularly if crystallising liquids
may be present where a potential danger of crystal growth within the pores can occur,
resulting in expansion and subsequent destruction of the brick.
Other bricks resist the penetration of liquids, in conjunction with low thermal conductivity
(closed porosity); hence, high thermal gradients within the brick can occur and subsequent
temperature shock will lead to thermal spalling.
Erosion resistance of the bricks and tiles shall be considered, if required.
Mechanical and physical properties of various chemical-resistant lining materials are given
in Appendix 1.
3.3.2
3.3.3
Carbon bricks
Carbon bricks as specified in Appendix 1 shall be used for the following:
if hydrofluoric acid is present;
alkali solutions with a mass fraction greater than 0.2;
alkali solutions at temperatures above 20 C.
Carbon has a moderate thermal conductivity and is very hard. These properties make it an
excellent material for corrosive and erosive services with high thermal loads. For these
conditions non-impregnated carbon bricks may be used, relying on mortars and membrane
to protect the concrete effectively.
3.3.4
4.
4.1
GENERAL
Chemical-resistant linings for concrete structures shall be designed and installed by a
qualified and experienced engineering contractor only. The need for such linings shall be
taken into account early in the design and calculation stages of the structure, so that the
required slope for drainage of floors, trenches and other provisions, and the additional
weight of the lining, can be considered.
If a chemical-resistant lining has to be applied at a later stage, due to a change in
requirements or the extension of an installation, the concrete structure or equipment shall
be recalculated for the additional loads and/or the thermo-mechanical stresses.
If a change in chemical conditions from those originally anticipated in the design is
envisaged, the effects on the chemical-resistant lining shall be carefully scrutinised.
It is stressed that optimal chemical-resistant properties will only be achieved when
maximum attention is paid to the use of appropriate materials and installation requirements.
Prior to the application of lining systems, concrete vessels, sumps, pits etc., shall be water
tested to ensure liquid tightness in accordance with PTS 34.19.20.31
4.2
4.2.1
General
For the design and construction of reinforced concrete structures reference is made to
PTS 34.19.20.31
Hydraulic cements used in concrete and mortars as described below shall be in
accordance with Appendix 1.
The degree of chemical resistance of concrete based on these types of cement largely
depends on the composition of the mix.
Only concrete of high density and proper selected composition may be expected to provide
good resistance against alkalis, solvents, etc.
4.2.2
4.2.3
4.2.4
4.2.5
4.3
4.3.1
General
Although the following descriptions mainly relate to application on floors, they can also be
applicable to adjacent walls, corbels, foundation blocks, columns, etc., which are subject to
the same chemical loads.
Chemical-resistant floors can be subdivided as follows:
Floors without continuous chemical attack
Concrete constructions, e.g. floors, without a finish layer can produce considerable dust
when they are dry. Moreover, they are vulnerable to incidental spillage of e.g. oils, fat
and various chemicals. For such conditions an epoxy lining system, optionally fibrereinforced, should be used (4.3.3 and 4.3.4).
Acid-resistant floors
Floors for acid service only and not exposed to traces of alkali, steam or hot water shall
be provided with a layer of bricks or tiles, which are laid in silicate-cement-based
bedding mortar on the selected membrane. The thickness of the mortar layer should be
3 - 5 mm.
When the mortar has cured, after about 4 days, an acidification treatment is essential
(6.4.3).
Acid-resistant and alkali-resistant floors
Floors exposed to alkali or alkaline solutions, and to acids, shall be provided with acidresistant bricks or tiles, which shall be laid in synthetic-resin-based mortar on the
selected membrane.
Acid-resistant, alkali-resistant and solvent-resistant floors
Thermoplastic materials, if resistant against the specified solvents, may be used.
Generally a mortar based on polyester, vinyl-ester or epoxy resin, or a mortar of the
same base material as used for laying the bricks or tiles, shall be applied as the
membrane.
Floors for mildly to moderately aggressive conditions
For exposure to mildly aggressive conditions or for temporary service, two methods of
protection are recommended:
- a layer of bricks or tiles which are embedded in a hydraulic mortar and joined with a
synthetic-resin-based mortar, or
- a jointless floor based on synthetic resin.
NOTE:
Jointless systems shall be continuous, liquid-tight and resistant to the chemicals to which
they may become exposed.
The floors shall have a slope of at least 1:50 for the drainage of rain water and spillage
water, which can be best obtained by applying a concrete fill to the sub-floor.
Figure 4-1: Typical construction of flooring
Normal flooring
(zero to moderate
chemical-resistance)
Chemical resistant
5 - 8 mm
Standard drawings S 19.050 (Figure 4-1) and S 19.055 show respectively the construction
of a chemical-resistant floor and drains for the discharge of rain water and/or spillage water.
4.3.2
Synthetic-resin-based systems
For exposure to mildly aggressive conditions or for temporary services, the use of jointless
floors based on synthetic resin should be considered.
The floors should be provided with a non-slip surface layer, especially where frequent
access will be required. Surfaces can be made slip proof by scattering sand, powdered
quartz or silicon carbide (e.g. carborundum) on the wet surface immediately after
placement.
The following types of floors are commonly used:
Trowelling floor
The trowelling floor should be applied in one layer with a thickness varying between
5 mm and 10 mm.
The trowelling compound has a high content of filler material. The ratio of binder to filler
material is about 1 : 7.5 by weight. An optimum density of the trowelling layer can be
obtained by grading the filler material.
Trowelling compounds have high compressive strength, excellent adhesion to a wide
range of materials and good resistance against corrosive agents.
Self-levelling floor
The self-levelling floor should be applied in one layer with a thickness varying between
2 mm and 4 mm. This type of floor has good chemical resistance but a low mechanical
strength. By adding filling materials in the ratio of binder to filling material of 1 : 2.5 by
weight (but without adding solvents) a sufficiently self-levelling system can be obtained.
4.3.3
4.3.4
4.4
4.4.1
General
Chemical-resistant brick linings consist of bricks or tiles laid in mortar. They are part of a
multi-layer system which generally consists of:
concrete, providing rigidity and strength;
an impervious membrane, to prevent the corrosive medium from reaching the concrete;
one or more layers of chemical-resistant bricks or tiles laid in a chemical-resistant
mortar, mainly as a protective layer for the membrane (i.e. thermal loads and
mechanical impact).
The chemical-resistant brick lining, including the membrane, primarily protects the
concrete. It is necessary for each layer of brick, including every joint, to be bonded to the
next layer in order to form a composite construction with the concrete and the membrane.
Great care shall be taken to avoid anything that might lead to failure of the bond between
adjacent layers of brick or the complete lining and the concrete structure. Although bricks,
tiles and mortars are to some extent permeable, the action of the corrosive medium within
the porous material is hampered by the corrosion products formed within the pores, thus
preventing further attack.
A chemical-resistant brick lining is liable to crack formation due to the brittleness of the
ceramic materials and the bonding strength between the cement and bricks or tiles. The
difference in thermal expansion between the lining and the concrete substrate should
therefore be taken into account. Cracks in the brick lining will allow penetration of the
corrosive agents/fluids through the lining, which will result in damage to the concrete if the
membrane fails.
Tiles are generally applied to surfaces which are readily accessible and to floors which are
not heavily loaded, otherwise bricks should be used.
Various types of mortar can be used for laying bricks or tiles, a summary of which is given
in (6.4).
4.4.2
Membranes
The chemical resistance of the various membrane materials is given in (2) and
PTS 30.10.02.13
A summary of the main inspection requirements which are to be met by the various
membrane materials is given in Table 10-1. The materials used for membranes on concrete
structures are dealt with in Appendix 1, and the requirements for installation are given in
(6.3).
Membranes or protective intermediate layers between chemical-resistant brickwork and a
reinforced concrete structure are of prime importance for the operation and service life of a
brick lining.
Membranes shall be continuous, vapour-tight and, in order to prevent damage to the joints
in the chemical-resistant layer, sufficiently flexible to allow for expansion and contraction
induced by structural movements.
4.4.3
Expansion joints
Expansion joints are the weakest parts in chemical-resistant brickwork and tiling, and
should therefore be installed outside the zones of chemical attack.
When this cannot be avoided, they should be located in areas where there is the least
possible chance of aggressive liquids permeating them, e.g. not at the lowest point of the
drainage slope.
Figure 4-2:
Reinforced concrete
Backing material
Standard Drawings S 19.051 (Figure 4-2) and S 19.052 (for (limited) multidirectional
movement) show typical details of sealing expansion joints.
Joints sealed with chemical/temperature resistant elastic sealing compound
This type of joint is the most suitable construction at locations subject to severe
chemical attack.
At the expansion joint, the reinforced concrete shall have a 10 mm wide gap filled with a
plastic joint filler.
The concrete fill applied on top of the concrete provides the required slope for drainage
and shall have a gap at the same location and of the same width as the joint. The joint
shall be sealed with a plastic foil, adhesive-bonded to the concrete, and the gap shall be
filled with a chemical/temperature resistant elastic sealing compound.
Joints filled with asphaltic bitumen
The construction shall be similar to that described above. However, in this case the joint
is completely filled with Shell Cariphalte JS or equivalent.
NOTE: Shell Cariphalte is a product of Synthasco Bouwchemie B.V., NL (1.1).
4.5
TRENCHES
Chemical-resistant trenches can be subdivided as follows:
Trenches without continuous chemical attack
Drains, sewer systems, pits, etc., are often attacked by chemical products present in the
waste water. For such conditions a trowelling compound (4.3.2) or an epoxy coating
system (4.3.4) should be applied.
Acid-resistant trenches
Trenches for acid service only, and not exposed to traces of alkali, steam or hot water,
shall be provided with a layer of acid-resistant bricks or tiles. They shall be laid in silicate
mortar on the membrane, as described for acid resistant floors (4.3.1).
Acid- resistant and alkali-resistant trenches
Trenches exposed to alkali, alkaline solutions or acids shall be provided with acidresistant bricks or tiles, which shall be laid in synthetic resin-based mortar on the
membrane, as described for acid- and alkali-resistant floors (4.3.1).
Acid-resistant, alkali-resistant and solvent-resistant trenches
For trenches designed for transport of corrosive effluents containing petrochemical
solvents, the recommendations as laid down in (4.3.1) shall be followed.
Trenches exposed to chemical attack will normally be constructed of reinforced concrete,
and shall be provided with a lining suitable for the respective chemical and thermal
conditions.
The trench bottom should have a slope of 1: 50 for drainage. A lesser slope may be
considered for long trenches, but shall not be less than 1: 200.
The slope may be obtained by the application of a concrete fill on the trench bottom.
The trench shall be wide enough to ensure that the acid-resistant tile or brick lining can be
properly laid, i.e. preferably based on their standard dimensions to avoid unnecessary
cutting and material loss. The side walls shall be vertical.
When a trench is constructed in an acid-resistant floor, the membrane of both the floor and
the trench shall be continuous.
Figure 4-3:
4.6
NEUTRALISATION PITS
Deep pits should be lined with acid-resistant bricks instead of tiles because of the
mechanical impacts due to filling of the compartments or removal of the fill and scraping for
cleaning during maintenance.
Acid-resistant bricks shall also be used for:
Partition walls
Lining of compartments to be filled with chalk or lime, because tiles may be damaged
when the compartments are scraped out
The contents of these compartments will generally be acidic or neutral. The
acid-resistant bricks shall therefore be laid in silicate mortar on the selected membrane
(6.4.3).
For selection of the membrane, see (3.1).
Other compartments
The contents of compartments are normally alkaline but may become locally or
completely acidic, depending on the nature of the liquid to be neutralised.
The acid-resistant bricks shall therefore be laid in synthetic resin-based mortar on the
selected membrane (6.4.4).
If the contents of a trench leading to a neutralisation pit are expected to occasionally
become alkaline, the bricks in the neutralisation pit (including the compartments to be
filled with chalk) shall be laid in synthetic-resin-based mortar (6.4.4).
NOTE:
Trenches discharging acidic liquids need a certain slope for drainage, therefore
neutralisation pits should be built as near as possible to the location where the acid is
discharged, to keep the depth of the trench to a minimum.
Neutralisation pits should normally be constructed of reinforced concrete (4.8). They shall
have vertical walls and may consist of a number of compartments.
For neutralising acidic effluents, neutralisation pits may be filled with chalk (calcium
carbonate), lime (calcium hydroxide), a lime slurry or a solution of sodium hydroxide.
The contents of chalk-filled compartments into which an acidic liquid flows will generally be
acidic or neutral.
The contents of compartments filled with lime, sodium hydroxide solution or a lime slurry
will normally be alkaline, but may become locally or completely acidic depending on the
liquid to be neutralised.
4.7
4.8
CONCRETE VESSELS
During initial design, attention shall be paid to possible alternative construction materials,
e.g. the use of steel for neutralisation pits and sulphur-containing vessels, or the use of
proprietary systems as false form work, etc.
Such proprietary plastics systems, e.g. Bekaplast from Steuler Industriewerke GmbH,
Kera from Keram-Chemie GmbH, (1.1), available in both thermoplastic and thermosetting
materials, may be used if the Manufacturer/Supplier can provide evidence of the long
term reliability and economic benefit of such systems to the Principal.
Design and acceptance of concrete vessels shall meet the requirements of
PTS 34.19.20.31 For underground sulphur storage tanks for Sulphur Recovery Units,
reference is made to PTS 64.24.32.11
Tongue and groove materials are often used in larger constructions, to obtain improved
stability and a labyrinth-like joint lengthening. Concrete vessels of great length, which are
also exposed to temperature variations and which cannot be constructed with curved walls
or with pillar piers, should be designed with dowel-brick constructions, i.e. a dovetail groove
in the concrete in which similar shaped bricks are placed, generally at 1.5 m to 2 m
intervals.
The concrete vessel shall be water tested to ensure liquid-tightness before construction of
the lining, and subsequently dried in accordance with (6.1) prior to instllation or
preparations for installation of any chemical-resistant lining.
The lining shall be selected in accordance with the previous sections of this PTS, according
to the corrosiveness of the fluid to be contained.
4.9
4.9.1
Pump foundations
For chemical-resistant protection of reinforced concrete pump foundations, typical details
are shown on Standard Drawing S 19.071.
The membrane of the floor and that of the pump foundation shall be continuous. The
membrane shall also be continuous under the pump base.
Special care shall be taken where bolts penetrate the membrane construction, i.e. that no
aggressive medium can penetrate along bolts to behind the membrane and/or that no
sharp edges of the pump-base or ceramic materials can damage the membrane.
The sides and top of the pump foundation shall be protected by the same lining as the floor
on which it is placed.
Acid-resistant bricks or tiles shall be applied to the pump foundation membrane, as
described for chemical-resistant floors in (4.3).
For pump foundations exposed to petrochemical solvents, the directions given in (4.3) shall
be followed.
If the floor is provided with a trowelling compound, the pump foundations shall have the
sides and top protected with the same material and construction.
On the top of the foundation the trowelling compound shall have a liquid-tight joint with the
grouting of the pump.
If the floor is painted (4.3.4), the whole pump foundation shall be treated with the same
paint system.
4.9.4
Figure 4-4:
5.
6.
LINING INSTALLATION
6.1
6.2
EXPANSION JOINTS
The expansion joint provided in the reinforced concrete structure (4.4.3) shall be filled with
semi-rigid polyurethane foam, insulation cord, or other appropriate material. Concrete fill
shall be applied on top of the concrete to provide the required slope for drainage and shall
have a gap at the same location, and of the same width, as the joint.
The joint shall be sealed with a plastic, e.g. polyisobutylene foil 3 mm thick, or other
suitable material.
The foil shall be installed as shown in Standard Drawing S 19.051, and adhesive-bonded to
the substrate; the adhesive should be of a bituminous or rubber type. The membrane and a
layer of bricks or tiles shall then be applied, keeping the joint open.
The joint shall then be cleaned (up to the joints backing material) and filled with a chemical/
temperature resistant elastic sealing compound.
6.3
MEMBRANES
Membranes, other than (6.3.1), shall be clean and free of dust, oil, grease or other
contaminants.
6.3.1
6.3.2
Thermoplastic membranes
Before the membrane is adhesive bonded to the concrete surface, the latter shall be
prepared in accordance with the Manufacturer's instructions. A primer shall be applied to
the concrete surface if required.
The membrane shall not be applied at substrate or ambient temperatures below 5 C.
6.3.3
Thermosetting membranes
The cement skin of the concrete surface shall be removed by means of grit blasting and the
surface shall be freed of grit and loose debris.
The cleaned/rough surface shall be given an epoxy-resin-based primer, and then within
24 hours the epoxy resin and the glass fibre reinforcement (if any) shall be applied to the
specified thickness.
An epoxy membrane shall not be applied during rain if the surface is not suitably protected,
or at substrate/atmospheric temperatures below 10 C.
6.4
MORTARS
6.4.1
General
The mortar shall be mixed in accordance with the Manufacturer's instructions. The tools
and mixer shall be clean and dry. Specific constituents to be used for mixing a certain type
of mortar shall never be mixed with constituents for other type of mortars.
Mortars shall not be applied under freezing conditions.
As the setting time of most resin-based mortars is influenced by atmospheric conditions,
special attention should be paid to the Manufacturer's instructions.
Prior to the application of mortars directly to a concrete and/or brickwork substrate, the
surfaces shall be made liquid-tight with an adequate primer. Additional sanding may be
required to improve adhesion of subsequent mortar layers.
6.4.2
The mortar used as bedding mortar should normally have a cement/sand ratio of 1 : 3 by
volume.
6.4.3
6.4.4
6.4.5
6.4.6
6.5
6.5.1
6.6
6.6.1
General
Concrete floors to be provided with jointless flooring shall have an even, smooth surface,
prepared in accordance with (6.1) and shall be at least 6 weeks old prior to application of
the flooring.
To obtain good adhesion between the flooring and the concrete, the latter shall be sealed
with one or more coats of an unfilled solvent-free resin primer. In general the unfilled liquid
component of the flooring compound is used as a primer.
6.6.2
6.6.3
6.6.4
6.6.5
7.
8.
QUALITY CONTROL
The installation of chemical-resistant linings on concrete constructions is critical for the
reliability of these structures.
The required properties of the chemical-resistant materials and the sampling and testing
requirements are specified in Appendix 1.
The application of chemical-resistant linings involves several distinct steps from design to
installation. Lack of quality control in any of these steps could lead to complete failure of the
lining. It is therefore of vital importance for a quality control procedure to be established for
each chemical-resistant lining application, covering all aspects from material selection up to
and including final inspection of the installed lining.
This principal procedural aspects of quality control which should be covered as a minimum
are as follows:
Base material selection
Manufacturing of materials
Inspection, testing
Design
Installation/application
Completed lining
Lining repairs
The Contractor shall set up an appropriate quality control programme addressing at least all
steps described above.
The Contractor shall provide Suppliers and Applicators with sufficiently detailed
specifications for each of their specific activities. In particular the demarcation of
responsibilities and the smooth hand-over between the parties involved should be duly
covered in the quality assurance programme.
Lining details shall be included on drawings. They may also be provided by equipment
suppliers. Any conflicting requirements shall be investigated by the Contractor and referred
to the Principal for resolution before quoting for the work or proceeding with the lining
execution.
The properties and applications shall be tested in accordance with ISO or equivalent
standards. All chemical-resistant materials shall be tested by a recognised laboratory,
experienced in testing refractory materials.
For the applicable testing standards for ceramic materials, refer to PTS 64.24.32.30, Table
3-1.
9.
Test method/criteria
Surface condition/
Visual examination
Adhesion
No surface defects.
Porosity
Thickness 1)
Curing
Check by careful
knocking.
No lack of adhesion.
Visual examination.
No porosity.
Physical measurement.
No softening after 1 minute
rubbing with acetone.
Membrane material
Asphaltic bitumen
Plastics
(3.1.2)
(3.1.3/3.1.4)
x
x
x 2)
Pull-off tests and holiday testing of plastic membranes shall be done in accordance with
PTS 30.48.60.10
During application of the membrane, inspection shall be carried out and due attention
should be paid to the following points:
sufficient adhesive shall be applied;
the membrane shall be applied without air inclusions or other visible defects;
NOTE: In pits or tanks final inspection can be carried out after hydraulic or vacuum testing.
10.
When a defect is detected, repairs shall be carried out immediately in order to prevent serious attack
of the concrete substrate.
The main defects are spalling of the bricks or tiles, erosion effects, cracks in the lining and
degradation of the chemical-resistant lining materials.
Spalling of the brick lining may be due to:
inadequate brick quality, e.g. composition, porosity;
exposure to exceptional operating conditions, e.g. thermal, chemical or other loads more
severe than those foreseen;
local spalling by the impact by a falling object.
Damaged areas or spots shall be opened up to sound material and shall be repaired by
replacement with new material, either of the original quality or of another quality, providing
the latter is fully compatible with the adjacent original material with respect to physical and
chemical properties.
If the effects of erosion or attack by chemicals are slight, the joints can be repaired by
means of scraping out to sound material and filling with fresh mortar. If the depth of the
scraped-out joint is 75% or more of the thickness of the brick layer, all the cement in the
joint shall be removed and replaced. If necessary the bricks shall be re-laid, for which
purpose a sufficient number of bricks shall be taken out to restore the brick lining
configuration.
If cracks in the lining are present, they shall be opened completely to establish the
condition of the membrane and/or substrate. Care shall be taken not to extend the damage
by removing the affected parts.
Degradation of the lining materials may indicate excessive chemical attack. The chemical
conditions causing the degradation shall be established and appropriate countermeasures
shall be taken.
If defects other than those described above are found, their cause should be determined
and the construction reviewed to avoid further attack of the concrete construction.
11.
REFERENCES
In this PTS, reference is made to the following publications:
NOTE:
Unless specifically designated by date, the latest edition of each publication shall be used, together
with any amendments/supplements/revisions thereto.
PETRONAS STANDARDS
Index to PTS publications and standard
specifications
PTS 00.00.05.05
PTS 00.00.06.06
PTS 30.10.02.13
PTS 30.48.00.31
PTS 30.48.60.10
PTS 30.48.60.13
PTS 34.14.20.31
PTS 34.19.20.31
PTS 44.24.90.31
PTS 64.24.32.11
PTS 64.24.32.30
STANDARD DRAWINGS
Note:
S 19.050
S 19.051
S 19.052
S 19.055
S 19.060
S 19.062
S 19.065
Detail of foundation
S 19.071
GERMAN STANDARDS
Chemical equipment; building materials for bricklining, classification, properties, testing
Issued by:
Beuth Verlag GmbH
Burggrafenstrae 4-10,
1000 Berlin 30,
Germany
DIN 28062
INTERNATIONAL STANDARDS
Refractory products; Measurement of dimensions
and external defects of refractory bricks:
Part 1: Dimensions and conformity to
drawings
ISO 12678-1
ISO 12678-2
Issued by:
International Organisation for Standardization
1, Rue du Varemb
CH-1211 Geneva
Switzerland
Copies can also be obtained from national standards
organizations
12.
BIBLIOGRAPHY
NOTE:
The documents listed in this Bibliography are for information only and do not form an integral part of
this PTS.
NACE RP0892
NACE RP0591
Issued by:
NACE International
1440 South Creek Drive
Houston, Texas 77084
USA
ISBN-0-89573-370-6
APPENDIX 1
1.
GENERAL
This specification provides the requirements for the physical properties of chemicalresistant lining materials for application in both process equipment and concrete structures,
including the testing and acceptance criteria for these materials.
Unless otherwise specified, acid-resisting materials shall be selected in accordance with
DIN 28062. The properties of ceramic materials shall be tested in accordance with the
standards shown in Table 3-1 of PTS 64.24.32.30 They shall meet the requirements of the
purchasing documents.
Sampling and dimensional control shall be done in combination with PTS 44.24.90.31,
appendix 2.
For (acid-resistant) refractory bricks and shapes reference is made to PTS 44.24.90.31
2.
2.1
MEMBRANES
Membranes shall be continuous, vapour-tight and resistant to the chemicals to which they
may become exposed.
It is stressed that the optimum properties of the membranes are achieved only when
installed in accordance with the appropriate installation specifications.
2.1.1
Asphaltic bitumen
Asphaltic bitumen membranes not subject to mechanical loads shall be made of blown
bitumen, i.e. a softening point 115 C and a penetration depth of 0.5 mm at 25 C, without
fillers and consisting of a 6 mm dry film thickness layer.
Asphaltic bitumen membranes, designed to sustain mechanical loads in service and
consisting of a 20 mm dry film thickness layer, shall be prepared as follows:
A filler shall be made by mixing 80 parts by weight of river sand (passing a sieve
opening of 2 mm or finer) and 20 parts by weight of fine quartz powder, of which at
least 75% should pass a sieve opening of 75 m or finer.
12 to 13 parts by weight of asphaltic bitumen, i.e. penetration range 2 - 3 mm, shall
be added to 100 parts of filler, and the components shall then be heated to 200 C
and properly mixed.
If required a primer shall be provided under a membrane of asphaltic bitumen.
NOTE: Belgian Shell or Synthasco Bouwchemie B.V., NL could be contacted for availability and/or equivalent
bituminous materials.
2.1.2
Thermoplastics
Thermoplastic membranes are principally based on polyisobutylene. They may be used for
membranes on concrete surfaces, depending on the required chemical and temperature
resistance.
The polyisobutylene sheet shall meet the following requirements:
colour
: black
: minimum
1.5 mm
thickness
density
: minimum
1.4 kg/dm3
tensile strength
: minimum
2 N/mm2
elongation
: minimum 300 %
The minimum required thickness is 5 mm.
The maximum allowable operating temperature is 70 C.
If the use of proprietary systems is considered, approval from the Principal shall be
obtained.
2.1.3
Thermosetting materials
Resins based on epoxy, polyurethane, furane, phenol, polyester and acrylic may be used
for membranes on concrete surfaces, depending on the required chemical and temperature
resistance.
Properties are dependent on the type of resin, type of filler or pigment, curing agent, curing
method and the possible use of fibrous reinforcements (e.g. glass fibre). The Manufacturer
shall state the composition.
The average thickness of this membrane should be 5 mm, with a minimum of 3 mm.
The in-service temperature resistance of glass fibre reinforced synthetic-resin systems
ranges from -40 C up to +140 C.
No additional fillers or pigments etc. shall be used in membranes, except where a resinbased membrane is used as a final (concrete) surface finish.
2.2
2.2.1
Hydraulic cement
Hydraulic cements, based on Portland clinkers, blast furnace slag or high aluminium oxide
containing raw materials, shall be in accordance with PTS 34.19.20.31 or internationally
accepted standards.
2.2.2
2.2.3
on addition of suitable catalysts. Furane based resins shall contain less than 1% of free
furfural.
The operating temperature limit of furane resin cement is approximately 140 C.
Polyester resin
Mortars based on (unsaturated) polyester resin are supplied in two or more
components, i.e. liquid resin, catalyst, accelerator, filler, etc., which shall be mixed
together.
The addition of inert fillers such as graphite to the mortar extends its resistance even to
hydrofluoric acid and its resistance against alkalis increases.
The operating temperature limit of polyester resin based mortars is 120 C.
Epoxy resin
Mortars based on epoxy resin are supplied in two or more components.
Various formulations will have different properties, according to the different curing
agents used.
The temperature limit of epoxy resin based mortars is 110 C.
2.2.4
2.3
2.3.1
Usually the Al2O3 content is between 15 and 30% by weight, but if kept below 10% by weight
an improved chemical resistance will be achieved. Conversely, the chemical resistance will
decrease at an Al2O3 content higher than 30% by weight .
Acid-resistant bricks and tiles (including 'Glover' bricks) shall be in accordance with
DIN 28062 type 1.1.2. For convenience a summary is given in section 5 of this appendix.
Unless otherwise specified acid-resistant bricks and tiles with an apparent porosity of 5%
maximum, which are resistant against all acids except hydrofluoric acid (HF), shall be used.
Additionally this type of brick has a good resistance to solutions of alkalis up to 20% by
weight at room temperature, but will not withstand stronger concentrations, especially
under hot conditions. For such conditions, carbon or graphite bricks should be used.
In order to provide thermal shock resistance, acid-resistant bricks with a higher apparent
porosity than 12% and lower chemical resistance, such as red or blue acid-resistant bricks,
may be used. The use of these bricks is subject to approval of the Principal.
Brick and tiles for accessible/passable floors shall be furnished with an adequate anti-slip
provision or profiled surface.
2.3.2
2.4
Carbon bricks are porous but they can be made liquid-tight by impregnating them with synthetic resins
during the manufacturing process. Impregnation does not significantly change the thermal conductivity
of the material, but it does improve its strength.
3.
3.1
3.1.1
Properties
The selected bricks and tiles shall be tested for the following properties:
bulk density;
water absorption;
cold crushing strength, at ambient temperature;
acid resistance, (once per order);
content of fluxes, (once per order);
Refer to PTS 64.24.32.30, Table 3-1 ("Reference Table for Testing") for appropriate ISO,
ASTM, DIN and JIS testing standards.
The acceptance criteria for the above tests shall be based on the Manufacturer's data and
shall be agreed in the order.
3.1.2
3.1.3
Laminations
None
Texture
Dimensional tolerances
DIMENSIONAL TOLERANCES:
Length
+/- 1%
Width
+/- 1.5%
Thickness
+/- 1.5 mm
Taper
+/- 1.5 mm
Warpage
(See Note)
350 mm
> 350 mm
Assemblies
The mortar joints of assembled shapes shall not be larger than 3 mm.
Shapes of one set shall be clearly marked with a set number, followed by a
sequential number.
The tolerances for the main dimensions shall be stated on the drawing(s) or
purchasing documents.
NOTE: Warpage is expressed as the largest deviation from a straight line across the
diagonal of a brick face
4.
for safe handling. The cements should not be stored longer than the period indicated by the
Manufacturer, generally about 6 months.
After this period their use shall be permitted only when a new and complete recheck has
indicated that the products are in accordance with the original specification.
Cements from different Manufacturers shall not be mixed.
5.
5.1
Maximum
temperature
C
70
70
Butyl rubber
120
Polyisobutylene
100
Silicate-based cement
Synthetic-resin-based cement
Note:
Poissons Modulus of
Thermal
ratio
Elasticity conductivity
MPa
W/(m.K)
Thermal
expansion
10-5/K
0.5
3500
0.3
2.0
110 1)
0.3
1.2 x 104
0.29
2.0
5 - 10
900
0.5
5 - 10
180 1)
0.6
5.2
Silicatebased
cements
kg/m3 1900 - 2500 2200 - 2500 2200 - 2500 2800 - 2900 1400 - 1600 1600 - 1800 1600 - 1700 1700 - 1900 1800 - 2000
Water absorption
4 - 10
Apparent porosity
Acid resistance
2.5 - 8
Coefficient of thermal
expansion
10-5/K
Specific heat
Thermal conductivity
0 - 3.0
Synthetic-resin-based cements
Phenolic &
Furane
Polyester &
Epoxy
1400 - 2100
1500 - 2100
0.05 max.
18 - 22
17 - 19
0 - 10
6 - 10
0.3 - 3.0
0.1 - 0.5
18
20
12
0.3 - 0.8
0.5 -1.0
0.5 max.
0.5 max.
0 - 10
0.5 max.
0.5 max.
0.5 - 0.6
0.4 - 0.55
0.4 - 0.7
0.6 - 0.8
0.3 - 0.5
0.35 - 0.5
0.18 - 2.0
0.35 - 0.4
1.0 - 1.2
2.0
3.0
J/(kg.K)
800 - 840
750 - 840
800
670 - 1090
800 - 1170
670 - 1090
800 - 1170
W/(m.K)
0.9 - 1.3
1.3 - 1.6
1.2 - 3
1.0 - 1.2
1.7 - 7.0
1.7 - 7.0
90 - 140
90 - 140
1.63
1.6
1.1
50 - 150
100-500
350 - 650
450 - 550
20 - 40
90 - 110
25 - 40
80 - 100
15 - 29
25 - 60
at 300C
Compressive strength
MPa
Tensile strength
MPa
12
15
Flexural strength
MPa
10 - 20
30 - 90
40 - 160
30
8 - 12
25 - 35
10 - 20
25 - 35
Modulus of elasticity
GPa
20 - 40
45 - 60
50 - 80
100 - 120
5 - 15
10 - 25
5-9
9 - 16