COURSE OVERVIEW:

Refractory materials are vital for protecting high-temperature industrial equipment from thermal degradation and erosion. This practical course is meticulously aligned with the API 936 standard, providing inspectors with the specialized knowledge required to ensure the quality of refractory installations. Without rigorous inspection and testing, even the best refractory materials can fail prematurely, leading to catastrophic equipment damage and unplanned outages.

The scope of this training focuses on the quality control of monolithic refractories, including castables, gunning mixes, and plastics. Participants will learn the critical requirements for material qualification, applicator certification, and on-site installation monitoring. We will examine the technical nuances of anchor systems, moisture management, and the drying out process, which are often the primary causes of refractory failure if not handled correctly.

Coverage includes hands-on techniques for physical testing and visual inspection of refractory linings in vessels, heaters, and FCC units. The curriculum delves into the laboratory testing procedures required by API 936, such as density, cold crushing strength, and permanent linear change. By completing this course, inspectors will be able to verify that refractory systems are installed according to engineering specifications and industry best practices.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Interpret the requirements of the API 936 standard for refractory quality control.
• Identify different types of refractory materials and their specific applications.
• Verify the qualification of refractory materials and installers prior to work.
• Supervise the mixing and application of castable and gunned refractories.
• Inspect anchor patterns and welding quality for refractory support systems.
• Perform on-site quality control tests including hammer testing and visual checks.
• Review laboratory test reports for compliance with project specifications.
• Manage the critical dry-out schedules to prevent explosive spalling.
• Detect common installation defects such as laminations, voids, and cracks.
• Document inspection findings in a clear, standardized reporting format.
• Ensure compliance with health and safety regulations during refractory work.
• Facilitate effective communication between owners, contractors, and inspectors.

TARGET AUDIENCE:

This course is intended for Quality Control Inspectors, Refractory Technicians, Maintenance Engineers, Plant Inspectors, and Project Managers involved in high-temperature equipment maintenance.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.