Certified Refractory Professional
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Program Professional Framework
Certified Refractory Professional
Program Overview
Refractory linings protect fired heaters, sulphur recovery units, FCC units, reformers, boilers and incinerators from extreme heat, erosion and chemical attack, and their failure can force unplanned shutdowns. This course covers refractory materials and selection, including dense and insulating castables, bricks, plastics and ceramic fibre; anchoring systems; installation by casting, gunning and ramming; curing and dry-out; and quality control of installation, inspection and testing in line with API Standard 936. Participants also study failure mechanisms and turnaround inspection, using examples from refineries, gas plants and petrochemical complexes in the GCC.
Learning Outcomes
- ✓Select refractory materials and lining designs for given temperature, chemical and abrasion conditions.
- ✓Specify anchor types, spacing and materials for monolithic linings.
- ✓Define installation, curing and dry-out requirements for castable and gunned linings.
- ✓Prepare a quality control plan with material qualification and production tests consistent with API Standard 936.
- ✓Inspect in-service linings and identify failure mechanisms such as spalling, erosion, shrinkage and chemical attack.
- ✓Recommend repair methods and acceptance criteria during a turnaround.
Target Audience
- Refractory inspectors and QA/QC engineers
- Static equipment and mechanical engineers in refineries and gas plants
- Maintenance and turnaround engineers
- Supervisors of refractory contractors
Detailed Program Modules
01Refractory Applications in Process Plants
- Fired heaters, SRU thermal reactors, FCC units and reformers
- Operating conditions and service demands
- Consequences of lining failure
02Refractory Materials and Selection
- Dense and insulating castables, bricks and plastics
- Ceramic fibre and multi-component linings
- Key properties and product data sheets
03Lining Design and Anchoring
- Lining thickness and heat flow considerations
- Metallic and ceramic anchor systems
- Expansion allowance and joints
04Installation Methods
- Casting, pumping, gunning and ramming
- Mixing water control and ambient conditions
- Curing and dry-out schedules
05Quality Control and Testing
- Material qualification and production test panels
- Cold crushing strength, density and abrasion testing
- Inspection hold points and records under API Standard 936
06In-Service Inspection and Repair
- Failure mechanisms and hot spot investigation
- Turnaround inspection and repair techniques
- Documentation and lessons learned
Training Methodology
Applied Project & Assessment
Applied Project
Participants develop a refractory installation and quality control plan for a fired heater or SRU repair at a GCC plant, covering material selection, anchoring, installation method, test requirements, hold points and the dry-out schedule.
Assessment
Short diagnostic at the start, practical tasks linked to each learning outcome, and evaluation of the applied project against published criteria.