REFRACTORY INSPECTION CODE: INSTALLATION, INSPECTION, TESTING

Transcription

1 Training Title REFRACTORY INSPECTION CODE: INSTALLATION, INSPECTION, TESTING Training Duration 5 days Training Venue and Dates Refractory Inspection Code: Installation, Inspection, Testing 5 30 Mar 3 Apr $3,750 Dubai, UAE Training will be held at any 5 Star Hotels. Exact venue will be informed once finalized. Training Fees 3,750 US$ per participant for Public Training includes Materials/Handouts, tea/coffee breaks, refreshments & Buffet Lunch Training Certificate Define Management Consultancy & Training Certificate of course completion will be issued to all attendees. TRAINING OVERVIEW TRAINING DESCRIPTION & OBJECTIVES Reviewing types, characteristics, selection criteria as well as factors influencing performance and failure of the various thermal insulating materials for low-, medium- and high- temperature applications with simple calculations for heat transfer and energy saving. Describing standard methods used for investigation of composition, microstructure and physical properties of the refractory materials. Discussing data concerned with composition, properties and performance of International shaped and unshaped as well as dense and lightweight linings. Presenting design, installation, inspection and maintenance considerations of the refractory linings used for medium- and high- temperature applications. Studying the installation quality control guidelines of the American Petroleum Institute (API-RP-936) and the American Concrete Institute (ACI-RP-574) for inspection and testing of the refractory monolithic linings. Discussing effect of service conditions on performance and failure of the refractory linings applied for reactors and boilers in refineries, petrochemical and power-generation plants. Appendices including the following attachments: - Arabic copies for all lectures - Original API-RP-936 and ACI-RP-574 reports for inspection and testing of the refractory monolithic linings

2 - Original ASTM standard-specifications for testing: water of consistency, bulk density, reheating permanent linear change and abrasion resistance of the shaped and unshaped refractory products - Thermal calculations for specific heat, heat capacity and overall heat transfer by conduction, convection and radiation of multi-layer refractory linings. WHO SHOULD ATTEND? A training program, designed and prepared for the Engineers, responsible on design, installation, inspection, repairing and performance of the different types of thermal insulating and refractory materials applied for reactors, vessels, pipes and boilers in refineries, petrochemical and power-generation plants, according to API-936 and ACI-547 reports TRAINING METHODOLOGY A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions, and motivate everybody find the right answers. The delegates will also be encouraged to raise their own questions and to share in the development of the right answers using their own analysis and experiences. Tests of multiple-choice type will be made available to examine the effectiveness of delivering the course. DAILY OUTLINE 1. Introduction, (19 pp): 1.1 What are thermal insulation and thermal insulating materials? 1.2 General functions of the thermal insulating materials 1.3 What are refractory materials or refractories? 1.4 Thermal insulating and refractory raw materials 1.5 What are refractory materials or refractories? 1.6 Fundamentals of heat transfer 1.7 Calculation of economic thickness of any insulating material 2 Thermal Insulation for Low- and Medium- Temperature Applications (17 pp): 2.1 Low-temperature applications Cryogenic applications, (below -100 o C) Other low-temperature applications Insulation and moisture Requirements for vapour barriers and insulation coverings Insulation properties and characteristics 2.2 Medium-temperature applications

3 2.2.1 Insulation and moisture Insulation used to control surface temperature Insulation on heat-traced pipes Insulation used to maintain the heat in stored materials Assessment of insulation properties and characteristics Insulation shapes and configurations Applications and selection criteria 3 Quality control on composition, microstructure and physical properties of the Refractory Products (37 PP): 3.1 Chemical composition: 3.2 Solid-phase composition: 3.3 Microstructure 3.4 Physical properties: Densification properties Mechanical properties Thermal properties Refractory properties 4 Composition, Microstructure and Properties of International Shaped and Refractory Alumino-silicate Products, (15 pp): 4.1 Dense alumino-silicate bricks 4.2 Lightweight granular alumino-silicate bricks 4.3 Lightweight cellular and flaky alumino-silicate bricks 4.4 Lightweight fibrous refractory products 5 Unshaped alumino-silicate products (monolithics), (29 pp): 5.1 Hydraulic/ceramic -bonded alumino-silicate castables Types, composition and properties of the refractory calcium-aluminate cement (CAC): Effect of curing temperature and time on hydration and strength development of the CAC pastes Effect of water ratio of castables on their properties before and after drying Effect of preheating on phase composition and properties of the CAC-bonded castables Development of the hydraulic/ceramic -bonded castables 5.2 Chemical/ceramic- bonded castables 5.3 Lightweight alumino-silicate castables 6. Design, installation, inspection, maintenance, Selection Criteria and Thermal Calculations for shaped and unshaped Refractory Materials, (34 pp): 6.1 Design and installation for shaped materials

4 6.1.1 Anchoring Joints Designation of courses and bonds 6.2 Design and installation for unshaped (monolithic) materials Anchoring Joints Curing of newly installed linings Preheating (Dry-out) of the cured linings up to service temperatures 6.3 Inspection and maintenance of thermal insulating systems 6.3 Inspection and maintenance for shaped and unshaped materials 6.4 Selection criteria 7 Summary of API Report: 936 on Refractory Installation Quality Control Guidelines: Inspection and Testing Monolithic Refractory Linings and Materials, (20 pp): 7.1 Introduction 7.2 References 7.3 Definitions 7.4 Work execution 7.5 Testing 7.6 Post installation testing Appendix A: Glossary Appendix B: A Colour Coding for Metallic Anchors 8 Summary of ACI Report: 547 on Refractory Concrete, (36 pp): 8.1 Introduction 8.2 Criteria for refractory concrete selection 8.3 Constituent ingredients Composition and proportioning 8.5 Installation 8.6 Curing, drying, firing 8.7 Properties of normal weight refractory concretes 8.8 Properties of lightweight refractory concretes 8.9 Construction details 8.10 Repair 8.11 Applications 8.12 New developments and future use of refractory concrete 9 Reactors, Reformers and Boilers used in Petroleum Refining, Petrochemical and Power Generation Plants, (19 pp): 9.1 Stills, reactors and reformers used in petroleum refining 9.2 Reactors used in petrochemical industries

5 9.3 Reformers used in nitrogen (N) fertilizer manufacturing 9.4 Steam generating boilers Appendices: 1 The original API-RP-936 report 2 The original ACI-RP-574 report 3 The original ASTM specifications for testing water of consistency, density, reheating linear change & abrasion resistance shaped and unshaped refractory products: (ASTM Nos.: C-113, C-133, C-181 and C-704, respectively) 4 Thermal calculations, including specific heat and heat capacity as well as overall heat transfer by conduction, convection and radiation of multi-layer refractory linings. Questions/Discussion and Wrap-up Real Life Case Studies, Group Discussions, Last Day Review, Assessments will be carried out..