API 936 Refractory Personnel Certification

In this module, learners are introduced to the relevant codes, standards, and references used in conjunction with API 936. The primary focus is on the role of various industry standards, such as those from ASTM, and their application in ensuring the quality and safety of refractory installations. It also covers the essential codes and regulatory frameworks that must be adhered to in the UK and globally.

Key Points:

• Introduction to ASTM standards.
• Understanding the relationship between API 936 and other industry standards.
• Application of regulatory codes in the UK and internationally.

This module provides an in-depth exploration of the different types of refractory materials, including monolithic refractories and castable materials. Learners will discover the physical properties that make each material suitable for different applications, along with the testing and qualification processes that ensure these materials meet the required standards. The importance of material storage and handling, particularly in relation to shelf life and environmental conditions, is also discussed.

Key Points:

• Types and properties of refractory materials.
• Material qualification processes and testing methods.
• Handling and storage of refractory materials, including environmental considerations.

This module outlines the essential elements of a QA/QC programme specific to refractory installation. It explains how quality control is maintained at every stage of the installation process, from material procurement to final inspection. Learners will gain insight into the various tests used to ensure compliance with project specifications, such as cold crushing strength (CCS), permanent linear change (PLC), and abrasion resistance.

Key Points:

• Quality control elements during refractory installation.
• Inspection and test plans (ITP).
• Understanding CCS, PLC, and abrasion resistance testing.

This module details the roles and responsibilities of each party involved in a refractory installation project, including the owner, refractory contractor, inspector, and manufacturer. Each party’s obligations are clearly defined, with a focus on ensuring clear communication and adherence to project specifications. This module highlights the importance of well-documented specifications and execution plans, which are critical to the success of any refractory project.

Key Points:

• Roles of the owner, contractor, inspector, and manufacturer.
• Importance of detailed specifications and execution plans.
• Ensuring accountability and clear communication throughout the project.

This module explores the qualifications necessary for inspectors overseeing refractory installations. It covers the competencies required to carry out quality inspections and ensure compliance with API 936. The module discusses how inspectors are certified, their role in the quality control process, and the responsibilities they hold in ensuring the integrity of the installation.

Key Points:

• Inspector qualification requirements under API 936.
• Inspector responsibilities during installation and testing.
• Ensuring compliance with industry standards.

This module delves into the physical property requirements of refractory materials as outlined in API 936. It covers key tests, such as density, CCS, and PLC, and explains how these properties are critical in ensuring the long-term performance of refractories in demanding industrial environments. Learners will also be introduced to the procedures for conducting these tests and interpreting the results to ensure compliance with specifications.

Key Points:

• Key physical properties of refractories: density, CCS, PLC.
• Procedures for testing physical properties.
• Interpreting test results to ensure material compliance.

In these modules, learners will focus on the qualification testing required for applicators, who are responsible for the installation of refractory linings. These modules emphasise the importance of pre-installation tests, such as gunning and casting qualifications, to ensure that both the applicators and the materials meet the necessary quality standards. Practical examples of gunning and casting methods are discussed, and the importance of documentation and inspection is highlighted.

Key Points:

• Applicator qualification testing.
• Pre-installation simulation and testing for gunning and casting.
• Documentation and inspection requirements.

These modules cover the testing of refractory materials during the production phase. Learners will be introduced to the procedures for collecting samples, performing tests, and ensuring that the materials installed meet the required specifications. The module explains the significance of production testing in verifying the quality of the refractory linings after installation and ensuring they meet durability standards.

Key Points:

• Sampling and testing of installed refractory materials.
• Testing frequencies and allowable defect rates.
• Managing non-compliance and corrective actions.

This comprehensive module covers the installation process for refractory materials, including preparation, gunning, casting, and curing. Learners will be guided through each step, with practical advice on how to avoid common installation issues, such as improper curing or surface preparation. The module also discusses the importance of maintaining environmental controls and adhering to project specifications to ensure the longevity and performance of the installed lining.

Key Points:

• Detailed installation procedures for different refractory methods.
• Surface preparation, gunning, casting, and curing techniques.
• Avoiding common installation errors.

The dryout process is critical to the successful performance of refractory linings. This module explains the procedures and best practices for drying out refractory linings after installation, with a focus on temperature control, holding times, and the prevention of thermal shock. Learners will also explore how improper dryout can lead to cracking, spalling, or other damage to the refractory lining, and the methods used to monitor the dryout process effectively.

Key Points:

• Dryout procedures and best practices.
• Importance of temperature control and monitoring.
• Preventing thermal shock and cracking during dryout.

This final module provides learners with the tools and resources they need to successfully prepare for the API 936 Refractory Personnel certification exam. The module includes tips for exam success, sample questions, and a review of key topics covered in the course. Learners will also gain access to mock exams and study guides designed to reinforce their understanding and readiness for the official exam.

Key Points:

• Key revision strategies for the API 936 exam.
• Sample exam questions and mock exams.
• Final review of course materials to ensure readiness.

This module provides learners with access to comprehensive mock exams designed to simulate the actual API 936 Refractory Personnel certification exam. The mock exams include a range of questions covering all key topics, from refractory material properties to quality control procedures, installation methods, and inspector responsibilities. By completing these timed exams, learners will gain a better understanding of the exam format, time management strategies, and the types of questions they can expect.

Key Features of the Mock Exams:

• Realistic Exam Conditions: The mock exams are structured to replicate the timing and format of the actual API 936 exam, helping learners to practice under realistic conditions.
• Question Variety: A broad range of question types, including multiple choice, scenario-based questions, and questions requiring knowledge of standards like ASTM and API 936, will ensure thorough exam preparation.
• Immediate Feedback: Upon completion of each mock exam, learners receive detailed feedback on their performance, including explanations of correct answers and references to relevant sections of the standard, allowing them to identify areas for further study.
• Performance Tracking: Learners can track their progress and improvement over time, using performance analytics to focus on weaker areas and ensure they are fully prepared for the actual exam.

What You’ll Learn:

• How to manage your time effectively during the exam.
• Strategies for answering complex, multi-part questions.
• Reinforce your understanding of key concepts from the API 936 standard.
• Identify and improve on areas of weakness before sitting the official exam.

This module is an essential part of the course, allowing learners to build their confidence and ensure they are fully equipped to pass the API 936 certification exam on their first attempt.