API 936 PRACTICE TEST
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1. After refractory specimens have been
fully cured and removed from forms and
or cut to required dimensions what is
then required?
2. As part of Applicator Qualification
Testing, List 4 contractor responsibilities
3. As part of refractory installation, list 4
contractor responsibilities
4. Briefly describer metal fiber
concentrations and dimension
requirements
5. Briefly describe the procedure for adding
metal fibers during lining installation
6. Define Independent Laboratory
7. Define Material Qualification Testing
8. Define Monolithic Refractories
9. Define the Heating Contractor?
10. Describe alternative panels that may be
used in lieu of "wire mesh basket
11. Describe a Test Specimen
12. Describe oven drying that is required for
Heat Setting plastics only
13. Describe Oven firing temperatures
14. Describe the beginning gunning
operations
Specimen shall be marked with temperature resistant pain (to prevent burn-off during
firing), dried, and / or fired
1. Scheduling of Materials Qualifications test and delivery of those materials and test
results to the site
2. Scheduling and execution of work to qualify all equipment and personnel needed to
complete installation work, including documentation and verification by the inspector
3. Preparation and identification of all testing samples and timely delivery to the testing
laboratory
4. Advance notification to the owner of the time and location where work will take place
so that this information can be passed on to the inspector
Advance agreement with the owner on all installation details
Execution of installation work
Inspector verified documentation of installation records
Accountability for installed refractories meeting specified standard
typically range 1-4wt percent with effective diameters of 0.010 in. - 0.022in (0.3mm -
0.6mm) and lengths 3/4 or 1 in (19mm or 25mm)
Loading castable into mixer and pre-mix
Add pre-wet or mixing water
Using a dispersing device, such as 1/2" (13mm) hardware mesh, sieve fibers into castable
with mixer operating
refractory testing facility not affiliated with the manufacturer or contractor
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
Castable or plastic refractory applied by casting, gunning, or hand/ram packing to form
monolithic lining structures
The contractor or subcontractor who specialized in the dry out of monolithic refractory
linings
Alternatively, panels with enclosed sides may be used in place of the wire basket if the
panel dimensions are at least 18in x 18in x 4in (450mm x 450mm x 100mm) and test
specimens are cut from the center of the panels to avoid possible rebounds traps along
the sides of the panels
Test Specimens are either individual cubes, bars, or plate test pieces used for physical
testing
Oven dry ( required for heat-setting plastic only) 12hrs minimum at 220F - 230F (104C -
110C) in a force air convection dryer. Heating to this level shall be per manufacturer's
recommendation
Oven fire, heat at 300F per hour (170C per hr) to 1500F (815C) hold for 5hrs at 1500F
(815C) cool at 500F per hour (280C per hour) maximum to ambient
Start gunning at the lowest elevation, building up the lining thickness gradually over an
area of not more than 10ft 2in (1m2) to full thickness and working in an upward direction
to minimize the inclusion of rebound. Rebound material shall not be reused
15. Describe the contractors
responsibility for material
qualifications testing
16. Describe the density testing
procedure as per API 936
17. Describe the installations for each
a) vibration cast
b) pump cast
c) hand pack
d) gunning
e) plastic and other ramming
18. Describe the operative testing party's
responsibilities
19. Describe the requirement for vibration
cast installation
20. During the curing period the
refractory shall be covered or sealed
and maintained at what temperature
range?
21. Erosion Services can be defined as:
22. For casting applicator qualification
testing, what mandatory item is
required for the installation?
23. For Casting installation what type of
testing is required?
24. For Casting Testing, what is the
minimum sample requirement?
25. For Chemically bonded refractories,
what specific requirement shall be
done during the curing stage?
26. For gunning operations, what 2 items
shall be used to terminate areas?
27. Forms for Casting operations shall
have, what 2 mandatory items?
28. For Permanent Linear Change Test
specimens, describe how to calculate
the length change
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
Measure specimen dimension to the nearest 0.02in (0.5mm) and weight to the nearest
0.002 lb (1.0g)
Calculate density by dividing weight by volume and report in units of pound per cubic ft.
or kilograms per cubic meter
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
To conduct of sampling specimen preparation, testing, and documentation of results
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
During the period of time the refractory shall be covered or sealed with an impermeable
material and maintained at an ambient temperature of 70F-85F (20C-30C)
Fluid solid units, such as transfer and overhead lines
Cyclones Linings
Deflector Shields
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
Specimen shall be tested for density permanent linear change, and cold crushing strength
or abrasion resistance
A minimum of 1 sample shall by each mixing crew per material per shift
For chemically bonded refractories, the lining surface shall remain uncovered and free
from contact with moisture during the curing period
Shot boards or perpendicular edge shall be used to terminate work areas
Waterproof and leak free
Calculate length for each of the four measurements per specimen and divide by the initial
green or dried dimension. Report permanent linear change green to fired, and dried to
fired as total average percentage shrinkage in length for each specimen to +-0.05%
29. For placement of Thin Layer, Erosion All air-setting phosphate bonded refractories shall be mixed in a rotating paddle
Resistant Linings, how shall air setting mixer, such as those manufactured by Hobart
phosphate bonded refractories be mixed?
30. Give 2 primary duties of the inspector To monitor refractory installation work being conducted by the contractor

Supply materials and manufactures

31. Give 3 examples of Hexalt type Anchors S-Bar
Hexcel
Curl and Tacko anchor
32. How are densities determined as per API Densities shall be determined at room temperature on specimens after firing per 5.2.5b
936 requirements? testing procedures
33. How long is the cure time before larger A minimum of 24 hrs
dimensions may be cut to the required
dimension?
34. How many test specimens are normally The average of two or more specimens made up from the same sample
taken for testing?
35. How shall chemical setting refractories be in heat sealed plastic to assure vapor-tight enclosure
packaged?
36. How shall dryout heating be controlled? Heating shall be controlled using either process or temporary thermocouples to
monitor gas temperatures throughout the newly lined areas
37. How shall dryout heating of Cold Wall Cold wall refractory lined components shall be dried out by heating from the
refractory be done? refractory hot face only, with approved dryout procedures
38. How shall dryout heating of Hot Wall Hot wall refractory line component shall be dried out by the application of heat from
refractory be done? either the inside or outside surface or placed within an oven and heat soaked from
both sides, in accordance with approved dryout procedures
39. How shall hydraulic bonded castable in moisture-proof bags with the product name, batch number, and date of manufacture
refractories be backed? clearly shown
40. How shall Permanent Linear Change test Test specimens shall be measured along the 9in. dimension at each of the same four
specimens be measured? corners of the specimen to the nearest 0.001 in (0.025mm)
41. How shall the initial dryout heating of Initial heating of newly installed refractory linings shall be performed by process
newly installed linings be performed? heating devices or temporary equipment such as electric heating elements or portable
burners
42. How shall Thick Layer, Plastic Installations Refractory shall be ram packed in successive handful sized clumps using a handheld,
be installed? reciprocating pneumatic rammer fully consolidating each clump into a uniform mass
and compacting the material in and around anchor supports to form a homogenous
lining structure free of voids and lamination that is greater than the desired lining
thickness
43. How shall Thin Layer, Erosion Resistant Refractory shall be applied using a handheld, reciprocating pneumatic rammer, rubber
refractory linings be applied? mallet, and/or wood block as demonstrated in applicator qualification test
44. How soon shall all refractory be applied Every refractory shall be applied within 4 months of initial qualification test, or 3
of initial qualifications? months of a succeeding qualification test per the procedures here in API 936
45. If a sample fails to meet specific results Yes, it may be rested and shall be conducted using the same testing facility and
may it be retested? inspection, or at a different subject to the owner approval
46. If the initial qualification period of 4 Re-qualification permits usage for an additional 3 months after each succeeding
months of initial qualification test or 3 qualification test up to the manufacture's recommended shelf life
months of a succeeding qualification test
is exceeded may the respective batch be
re-qualified?
47. Is field water addition or reconditioning NO - Field water addition or reconditioning is not permitted
permitted for heat-setting refractories?
48. Is "water slicking" of the finished lining No- water slicking of the lining surface is not permitted
surface permitted?
49. List 4 physical property requirements Density
required for Material Qualification Testing Permanent Linear Change (PLC)
Cold Crushing Strength (CCS)
Abrasion Resistance (where applicable)
50. May aluminum paddles and bowls be used? Aluminum paddles and bowls shall NOT be used due to their potential to react
with the acid component in the refractory
51. May cutback material be reused? Cutback material may be reused of workability characteristics are not diminished.
under no circumstances shall dry or crumbly material be installed
52. Name 3 items that shall be included in the Installation and quality control procedures
Execution Details Designation of responsible Parties
Curing and dryout procedures
53. Name 3 items the test specimen shall be physical property standard for density
tested
permanent linear change

cold crushing strength or abrasion resistance

54. Name 3 items to be used to aid refractory Pouring or pump casting, submersion vibrators or roding may be used to aid
flow refractory flow and filling of the formed enclosure
55. Name 3 release agents required in casting grease, form release, or wax shall be used to facilitate stripping of the forms
forms
56. Name 4 items to be included in the design Lining products, thickness, method of application, and extent of coverage
details
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
57. Name 5 results taken from a Test Sample Compressive Strength
Erosion Resistance
Density
Linear Change
Any other physical property determination
58. Name and describe 5 requirements in
Quality Standards
59. Name at least 2 types methods of
providing excess moisture during the
curing stage?
60. Other than the acceptance rejection
criteria required by para 1.3.3 and para
4.1.2, what additional requirements are
required?
61. Satisfactory examination and test results
for pump and cast installation will also
qualify what?
62. Sealing or excess moisture is allowed
for what type of refractory during the
curing stage?
63. Under who's direction shall the test
sample refractories be mixed and
formed?
64. Vibration is only allowed to be used in
the actual installation of what 3 types of
casting?
65. What 2 items shall be used for thickness
measurement guides during gunning
operations?
66. What 2 materials are allowed for forms?
67. What 2 types of anchoring systems
maybe used in thin layer erosion
resistance refractories?
68. What are the acceptance / rejection
criteria for as-installed testing?
69. What are the codes / standards /
specifications that are cited in this
recommended practice?
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
Applying membrane type (nonreactive) curing compound to all exposed surfaces before
the surface is dry to touch. No part of the lining shall be allowed to air dry more than
2hrs prior to the application of curing compound
Wetting the exposed surfaces of the newly installed lining with fine water spray at
approximately 2hrs interval
The inspector to verify all record kept by the contractor to identify samples and the
areas that represent. Failure to meet the preceding criteria shall be caused for rejection,
in the even of disagreement over installed refractory quality, core samples may be taken
and retested
Qualifies the missing and installation procedures as well as mix water levels
Sealing and / or excess moisture shall be provided for the curing of hydraulic bonded
castable
The contractor is responsible
Pump and Cast installation
Shot board height and depth gauges shall be used for thickness measurement guides
Metal or plastic forms may be used at the required specimen dimensions
Hexmesh or hexalt anchoring system (as the case may be) shall be attached to a backing
plate such that the backing plate may be removed and the applied refractory lining
examined from the backside
Based on criteria and procedure prior to work to start
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
70. What are the curing times and
requirements for Heat Setting and
Plastic Refractories?
71. What are the other references
recommended practice?
72. What are the qualifications of
inspection personnel?
73. What are the responsibilities of
inspection personnel?
74. What are the temp. limits for
refractory and water mix?
75. What are the testing frequencies for
erosion service or other services?
76. What ASTM standard is required for
all Abrasion (Erosion) Resistance type
refractory testing?
77. What ASTM standard is required for
all Cold Crushing Strength Testing?
78. What does the scope of API 936
provide?
79. What down hand gunning limit is
prohibited?
80. What initial steps must the contractor
take for applicator qualification
testing?
Heat-Setting, plastic refractories shall be allowed to air dry at an ambient temperature of
70F - 85F (20C-30C) for a minimum of 24hrs and oven dried in a form suitable for drying
temperatures
API Std 560 - Fired Heaters for General Refinery Service
ACI 3 547R - Refractory Concrete: Stage-of-the-Art Report
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.
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
in accordance with the manufacturer's requirements. in the absence of manufacturer's mix
temp limits, mix temp shall be between 60F (15c-27c)
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
ASTM C704
ASTM C133
Provides installation quality control guidelines for monolithic refractory lining and may be
used to supplement owners specifications
Down hand gunning beyond 30 degrees below horizontal is prohibited unless agreed to
otherwise by the owner
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
81. What installation method may be used in testing of Vibration may be used in casting of samples as applicable to simulate
casting s installation work
82. What is a Production Run? Quantity of refractory having the same formulation that is prepared in an
uninterrupted manufacturing operation
83. What is "flashing"? a layer coat of refractory usually gunned which is applied over refractory
that has already been applied and allowed to set up
84. What is required for dryout heating of complex The dryout plan should be reviewed by an engineer experienced in dryout
vessels, or vessel/duct/pipe systems that have more of complex systems. The dryout plan should include heat up/cool down
than one burner, more than two flue gas exit points, rates for all control temperature indicators and the maximum difference
or eight or more thermocouples? between temperature indicators
85. What is required for visual inspection of the test shall be constructed with removable back for visual inspection of the
panel? castable
86. What is required when installing all heat-setting All heat-setting plastic refractories shall be installed at the manufactured
plastic refractories? consistency
87. What is testing machine minimum sensitivity and Testing machine minimum sensitivity and maximum loading rate shall be
maximum loading rate for Castable type refractory castable type is >100lb/ft3 (>1600kg/m3), testing machine sensitivity rate
rated > 100lb.ft3 500c (2222) note: c50% of the expected load may be applied initially at any
convenient rate, the loading rate 2500c (290)
88. What is the acceptance / rejection criteria for For both material and applicator qualification testing, the average physical
qualifications testing as per API 936? properties for each sample shall fully meet the criteria established for that
material in API 936
89. What is the application temperature for installation the temperature of the air and shell at the installation site shall between 50F
of refractory? (10c) minimum and 90F (32c) maximum during refractory installation and
the 24hr there after
90. What is the cool down temperature rates when Cooling rates shall not exceed 150F (85C) per hour
included in the dryout plan?
91. What is the cure time for newly installed linings? Newly installed air-setting, hydraulic, and chemically bonded lining shall be
allowed to cure at 50F - 90F (10C-32C) for 24 hrs minimum before initial
heating of the lining
92. What is the max weight of refractory in the bag? The weight of the refractory in the bag shall not deviate from this value by
more than +-2%
93. What is the minimum curing time for refractory cast Refractory cast in the mock-up shall be cured for 12hrs minimum and then
in mock-up panels? stripped of forms for visual inspection only
94. What is the minimum sample requirement for A minimum of 1 sample of applied refractory shall be gunned by each
gunning as-installed testing? gunning crew per material per shift using a "wire mesh basket" which is
about 12in x 12in (300mm x 300mm) and at least 4in (100mm) deep
95. What is the minimum sample requirement for a minimum of 1 sample shall be packed by each applicator per material per
placement of thin layer, erosion resistant linings and shift
plastics?
96. What is the minimum time required for curing freshly Freshly placed air setting and cement-bonded refractories shall be allowed
placed air-setting and cement bonded refractories? to cure for 24hrs minimum before being removed from the molds or being
cut into bar specimens
97. What is the minimum time requirement before The newly applied lining shall cure per the manufacturer's recommendation
moving the form piece or stripping the forms? (minimum of 24hrs) before moving the piece or stripping the forms
98. What is the minimum time that air setting, phosphate Air-setting phosphate bonded castable refractories shall be air cured,
bonded castable refractories must be cured? uncovered for a minimum of 24hr after forming
99. What is the minimum time the hydraulic bonded Hydraulic bonded castable refractories shall be cured for a minimum of
castable refractory shall be cured? 24hrs after forming
100. What is the mixer capacity requirement for
pump casting?
101. What is the mixer capacity requirement for
vibration casting?
102. What is the mixer capacity requirement for
vibration casting in pipe sections?
103. What is the number of specimens to be
taken "For Erosion Service" type of test
Abrasion Resistance?
104. What is the optimum amount of mixing for
gunning?
105. What is the panel dimensions required for
Thick Layer, Plastic Installations?
106. What is the qualification test shall apply to
set the refractory shelf life?
107. What is the testing measurement as per
ASTM C113?
108. What is the test panel position for the
nozzle / gun operator to demonstrate their
abilities?
109. What kind of water is to be used for
missing in the refractory?
110. What section of API 936 mentions the
responsibilities of the inspector?
111. What shall the backing plate to be used for
Thick Layer, Plastic Installations be coated
with?
112. What size test panel is required for
pneumatic gunning?
113. What size test panels is required for thin
layer erosion resistance refractories?
114. What two items if using API 936 are
mandatory to be done?
115. What type of refractory does NOT require
air curing?
116. What type of test shall be made of test
specimens for Thin Layer Erosion
Resistance Refractories?
117. When gunning stoppages are greater than
30min or the initial set is determined by
the inspector, what thickness lining shall be
retained?
118. When is "flashing" not permitted?
119. When may the inspectors participation be
waived or reduced by the owner?
Pump casting mixer capacity shall sufficient to allow for continuous pump operations
without stops and starts to wait for materials
Vibration casting, 2 or more rotary vibrators shall be mounted externally on the
equipment or component to be line
Should be sufficient to facilitate placement with no more than 10 minutes between
successive mix batches
For Erosion Service type of test abrasion resistance 2 number of specimens shall be
required (size of specimens 4 1/2 x 4 1/2in (114 x 114 x 25mm) table 3. II - For other
service type of test cold crushing strength 3 number of specimens are required
(2x2x2in (50x50x50mm)
of the pre-wetted material shall be per the applicator qualification testing. Use of
pre-wet may be waived for some products, subject to the manufacturer's
recommendation and the owner's approval
The test panel shall be 24in x 12in (600,, x 300mm) with applied lining thickness and
anchorage that are the same as the actual installation
Refractory materials shall be stored in a weather protected area. Time limits for
material qualification test shall set refractory shelf life. If the manufacturer's shelf life
recommendations are more stringent; the manufacturer's restrictions shall apply
All testing shall be determined on the 2in x 2in x 9in (50mmx50mmx230mm)
specimens per ASTM C113
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
Potable
The scope of the inspector responsibilities who monitor and control the quality
control process are also defined
The backing plate shall be coated with parting agent to facilitate removal from the
applied refractory
The test panel shall be fabricated measuring 24in x 24in (600mm x 600mm) with
thickness and anchors the same as the actual installation job
A test panel 12in x 12in x 3/4 or 1 in (300mm x300mm x 20 or 25mm) shall be
packed by each applicator and examined
The refractory applied by this guideline shall be sampled and tested to verify that
physical properties meet intended criteria
Heat Setting refractories DO NOT require air curing, but they shall not be exposed to
moisture or freezing conditions prior to initial heating
Specimens shall be tested for density, permanent linear change and abrasion
resistance
Only full thickness shall be retained
after initial set as defined by the surface being exposed for more than 20min or
becoming dry to the touch
Where an independent laboratory is utilized or the contractor assumes complete
accountability for as-installed testing results
120. When may the removal of the back panel be made?
121. When shall metal fiber reinforcement be allowed?
122. When shall the backing plate be removed when using
Thick Layer, Plastic Installations?
123. When the inspector is engaged as a witness what are
his duties?
124. Who is responsible and what is the time requirement to
measure the workability index on plastic refractories?
125. Who shall inform the owner of testing arrangement and
timing so that notification to the inspector is made?
126. Who shall prepare a detailed specifications and or
execution plan?
127. Who shall review the dryout plan prior to submitting for
approval with the owner?
128. Why are organic fibers sometimes installed in the
refractory?
129. You as an inspector reviewed a test report for an "As
installed material" you discover that the density was
reported at +6 lb/ ft 3. Is this acceptable?
130. You as the inspector reviewed a test report for "As
installed material" you discover that the density cold
crushing strength is reported at 50%. Is this acceptable?
Sectioning for breaking of the panels is permitted 18hrs after completion
of the panel unless otherwise directed by the owner
Metal fiber reinforcement shall be used only when specified by the
owner
After refractory installation is completed, the test panel backing plate
shall be removed immediately and examined for consolidation and
voids
The inspector shall select the container to be tested and observe all
sampling
Specimen preparation
Testing
The manufacturer shall measure the workability index on plastic
refractories per ASTM C181 seven days after manufacture and provide
this to the contractor
The contractor shall inform the owner
The owner shall prepare a detailed specification and or refer to the
contractor to prepare a detailed execution plan subject to the owner
approval
The contractor shall review dryout provisions with the manufacturer
based on the above criteria and submit a procedure to be approved by
the owner
They are used to facilitate moisture removal of refractory lining during
dry out and shall be used with owners approval. Fiber additions shall
be performed during manufacture of the castable or plastic refractory
No - Maximum density according to Table 2 is 5 -5lb / ft 3.
Yes - According to table 2, the minimum cold crushing strength allowed
is 80%