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1、TECHNICAL SPECIFICATION CHEMICAL-RESISTANT (CERAMIC) LINING MATERIALS DEP 30.48.60.33-Gen. May 1993 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 third party with
2、out 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 this documen
3、t 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. PREFACE DEP (Design and Engineering Practice) publications reflect the views, at the
4、 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 are based on the experience acquired during their involveme
5、nt with 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, national and international standards and codes of practice. The ob
6、jective is to set the recommended standard for good design and engineering practice applied by Group companies operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any other such facility, and thereby to achieve maximum technical and economic bene
7、fit 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 condition at each locality. The system of DEPs is expected to
8、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 the quality of work and the attainment of the required desi
9、gn 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 DEPs. If in doubt, the Contractor or Manufacturer/Supplier
10、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/Shell Group and other companies receiving technical advice
11、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 companies is subject in all respects to the terms and conditio
12、ns 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 2) which requires that tenders for projects, materials su
13、pplied 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 liability of whatsoever nature for any damage (including injury
14、 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 to SIOP, SIEP, SIC and/or any company affiliated to thes
15、e 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 disclosed by users to any company or person whomsoever and
16、 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. The copyright of DEPs vests in SIOP and SIEP. Users sha
17、ll 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 Administrator in SIOP. NOTE: In addition to DEP publications t
18、here 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 distribution and use of DEPs are also applicable to Standard Spec
19、ifications and DDDs. Standard Specifications and DDDs will gradually be replaced by DEPs. DEP 30.48.60.33-Gen. May 1993 Page 2 TABLE OF CONTENTS 1.INTRODUCTION.4 1.1SCOPE 4 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS4 1.3DEFINITIONS 5 1.4CROSS-REFERENCES5 2.MATERIALS FOR MEMBRANES.6
20、2.1GENERAL 6 2.2ASPHALTIC BITUMEN6 2.3THERMOPLASTICS6 2.4THERMOSETTING MATERIALS6 2.5LEAD 6 3.CHEMICAL RESISTANT CEMENTS7 3.1HYDRAULIC CEMENTS.7 3.2SILICATE BASED CEMENTS.7 3.3SYNTHETIC RESIN BASED CEMENTS7 3.4(EPOXY) PAINT SYSTEMS7 4.CERAMIC AND CARBONACEOUSMATERIALS.8 4.1GENERAL 8 4.2ACID RESISTAN
21、T BRICKS AND TILES.8 4.3CARBON AND GRAPHITE BRICKS AND TILES.8 4.4SPECIAL CERAMIC LINING MATERIALS.9 5.SAMPLING, TESTING AND INSPECTION10 5.1TESTING OF PROPERTIES.10 5.2VISUAL INSPECTION OF MANUFACTURING DEFECTS11 5.3DIMENSIONAL TOLERANCES11 6.PACKAGINGAND STORAGE.12 7.REFERENCES13 APPENDICES. 15 AP
22、PENDICES APPENDIX 1TYPICAL VALUES FOR MECHANICAL AND PHYSICAL PROPERTIES OF CHEMICAL-RESISTANT LINING MATERIALS.16 APPENDIX 2COMPARISON OF THE CHEMICAL RESISTANCE OF VARIOUS MATERIALS AT 20 C.17 DEP 30.48.60.33-Gen. May 1993 Page 3 1.INTRODUCTION 1.1SCOPE This DEP provides requirements for chemical-
23、resistant lining materials for application in both process equipment and concrete structures. It is a revision of the previous DEP of the same number dated December 1980. It principally covers the ceramic types of lining materials (e.g., bricks, tiles and mortars) and their underlying membranes, but
24、 also covers non-ceramic linings such as synthetic resin- based systems. Chemical resistant ceramic linings are used to protect concrete elements (such as floors and gutters) and steel process equipment (including connecting piping systems) against chemical attack. A combination of a ceramic lining
25、and a membrane is mostly used for this purpose. The ceramic lining serves to protect the membrane against chemical, mechanical and/or thermal loads (e.g. scaffolding, steam cleaning). The membrane is to prevent penetration of chemicals to the underlying concrete or steel surface. It is not the inten
26、tion to provide in this DEP detailed material specifications for 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 Principal, Contractor, Manufacturer and Applicator, leading to a durab
27、le protection of concrete structures and steel process equipment 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 mentione
28、d in various cases. A summary of the mechanical and physical properties required for the various materials is given in Appendix 1. For a comparison of the chemical resistance between the materials, reference is made to Appendix 2 and DEP 30.10.02.13-Gen. The design and installation of chemical resis
29、tant linings for concrete structures is covered in DEP 30.48.60.12-Gen. The design and installation of chemical resistant brick linings for process equipment is covered in DEP 30.48.60.13-Gen. and DEP 30.48.60.23-Gen. Excluded from the scope of this DEP are rubber lining materials, for which referen
30、ce is made to DEP 30.48.60.10-Gen. and DEP 30.48.60.30-Gen. Also excluded from the scope ofthisDEParerefractorybricksandshapes,forwhich referenceismadeto DEP 44.24.90.31-Gen. 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorised by SIPM, the distribution of this doc
31、ument 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 instal
32、lations 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 require
33、ments 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 then
34、 negotiate with the Authorities concerned with the object of obtaining agreement to follow this document as closely as possible. 1.3DEFINITIONS For the purpose of this DEP, the following definitions shall hold: DEP 30.48.60.33-Gen. May 1993 Page 4 The Applicator is the party which applies the chemic
35、al 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 M
36、anufacturer/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 re
37、quirements. 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. 1.4CROSS-REFERENCES Where cross-references are made, the number of the section or sub-section referred to is sho
38、wn in brackets. All publications referred to in this document are listed in (7). DEP 30.48.60.33-Gen. May 1993 Page 5 2.MATERIALS FOR MEMBRANES 2.1GENERAL Membranes shall be continuous, vapour tight and resistant to the chemicals to which they may become exposed. It is stressed that the optimum prop
39、erties of the membranes are achieved only when installed in accordance with the appropriate installation specifications. 2.2ASPHALTIC BITUMEN Asphaltic bitumen membranes not subject to mechanical load shall be made of blown bitumen, “Mexphalte “ R 115/5, without filler. The dry-layer thickness shall
40、 be at least 6 mm. Asphaltic bitumen membranes designed to sustain mechanical loads in service 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
41、% should pass a sieve opening of 75 micron or finer. 12 to 13 parts by weight of “Mexphalte“ 20/30 shall be added to 100 parts of filler, the components shall then be heated to 200 C and properly mixed. The dry-layer thickness of this filled membrane shall be at least 20 mm. Shell Pipe Primer shall
42、be used if a primer is required under a membrane of asphaltic bitumen. NOTE:Mexphalte and Shell Pipe Primer are Shell products. Alternate materials may be used subject to approval of the Principal. 2.3THERMOPLASTICS Almost all of the thermoplastic membranes are based on polyisobutylene. They may be
43、used for membranes on concrete surfaces, depending on the required chemical and temperature resistance. For alternatives the Principal shall be consulted. The polyisobutylenesheet shall meet the following requirements: colour: black thickness: minimum 1.5mm density: minimum 1.4kg/dm3 tensile strengt
44、h: minimum 2N/mm2 elongation: minimum 300 % 2.4THERMOSETTING MATERIALS Resins, based on epoxy, polyurethane, furane, phenol, polyester and acrylic may be used for membranes on metallic and concrete surfaces, depending on the required chemical and temperature resistance. Properties are dependent on t
45、he 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. In the case of membranes, no additional fillers or pigments etc. shall be used, except for those cases where a res
46、in-based membrane is used as a final (concrete) surface finish. 2.5LEAD Lead may be used as a material for membranes in process equipment, in which case they should be homogeneous lead membranes. The material shall be in accordance with DIN 28062 type 3.1. DEP 30.48.60.33-Gen. May 1993 Page 6 3.CHEM
47、ICAL RESISTANT CEMENTS 3.1HYDRAULIC CEMENTS These hydraulic cements , based on Portland clinkers, blast furnace slags or high Alumina raw materials, shall be in accordance with DEP 34.19.20.31-Gen. or internationally accepted standards: 3.2SILICATE BASED CEMENTS Sodium silicate, potassium silicate a
48、nd silica cements shall be in accordance with DIN 28062 type 2.2. 3.3SYNTHETIC RESIN BASED CEMENTS These cements shall be in accordance with DIN 28062 type 2.3. The main types are filled phenolic, furane, polyester and epoxy resin-based cements. Furane based resins shall contain less than 1% of free
49、 furfural. 3.4(EPOXY) PAINT SYSTEMS Paint systems are applied where aggressive products are incidentally present, e.g. on concrete constructions in plants, chimneys, and on dry or wet floors, where chemicals may be spilled. The 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 and the Principal shall be consulted . Paint systems shall not be used for protection against continuous chemical attack, not even for mildly aggressive con
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