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

• • 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