COURSE OVERVIEW:

Industrial operations involving extreme temperatures rely heavily on the integrity of refractory systems to prevent vessel wall melting and thermal energy loss. This course provides a foundational understanding of how refractory systems are designed and the common ways they deteriorate in service. By understanding these fundamentals, plant personnel can better predict when a system is nearing its end of life and plan for necessary interventions.

The scope of this training covers the mechanics of refractory degradation, including thermal shock, chemical attack, and mechanical erosion. Participants will explore the various failure modes specific to different industrial environments such as furnaces, kilns, and boilers. We will discuss the critical indicators of refractory distress and the tools used to monitor lining health without taking the equipment offline.

Coverage includes the strategic planning of refractory repairs, from minor patching to complete relining projects. The curriculum focuses on choosing the right repair methodology and material to match the existing system and the expected service conditions. By mastering these concepts, delegates will be able to extend the uptime of their high-temperature assets and ensure that repairs are executed with technical integrity.

COURSE OBJECTIVES:

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

• Describe the thermal and mechanical properties of various refractory materials.
• Identify the primary failure modes of refractory linings in process equipment.
• Analyze the impact of thermal cycling and thermal shock on refractory life.
• Recognize the signs of chemical degradation and slag attack on refractories.
• Plan effective inspection programs for offline and online assessments.
• Use infrared thermography to identify refractory hot spots and thin areas.
• Evaluate the severity of refractory cracks, spalling, and bulging.
• Select appropriate repair materials for different types of refractory damage.
• Develop detailed repair procedures for monolithic and brick linings.
• Coordinate the logistics and resource requirements for major relining projects.
• Assess the feasibility of "hot repairs" versus scheduled cold shutdowns.
• Implement preventative measures to minimize future refractory failures.

TARGET AUDIENCE:

This course is suitable for Plant Maintenance Engineers, Reliability Professionals, Refractory Supervisors, Operations Managers, and Process Engineers who manage high-temperature equipment.

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.