Refractory Installation, Inspection & Maintenance Training Course

Course Overview

Learning Objectives

• Analyze the role of refractory linings in high-temperature equipment and the consequences of refractory failures on Day 1.
• Identify refractory types, including shaped and unshaped refractories, castables, plastics, gunning and ramming mixes, mortars, and ceramic fiber products.
• Evaluate key refractory properties, including refractoriness, thermal conductivity, density, strength, abrasion resistance, thermal shock resistance, and chemical resistance.
• Select refractory materials and lining systems for fired heaters, boilers, catalytic cracking units, sulfur recovery units, reformers, incinerators, stacks, and ducts.
• Apply lining and anchoring design principles, including anchor types, spacing, and materials.
• Apply installation methods, including casting, gunning, ramming, hand packing, and brick laying, with correct mixing and water control.
• Plan curing, dryout, and heat-up schedules that prevent damage during commissioning and restart.
• Apply quality control practices, including installer qualification, material and sample testing, and inspection and test plans with hold points.
• Monitor refractory condition in service using infrared thermography and shell temperature surveys.
• Inspect refractory linings during shutdowns and identify cracking, spalling, erosion, anchor failure, and chemical attack.
• Analyze refractory failure mechanisms and select appropriate repair methods, including patching, hot gunning, and replacement.
• Plan refractory work for turnarounds, manage refractory contractors, and apply health and safety controls by the end of Day 5.

Who Should Attend

Learning Outcomes

• By the end of the course, participants will be able to:
• Explain why refractory linings are critical to equipment integrity.
• Identify the main types of refractory materials and their uses.
• Relate refractory properties to service conditions.
• Select suitable refractory materials and lining systems.
• Review lining and anchoring designs.
• Supervise refractory installation using correct methods.
• Plan and verify curing and dryout schedules.
• Apply effective quality control during installation.
• Detect refractory problems during operation.
• Inspect refractory linings thoroughly during shutdowns.
• Diagnose refractory failures and choose suitable repairs.
• Plan refractory work safely and efficiently during turnarounds.

Course Outline