Engineering Design & Analysis, Ltd.

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Design & Inspection of Refractory Materials for Refineries, Petrochemical & Power Generation Plants

This three-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, as well as other key data not covered by the API 936 body of knowledge, but essential for assessment of new and existing refractory installations.

Course Highlights

This course discusses the design, installation, inspection, and repair of refractory systems for processing & power generation applications in pressure vessels, piping systems, and fired equipment. The discussions include practical examples of refractory systems in demanding applications (such as FCCU's, Fluid Cokers, process vessels, fired heaters and steam generation equipment) and are illustrated by photos and video.

The course will present these topics in the context of API Recommended Practice 936 Guidelines for Refractory Installation Quality Control.    Attendees will be well prepared to challenge the API 936 Inspector certification exam upon completion of this course.    This course also goes beyond the simple API 936 requirements to bring a comprehensive understanding of refractories and refractory systems as used in process plant in facilities of the HPI / CPI and PGI industries.

This course is intended for individuals who are responsible for the design, installation, inspection, or repair, managing refractory projects and maintenance of refractory systems in the hydrocarbon processing, chemical & petrochemical, oil sands, heavy oil and power generation industries.

Detailed Course Description

Day I

1 Overview
     · History
     · Codes & Standards
     · API 936 Overview
     · ASTM standards
     · What are Refractories

2 API 936
    1. Scope
    2. Normative References
    3. Terms & Definitions
    4. Quality control elements
    5. Responsibilities
    6. Inspector Qualifications
    7. Materials
    8. Qualification & testing
    9. Installation / Execution
  10. Dryout
         · Appendices

3 API 936 Practice Exam & Review

4 API 936 Practice Exam Discussion

Day II

5 ASTM Standard Test Methods
    · Bulk Density
    · Cold Crushing Strength
    · Modulus of Rupture
    · Erosion Resistance
    · Temperature Resistance
    · Thermal Conductivity
    · Thermal Expansion
    · Permanent Linear Change
    · Thermal Shock & Cycling Resistance

6 Refractory Design & Failures
    · Erosion
    · Corrosion
    · Thermal Shock
    · Mechanical Abuse
    · Overheating
    · Chemical Attack

7 Reducing Failures in Refractory Applications
    · Unit Operation
    · Equipment Design
    · Material Specification
    · Anchor Systems
    · Metal Fibers
    · Design of Installations & Procedures
    · Application Crew Qualifications


8 Design & Evaluation of Refractory Systems
    · Vessels
    · Transfer Lines & Piping
    · Fired Heaters
    · Fired & Unfired Boilers
    · Ducting & Stacks

9 Class Discussions
    · Plant Equipment Problems

10 Case Studies
    · New Installation
    · Wall Failure in Fired Heater
    · Castable versus Plastic
    · FCCU Refractory Failure

The examination is administered by the Professional Examination Service (PES) and takes approximately four hours to complete.   There are 75 multiple-choice questions for this examination.  For more information on examination content please see the Body of Knowledge.  

As of 2014, API certification programs are computer based. Contact API or visit their website at

Contact us for location and registration information;

John Aumuller  P. Eng., Ph. D.