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
  • Structural (Anchors, Erosion)
  • Chemical (Process 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 ERSSIVE 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