API 936 - Refractory Material Design, Application, Installation and Inspection

M. El-Sayed Mahmoud Shama

API 936 - Refractory Material Design, Application,  Installation and Inspection


API 936 Refractory Technology: Refractory technology has changed significantly in recent years as new monolithic refractory materials have replaced brick in many industries. Vibratable and pumpable castables with superior properties, as well as significantly improved brick, ceramic fiber products, and other items, make optimum refractory selection complex.

Advanced construction methods must be utilized if these improved materials are to achieve their maximum service life.  This course includes a review of refractory fundamentals while emphasizing selection and construction techniques for a variety of applications in refineries, chemical plants, industrial furnaces, incinerators, and utility boilers.

The API 936 covers practical guidelines for inspecting and repairing existing linings, criteria for field testing and accepting new installations, and vendor certification of materials prior to shipment.

Day 1

  • Registration and Coffee
  • Welcome and Introduction
  • Pre – Test
  • Introduction of Refractories:
Types and Classifications
Test Procedures
Effects of Additives
Why Chemistry alone is not a Critical Factor
Phase Relationships
Fracture Mechanics


  • Refractory Inspection and Quality Control:
Acceptance / Rejection Criteria
Sampling and Testing
Records and Reports
Refractory Quality Control
Material and Installer 
Certification
  • Case Study:
  • Brick Failure
  • Cracking in Monolithic Lining

Day 2

  • Monolithics:
Casable and Plastic Refractories
Compositions and Properties
Achorage
Design and Installation
Effects of Firing on Strength and Thermal Properties
  • Case Study: 
  • SRU Brick Lining
  • Acid Gas Incinerator Refractory Damage

Day 3

  • Refractory Installation Techniques:
Modern Refractory State-of-the-Art
Self-Flow, Vibe/Pump Cast, Gunite/Shotcrete, 
Rammed Plastics
Precast Modules
Storage & Handling
Joints
Maintenance Practice
  • Refractory Repairs:
Failure Analyses
Structual (Anchors, Erosion)
Chemical (Proces Reactions, Slag Attack)
Thermal (Impingement, Spalling, Fusion)
  • Case Study:
  • Study Exposure to Thermal Cycle in FCUU
  • Fibber Modules fallen from the Roof

Day 4

  • Furnace Linings:
Design of Various Refractory Lining Types
Thermal Curing and Drying
Explosive Spalling
Effects of Aggressive Atmospheres
  • Refractory Selection Guidelines:
Data Sheet Interpretation
Product Choices for Design Exposures
Castable, Plastic, Fiber and Brick Selection-
Criteria for FCB and MSW
Boilers, Incinerators, Gasifiers and Heaters
  • Case Study: 
  • Failing Brick Walls Deformations or Collapse Castable Cracking

Day 5

  • Refinery Application Refractories:
FCCU Applications
Effects of Coking
Reformers
Transfer Lines
Sulfur Plants
Stacks
Creep Tests
Hot Spot Detection
  • Case Study: 
  • Flare Brick Failure
  • Regeneration Heater H 1301 Accident Result
  • Course Conclusion
  • POST-TEST

What is API 936 training course objective?

  • Upon the successful completion of this course, each participant will be able to:

    • Design, apply, install and inspect refractory materials in a professional manner
    • Describe the refractory types and classification, test procedures, effects of additives and explain why chemistry alone is not a critical factor
    • Emphasize the refractory phase relationships and fracture mechanics
    • Inspect and quality control the refractory that includes acceptance/rejection criteria, sampling and testing as well as material and installer certification
    • Discuss monolithic refractories including castable and plastic refractories, compositions and properties, anchorage, design and installation and the effects of firing on strength and thermal properties
    • Employ the refractory installation techniques including modern refractory state of the art, precast modules, storage & handling, failure analyses, etc.
    • Carryout refractory repairs and design various refractory linings
    • Employ and apply the refractory selection guidelines from data sheet interpretation and product choice for designed exposure
    • Determine and practice the refinery application of refractories including FFCU applications, effects of coking, reformers, transfer lines, Sulphur plants as well as the stacks, creep tests and hot spot detection

Who should join API 936 training course by PetroSync?

This course provide an overview of all significant aspect and considerations of refractory for those who are responsible for refractory design, application, installation, and inspection.

You are also welcome to enroll in our class If you aspire to become an API 936 inspector.

M. El-Sayed Mahmoud Shama

International Certified Trainer

Mohamed Shama is a senior inspection engineer with over 23 years of extensive experience within the petrochemical, refinery, utilities and oil and gas industries.

He conducted training for API Certification Preparatory, Corrosion and Prevention, National Board and ASMPE PCC-2, ASME VIII Division 1 & 2, ASME V, ASME IV, Lifting Equipment Courses, CSWIP 3.2 and 3.1 Welding Courses, Pressure Relief Valves, NDT Techniques Training Courses.

He has experiences and involve in many huge shutdowns in the oil and gas field including supervision of inspectors and technicians and performing internal inspection for all kind of Piping Systems, Pressure Vessels, Tanks, Boilers, Heat Exchangers, Filters, Towers, Coolers, Columns, Drums and Incinerators, Heaters, Driers, Air Vessels, MCHE, Hot Oil Waste Heat Recovery Units, Spheres, ISO-Containers, Bullets and all kind of refractory materials shaped and un-shaped.

  • Code PST0438-202501
  • Start Date 17 Feb, 2025
  • End Date 21 Feb, 2025
  • Locations Kuala Lumpur, Malaysia
  • Cost USD 3285
  • Code PST0438-202502
  • Start Date 21 Apr, 2025
  • End Date 25 Apr, 2025
  • Locations Bandung, Indonesia
  • Cost USD 3285
  • Code PST0438-202503
  • Start Date 02 Jun, 2025
  • End Date 06 Jun, 2025
  • Locations Bandung, Indonesia
  • Cost USD 3285
  • Code PST0438-202504
  • Start Date 21 Jul, 2025
  • End Date 25 Jul, 2025
  • Locations Kuala Lumpur, Malaysia
  • Cost USD 3285
  • Code PST0438-202505
  • Start Date 15 Sep, 2025
  • End Date 19 Sep, 2025
  • Locations Bangkok, Thailand
  • Cost USD 3285
  • Code PST0438-202506
  • Start Date 27 Oct, 2025
  • End Date 31 Oct, 2025
  • Locations Bandung, Indonesia
  • Cost USD 3285
  • Code PST0438-202507
  • Start Date 01 Dec, 2025
  • End Date 05 Dec, 2025
  • Locations Kuala Lumpur, Malaysia
  • Cost USD 3285
  • Code PST0438-202508
  • Start Date 08 Dec, 2025
  • End Date 12 Dec, 2025
  • Locations Bali, Indonesia
  • Cost USD 3485
  • Code PST0438-202301
  • Start Date 04 Dec, 2023
  • End Date 08 Dec, 2023
  • Locations Kuala Lumpur, Malaysia
  • Cost USD 3150
  • Code PST0438-202401
  • Start Date 22 Apr, 2024
  • End Date 26 Apr, 2024
  • Locations Bandung, Indonesia
  • Cost USD 3250
  • Code PST0438-202402
  • Start Date 19 Aug, 2024
  • End Date 23 Aug, 2024
  • Locations Kuala Lumpur, Malaysia
  • Cost USD 3250

   Upcoming Training

Code Start Date End Date Locations Cost Instructor
PST0438-202501 17 Feb, 2025 21 Feb, 2025 Kuala Lumpur, Malaysia USD 3285 M. El-Sayed Mahmoud Shama
PST0438-202502 21 Apr, 2025 25 Apr, 2025 Bandung, Indonesia USD 3285 M. El-Sayed Mahmoud Shama
PST0438-202503 02 Jun, 2025 06 Jun, 2025 Bandung, Indonesia USD 3285 M. El-Sayed Mahmoud Shama
PST0438-202504 21 Jul, 2025 25 Jul, 2025 Kuala Lumpur, Malaysia USD 3285 M. El-Sayed Mahmoud Shama
PST0438-202505 15 Sep, 2025 19 Sep, 2025 Bangkok, Thailand USD 3285 M. El-Sayed Mahmoud Shama
PST0438-202506 27 Oct, 2025 31 Oct, 2025 Bandung, Indonesia USD 3285 M. El-Sayed Mahmoud Shama
PST0438-202507 01 Dec, 2025 05 Dec, 2025 Kuala Lumpur, Malaysia USD 3285 M. El-Sayed Mahmoud Shama
PST0438-202508 08 Dec, 2025 12 Dec, 2025 Bali, Indonesia USD 3485 M. El-Sayed Mahmoud Shama

   Past Training

Code Start Date End Date Locations Cost Instructor
PST0438-202301 04 Dec, 2023 08 Dec, 2023 Kuala Lumpur, Malaysia USD 3150 M. El-Sayed Mahmoud Shama
PST0438-202401 22 Apr, 2024 26 Apr, 2024 Bandung, Indonesia USD 3250 M. El-Sayed Mahmoud Shama
PST0438-202402 19 Aug, 2024 23 Aug, 2024 Kuala Lumpur, Malaysia USD 3250 M. El-Sayed Mahmoud Shama
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