API 936 PRACTICE TEST QUESTIONS AND CORRECT ANSWERS

API 936 PRACTICE TEST QUESTIONS AND CORRECT ANSWERS What does the scope of API 936 provide? Provides installation quality control guidelines for monolithic refractory lining and may be used to supplement owners specifications What section of API 936 mentions the responsibilities of the inspector? The scope of the inspector responsibilities who monitor and control the quality control process are also defined What two items if using API 936 are mandatory to be done? The refractory applied by this guideline shall be sampled and tested to verify that physical properties meet intended criteria What is the acceptance / rejection criteria for qualifications testing as per API 936? For both material and applicator qualification testing, the average physical properties for each sample shall fully meet the criteria established for that material in API 936 What are the acceptance / rejection criteria for as-installed testing? Based on criteria and procedure prior to work to start What are the qualifications of inspection personnel? 1. The inspector shall have no commercial affiliations with the contractor or manufacturer(s), unless otherwise agreed to by the owner 2. The inspector shall have a working knowledge of applicable standard and terms as defined in attached appendixes of this document 3. The inspector shall have a working knowledge or requirements defined in this document, owner specifications and job specific requirements outlined by the owner or manufacturer. What are the responsibilities of inspection personnel? 1. The inspector shall monitor qualification and production work conducted by the manufacturer(s) and contractor to ensure compliance with job specifications and agreed-to-quality standards 2. The inspector shall notify the owner and the contractor in a timely manner of any work deficiencies or potential deficiencies based on his or her monitoring of material qualification and the installation process 3. The inspector shall make no engineering decisions contrary or in addition to specified requirements 4. Any conflict between specified standards and installed refractory quality shall be submitted to the owner for resolution 5. In cases involving repair and maintenance of existing equipment, the owner may request the inspector to provide recommendations concerning the need and extent of repairs and procedures to be used to make those repairs 6. The inspector shall inspect the hammer test newly-installed lining before dry out and after dryout (when possible), and report any anomalies to the owner 7. The inspector shall ensure the material and applicator qualification test results are fully documented and the contractor is provided with all applicable data for the materials being installed 8. The inspector shall check and verify that accurate installation records are being documented by the contractor as per 4.4.8 9. The inspector shall record all nonconformance and/or potential problems to which the inspector has alerted the contractor and owner What are the codes / standards / specifications that are cited in this recommended practice? C113 - standard test method for Reheat Change of Refractory Brick C133 - standard test method for Cold Crushing Strength & Modulus of Rupture of Refractory C704- standard test method for Abrasion Resistance of Refractory Materials at Room Temperature What are the other references recommended practice? API Std 560 - Fired Heaters for General Refinery Service ACI 3 547R - Refractory Concrete: Stage-of-the-Art Report Erosion Services can be defined as: Fluid solid units, such as transfer and overhead lines Cyclones Linings Deflector Shields Define the Heating Contractor? The contractor or subcontractor who specialized in the dry out of monolithic refractory linings Give 3 examples of Hexalt type Anchors S-Bar Hexcel Curl and Tacko anchor Define Independent Laboratory refractory testing facility not affiliated with the manufacturer or contractor Give 2 primary duties of the inspector To monitor refractory installation work being conducted by the contractor Supply materials and manufactures Define Material Qualification Testing Pre-installed testing of refractory materials in which production lots of refractories manufactured for a specific installation are sampled and tested to confirmed that they meet specified physical property requirements Define Monolithic Refractories Castable or plastic refractory applied by casting, gunning, or hand/ram packing to form monolithic lining structures What is a Production Run? Quantity of refractory having the same formulation that is prepared in an uninterrupted manufacturing operation Name 5 results taken from a Test Sample Compressive Strength Erosion Resistance Density Linear Change Any other physical property determination Describe a Test Specimen Test Specimens are either individual cubes, bars, or plate test pieces used for physical testing How many test specimens are normally taken for testing? The average of two or more specimens made up from the same sample Who shall prepare a detailed specifications and or execution plan? The owner shall prepare a detailed specification and or refer to the contractor to prepare a detailed execution plan subject to the owner approval Name 4 items to be included in the design details Lining products, thickness, method of application, and extent of coverage Anchor material, geometry and layout. Suggested color coding for metallic anchors is given in appendix B Surface preparation, welding procedures and anchor attachment integrity When used, details of metal fiber reinforcement including dimensions, concentration, type, and metallurgy Name and describe 5 requirements in Quality Standards Physical Property Requirements - to be used for qualification and installation quality control by specific product and where it is being utilized. these requirements shall be in with manufacturer's datasheet claims or compliance unless amended by prior agreement with owner Sampling Procedures - Applicable to designations of products to be used in either erosion service or other service as defined in para 4.2.4 The Lining Thickness Tolerances - the tolerance shall be accepted as per original design details and owner agreement Acceptance criteria for hammer test - A subjective test of green or fired refractories in which the lining is impacted with a hammer to gauge soundness and uniformity via audible resonance Allowable cracking in the applied lining Name 3 items that shall be included in the Execution Details Installation and quality control procedures Designation of responsible Parties Curing and dryout procedures List 4 physical property requirements required for Material Qualification Testing Density Permanent Linear Change (PLC) Cold Crushing Strength (CCS) Abrasion Resistance (where applicable) Describe the contractors responsibility for material qualifications testing Arrange for testing at either an independent laboratory or the manufacture's plant Direct the work to assure the missing techniques, water contents, ambient temperatures, mix temperatures and so on adequately represent those needed for production installation Describe the operative testing party's responsibilities To conduct of sampling specimen preparation, testing, and documentation of results Who shall inform the owner of testing arrangement and timing so that notification to the inspector is made? The contractor shall inform the owner When the inspector is engaged as a witness what are his duties? The inspector shall select the container to be tested and observe all sampling Specimen preparation Testing When may the inspectors participation be waived or reduced by the owner? Where an independent laboratory is utilized or the contractor assumes complete accountability for as-installed testing results What are the testing frequencies for erosion service or other services? Erosion Service - one sample per pallet or less from each production run other service - one sample for 3 pallets or less from each production run Under who's direction shall the test sample refractories be mixed and formed? The contractor is responsible What 2 materials are allowed for forms? Metal or plastic forms may be used at the required specimen dimensions How long is the cure time before larger dimensions may be cut to the required dimension? A minimum of 24 hrs Describe the installations for each a) vibration cast b) pump cast c) hand pack d) gunning e) plastic and other ramming a) vibration cast - may be used in forming of the test specimens b) pump cast - installation refractory shall be poured into forms c) hand pack - refractory shall be hand packed d) gunned - refractory shall be gunned or cast (alternative specimens may be hand packed subject to prior approval by the owner) e) plastics and other ramming - may be formed using a mallet or handheld pneumatic rammer How soon shall all refractory be applied of initial qualifications? Every refractory shall be applied within 4 months of initial qualification test, or 3 months of a succeeding qualification test per the procedures here in API 936 If the initial qualification period of 4 months of initial qualification test or 3 months of a succeeding qualification test is exceeded may the respective batch be re-qualified? Re-qualification permits usage for an additional 3 months after each succeeding qualification test up to the manufacture's recommended shelf life If a sample fails to meet specific results may it be retested? Yes, it may be rested and shall be conducted using the same testing facility and inspection, or at a different subject to the owner approval What initial steps must the contractor take for applicator qualification testing? Prior to the installation, the contractor shall take the material qualified to job, and using equipment and personnel to utilize for the installation work, demonstrate that specified quality standards can be met What size test panel is required for pneumatic gunning? The test panel shall be fabricated measuring 24in x 24in (600mm x 600mm) with thickness and anchors the same as the actual installation job What is the test panel position for the nozzle / gun operator to demonstrate their abilities? The test panel shall be inclined 45 degrees above the horizontal and supported on a frame so that panels midpoint is approximately 6ft (1.9m) above ground level When may the removal of the back panel be made? Sectioning for breaking of the panels is permitted 18hrs after completion of the panel unless otherwise directed by the owner Name 3 items the test specimen shall be tested physical property standard for density permanent linear change cold crushing strength or abrasion resistance For casting applicator qualification testing, what mandatory item is required for the installation? a mock simulating the most difficult piece of the installation work or the size/shape agreed to in the documentation phase shall be completed, and applied materials sample and tested Describe the requirement for vibration cast installation The mock-up shall demonstrate the adequacy of vibration equipment and attachment method of vibrators, along with the general installation procedures, such as mixing, handling/delivery to lining cavity and associated quality control requirements