Design and Inspection of Refractory Materials for Refineries, Power Generation and Petrochemical Plants
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Design and Inspection of Refractory Materials for Refineries, Power Generation and Petrochemical Plants Course
Introduction:
In this course, participants will explore the design, installation, inspection, and repair of refractory systems used in pressure vessels, piping systems, and fired equipment for processing and power generation applications. Practical examples of refractory systems in demanding applications, including FCCUs, Fluid Cokers, process vessels, fired heaters, and steam generation equipment, will be discussed and supplemented with photos and videos.
The course will present these topics in alignment with the API Recommended Practice 936 Guidelines for Refractory Installation Quality Control. By the end of the course, attendees will be well-prepared to undertake the API 936 Inspector certification exam.
Course Objectives:
This Five-day course will provide an intensive overview of refractory materials used in refineries, power generation, and petrochemical facilities consistent with the body of knowledge contained in API 936.
Who Should Attend?
This course is intended for individuals who are responsible for the design, installation, inspection, or repair of refractory systems in refinery, power generation and petrochemical applications.
Course Outlines:
Introduction
- API 936 Overview
What Are Refractory?
- Definition
- Functions
- Insulation
- Corrosion Resistance
- Erosion Resistance
- Types of Refractories
- Ramming Mixes
- Plastics
- Gunning Mixes
- Castables
- Trowelling Mixes and Mortars
- Brick
- Ceramic Fiber
- Block Insulation
Raw Materials
- Aggregate
- Bonding Mechanism Phosphate (Acid) Bond
- Cement (Hydraulic) Bond
- Clay
- Sodium Silicate
- Curing & Drying
Physical Properties of Refractory Materials and Test Procedures
- Bulk Density
- Compressive Strength
- Tensile Strength (Modulus of Rupture)
- Erosion Resistance
- Heat Resistance
- Thermal Conductivity (How to Use K-Stick)
- Thermal Expansion
Refractory Failure Mechanisms
- Erosion
- Corrosion
- Thermal Shock
- Mechanical Abuse
- Overheating
- Atmospheric Reaction/Chemical Attack
Factors Affecting Refractory Performance
- Product Quality
- Anchoring Design
- Installed Quality
- Installation Procedures
- Unit Operation
- Material Specification
- Experience of Applicator/Crew
Benefits of Using Metal Fiber Reinforcement
- Randomized Cracking
- Holding Lining in Place, if Cracking Occurs
Refractory Linings for Miscellaneous Equipment
- Sulfur Recovery Unit
- Tail Gas Cleanup Unit
- Feed Fired Heater
- Flue Gas Cooler & Stack
- Fluid Coker
- Hydrogen Furnace
- FCCU
- Concrete/Gunite Lined Drums
Introduction to the API RP 936
- Documentation (2.1)
- Material Qualification (2.2)
- Applicator Qualification (2.3)
- Installation Monitoring (2.4)
- As-installed Testing (3.1)
- Pre-dryout Inspection
- Dryout Monitoring (4.2)
Pre-Turnaround Planning (At least 6 Months Prior to Turnaround)
- Review of Past Inspection Reports, Repairs, Quality Control Records and
- Recommended Future Repair Priority Areas.
- Review of Unit Operation since the Last Major Turnaround.
- Review of Refractory Material Types Needed for Unit Repairs.
- Review of a Thermographic Survey from the Beginning of Operation as compared with One of Current Operation.
- Formulation of Plan.
- The Benefits o