Haward Technology Middle East

COURSE OVERVIEW FE0850

API 936: Refractory Inspection Code
Installation, Inspection, Testing & Repair
(API Exam Preparation Training)
Course Title
API 936: Refractory Inspection Code: Installation,
Inspection, Testing & Repair (API Exam Preparation
Training)
Course Date/Venue
Course Date: February 02-06, 2020
Course Venue: Boardroom 3, Elite Byblos Hotel Al
Barsha, Sheikh Zayed Road, Dubai,
UAE
Exam Window: April 10-24, 2020
Exam Venue : Abu Dhabi, Dubai, Doha,
Al-Khobar, Kuwait and Cairo.
Participant has the option
to attend at any of the above cities
Exam Registration Closing Date: January 24, 2020
Course Reference Course Duration/Credits
FE0850 Five days (40 hours)/4.0 CEUs/40 PDHs
Course Description
This hands-on, highly-interactive course includes real-
life case studies and exercises where participants will
be engaged in a series of interactive small groups and
class workshops.

This API Certification Program is designed to train

individuals on Refractory installation, inspection, testing
and repair in accordance with API Recommended Practice
936. API RP 936 provides guidelines for the installation
quality control of refractory linings and usually used to
supplement owner specifications. The course also covers
the material, equipment and personnel qualification
requirements along with procedures and responsibilities for
quality control inspection personnel.

API Refractory Certification Program provides the industry

with a means for central, independent, unbiased and
legally defensible certification and ensures that refractory
personnel demonstrate competence in content areas that
are relevant to their practices. The program raises the bar
of competence for qualified personnel and provides a
peace-of-mind to the industry that the certified individual
has demonstrated knowledge of the relevant content of
refractory installation and inspection. For the refractory
personnel, this certification provides a method to
demonstrate knowledge and experience with refractories
and refractory inspection to employers and clients.
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By participating in API’s 936 Certification Program, inspectors and other professionals serving
the petroleum, petrochemicals, and chemical industries are readily able to provide evidence of
proper qualification. Certification provides personnel with industry-directed and industry-
accepted professional credentials.

This course is designed to train individuals who are interested in obtaining the API 936
Certification, as well as those who are seeking knowledge and skills needed for the
installation, inspection, testing and repair of refractory systems. Included with the course is a
pre-study guide and student classroom workbook. The student receives instruction regarding
how to take the test, as well as insight into the intricacies of "real world" situations. Daily tests
are designed to gauge students’ proficiency and understanding of the material.

Haward Technology is proud of its 90% pass rate on all API examinations.

Course Objectives
Upon the successful completion of this course, each participant will be able to:-
• Get prepared for the next API 936 exam and have enough knowledge and skills to pass
such exam in order to get the API 936 certification
• Perform the installation, repair, testing and inspection requirements of refractory systems
• Gain in-depth understanding on the laboratory testing procedures including the testing
equipment and methods, sample preparation techniques, dimensional requirements for
test specimen and the responsibilities for personnel and documentation requirements
• Determine what is an applicator and identify the various material qualification needed in
the installation, sample preparation and surface separation requirements of the refractory
system
• Recognize the responsibilities of personnel and list down the documentations needed in
the material qualification of a refractory system
• Enumerate the various requirements and guidelines needed in the installation of the
refractory system including the knowledge of detailed execution plan such as the design
details and quality standards
• List gunite procedures and equipment including variables that affect gunite quality
• Employ the procedures of inspection including the job specifications, application standards
and data collection procedures
• Identify the acceptance and rejection criteria for the inspection of the refractory system
• Develop an in-depth knowledge on the post-installation methods for refractory systems
and be able to learn the applicable heating rates for various classes of refractories

Exclusive Smart Training Kit - H-STK®

Participants of this course will receive the exclusive “Haward Smart

Training Kit” (H-STK®). The H-STK® consists of a comprehensive set of
technical content which includes electronic version of the course
materials, sample video clips of the instructor’s actual lectures & practical
sessions during the course conveniently saved in a Tablet PC.

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Who Should Attend

This course prepares participants for the API 936 exam. It is designed for those who are
involved in in the installation, inspection, testing or repair of refractory systems. Other
engineers, managers or technical staffs who are seeking broad knowledge of refractory
properties, installations and application will definitely benefit from this course.

Required Codes & Standards

Listed below are the effective editions of the publications required for the next API-936,
Refractory Personnel Certification Examination. Each student must purchase these
documents separately and have them available for use during the class as their cost is
not included in the course fees:-

API Publications
• API 936; 4th Edition, June 2014 – Refractory Installation Quality Control Guidelines –
Inspection and Testing Monolithic Refractory Linings and Materials
• API TR 979, 1st Edition, October 2018 – Applications of Refractory Lining Materials
• API TR 980, 1st Edition, April 2018 – Monolithic Refractories: Installation and Dryout

ASTM (American Society for Testing and Materials) Publications

• C113-14 – Standard Test Method for Reheat Change of Refractory Brick
• C133-97 (2015) – Standard Test Methods for Cold Crushing Strength and Modulus of
Rupture of Refractories
• C181-11 (2018) – Standard Test Method for Workability Index of Fireclay and High-
Alumina Plastic Refractories
• C704-15 – Standard Test Method for Abrasion Resistance of Refractory Materials at
Room Temperatures

API and ASME publications may be ordered directly through Haward Publications at +971-
2-309-1714. Orders may also be faxed to +971-2-309-1716, or e-mail [email protected]. More
information is available at www.haward.cc. When calling to order, please identify yourself as
an exam candidate and/or API member.

Note: API and ASME publications are copyrighted material. Photocopies of API and
ASME publications are not permitted. CD-ROM versions of the API documents are
issued quarterly by Information Handling Services and are allowed. Be sure to check
your CD-ROM against the editions noted on this sheet.

Training Methodology
This interactive training course includes the following training methodologies as a percentage
of the total tuition hours:-
30% Lectures
20% Workshops & Work Presentations
20% Case Studies & Practical Exercises
30% Videos, Software & Simulators
In an unlikely event, the course instructor may modify the above training methodology before
or during the course for technical reasons.
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Course Certificate(s)
Internationally recognized certificates will be issued to all participants of the course.

Certificate Accreditations
Certificates are accredited by the following international accreditation organizations:-

● USA International Association for Continuing Education and Training (IACET)

Haward Technology is an Authorized Training Provider by the International

Association for Continuing Education and Training (IACET), 2201 Cooperative Way, Suite
600, Herndon, VA 20171, USA. In obtaining this authority, Haward Technology has
demonstrated that it complies with the ANSI/IACET 1-2013 Standard which is widely
recognized as the standard of good practice internationally. As a result of our Authorized
Provider membership status, Haward Technology is authorized to offer IACET CEUs for its
programs that qualify under the ANSI/IACET 1-2013 Standard.

Haward Technology’s courses meet the professional certification and continuing

education requirements for participants seeking Continuing Education Units (CEUs) in
accordance with the rules & regulations of the International Association for Continuing
Education & Training (IACET). IACET is an international authority that evaluates programs
according to strict, research-based criteria and guidelines. The CEU is an internationally
accepted uniform unit of measurement in qualified courses of continuing education.

Haward Technology Middle East will award 4.0 CEUs (Continuing Education Units) or 40
PDHs (Professional Development Hours) for participants who completed the total tuition
hours of this program. One CEU is equivalent to ten Professional Development Hours
(PDHs) or ten contact hours of the participation in and completion of Haward Technology
programs. A permanent record of a participant’s involvement and awarding of CEU will be
maintained by Haward Technology. Haward Technology will provide a copy of the
participant’s CEU and PDH Transcript of Records upon request.

● British Accreditation Council (BAC)

Haward Technology is accredited by the British Accreditation Council for Independent

Further and Higher Education as an International Centre. BAC is the British
accrediting body responsible for setting standards within independent further and higher
education sector in the UK and overseas. As a BAC-accredited international centre,
Haward Technology meets all of the international higher education criteria and standards
set by BAC.

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Course Instructor(s)
This course will be conducted by the following instructor(s). However, we have the right to
change the course instructor(s) prior to the course date and inform participants accordingly:

Mr. Mahmoud Shama is a Senior Inspection Engineer with over 20

years of Offshore & Onshore experience within the Petrochemical,
Refinery and Oil & Gas industries. His expertise widely evolves in the
construction, installation fabrication, erection, inspection, maintenance,
assessment, rating, repair, alteration, reconstruction and integrity
assessment of Piping, Pipelines, Tanks, Fuel Storage Tanks, Rotating
Equipment, Static Equipment, Refractory Inspection, Pressure
Vessels, Heat Exchangers, Boilers, Furnace, Cryogenic (LNG) Tanks
Plant Piping, Welding Technology, Metallurgy, Condition Monitoring, Corrosion
Monitoring, Cathodic Protection, Process Inspections, Painting, Vibration Analysis,
NDT Activities, Construction & Mechanical Integrity, Process Piping Design and
Failure Analysis. He has further practical experience in ISO Certifications, QA/QC,
Lifting Equipment, Oil Heaters, Coolers, Re-Boilers, Separators, Gas Boots, LPG Bullets,
Air Driers, Sand Blasting and at the same time, he is an international expert with several
codes and standards in the process industry such as API, ASME, CSWIP, ANSI, ASTM,
NACE, TEMA, HEI, ISO, AUC, etc.

Throughout his career life, Mr. Mahmoud has provided significant contributions to the
industries by acquiring key positions such as being the Lead Integrity Engineer, Senior
Welding Inspector, Inspector Engineer, NDT & Document Controller, Technical
Instructor and API & Corrosion Instructor for international companies such as SEGAS
and GPC just to name a few.

Mr. Mahmoud has a Bachelor degree in Mechanical Engineering and is currently taking
a Diploma in Applied Chemistry. He is a Certified Senior Welding Inspector (CSWIP),
Certified Risk Based Inspection (API-580), Certified Tank Inspector (API-653), Certified
Pressure Vessel Inspector (API-510), Certified Damage Mechanisms Inspector (API-571),
Certified Refractory Inspector (API-936), Certified Piping Inspector (API 570), Certified
ISO9001-2000 Lead Auditor as well as a Certified ASNT Level I & II in Radiographic
Testing, Ultrasonic Testing (UT), Magnetic Testing (MT), Liquid Penetrate Test (PT), a
Certified Internal Verifier/Assessor/Trainer by the Institute of Leadership &
Management (ILM) and a Certified Instructor/Trainer.

Course Fee
US$ 6,750 per Delegate + 5% VAT. This rate includes H-STK® (Haward Smart Training Kit),
buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Accommodation
Accommodation is not included in the course fees. However, any accommodation required
can be arranged at the time of booking.

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Course Program
The following program is planned for this course. However, the course instructor(s) may
modify this program before or during the course for technical reasons with no prior notice to
participants. Nevertheless, the course objectives will always be met:

Day 1: Sunday, 02nd of February 2020

0730 – 0800 Registration & Coffee
0800 – 0815 Welcome & Introduction
0815 – 0900 Introduction
0900 – 0930 Students Take Initial Math Quiz
0930 – 1000 Review Math Quiz Answers
1000 – 1015 Break
1015 – 1045 Overview of Course Outline
1045 – 1230 Review of API 936 Body of Knowledge
1230 – 1330 Lunch
Laboratory Testing Procedures
Terms & Definitions ● Test Methods (E.G., C704, CCS, PLC, Density) & Related
1330 – 1500
Calculations ● Material Qualification ● Testing Equipment, Sample Preparation
Techniques, Dimensional Requirements for Test Specimens
1500 – 1515 Break
Laboratory Testing Procedures (cont’d)
Various Materials Utilized (For Example, Plastic, Ceramic Fiber, Anchor, Metal Fiber,
1515 – 1645
Corrosion, Coatings, Etc.) ● Curing & Firing Procedures ● Acceptance/Rejection
Criteria ● Responsibilities of Personnel & Documentation Requirements.
1645 – 1700 Distribute Homework & Recap
1700 End of Day One

Day 2: Monday, 03rd of February 2020

0730 – 0830 Review of Day 1 & Homework Answers
Applicator & Material Qualification
0830 – 0930 Installation Methods (E.G., Gunning, Casting, Ramming & Hand Packing) ● Sampling
& Sample Preparation Procedures ● Terms & Definitions
0930 – 0945 Break
Applicator & Material Qualification (cont’d)
Procedures for Determining Optimal Water Content & Mixing ● Applicable
0945 – 1215
Formulation & Manufacturing Information ● Applicable Knowledge of Equipment &
Qualification Process
1215 – 1230 Administer Quiz
1230 – 1330 Lunch
Applicator & Material Qualification (cont’d)
1330 – 1515
Applicable Test Panel/Mock-Up Requirements ● Applicable Environmental Controls
1515 – 1530 Break
Applicator & Material Qualification (cont’d)
1530 – 1630 Surface Preparation Requirements ● Responsibilities of Personnel & Documentation
Requirements
1630 – 1645 Administer Quiz
1645 – 1700 Distribute Homework & Recap
1700 End of Day Two

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Day 3: Tuesday, 04th of February 2020

0730 – 0830 Review of Day 2 & Homework Answers
Installation
0830 – 0930 Terms & Definitions ● Responsibilities of Personnel & Documentation Requirements ●
Knowledge of Detailed Execution Plan Including Design Details & Quality Standards
0930 – 0945 Break
Installation (cont’d)
Packaging & Storage Requirements ● Surface Preparation & Cleanliness Requirements
0945 – 1215
● Anchor: Welding, Layouts, Patterns, Materials ● Frequency & Methods of Production
Sampling: Gunning, Casting, Hand Packing
1215 – 1230 Administer Quiz
1230 – 1330 Lunch
Installation (cont’d)
Water Addition: Quantity & Temperature, Mixing Procedures ● Fiber Addition:
Percentage, Material, Mixing ● Installation Environmental Controls (Minimum &
1330 – 1515
Maximum Temperatures) ● Gunite Procedures & Equipment, Including Variables that
Affect Gunite Quality (I.E., Air Pressure, Humidity, Temperature, Aging, Water
Pressure, Water Purity, Additives)
1515 – 1530 Break
Installation (cont’d)
Knowledge of Flash Set ● Casting Procedures & Equipment (E.G., Air Vibrator, Vibrator
1530 – 1630
Frequency, Vibrator Sizing, Forming,Setup) ● Ramming/Hand Packed Procedures &
Equipment
1630 – 1645 Administer Quiz
1645 – 1700 Distribute Homework & Recap
1700 End of Day Three

Day 4: Wednesday, 05th of February 2020

0730 – 0830 Review of Day 3 & Homework Answers
Inspection
0830 – 0930 Terminology, Job Specifications, Application Standards ● Inspection & Data Collection
Procedures ● Lining Design & Installation Requirements
0930 – 0945 Break
Inspection (cont’d)
Visual & Non-Destructive Test Methods & Qualification Testing Methods ●
0945 – 1215 Application/Limitation for Various Inspection Techniques (For Example, Hammer
Testing, Sonic Testing, Radiography, Core Sampling, Portable Abrasion Testing) ●
Material Verification & Traceability
1215 – 1230 Administer Quiz
1230 – 1330 Lunch
Inspection (cont’d)
1330 – 1515
Acceptance & Rejection Criteria ● Repair Procedures ● Curing & Dry Out Procedures
1515 – 1530 Break
Inspection (cont’d)
1530 – 1630
Inspectors’ & Contractors’ Responsibilities ● Record Keeping Systems & Requirements
1630 – 1645 Administer Quiz
1645 – 1700 Distribute Homework & Recap
1700 End of Day Four

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Day 5: Thursday, 06th of February 2020

0730 – 0830 Review of Day 4 & Homework Answers
Post-Installation
Terms & Definitions ● Responsibilities of Personnel & Documentation Requirements ●
0830 – 1000
Knowledge of Dryout Requirements ● Sealing Requirements (For Example, Water Mist,
Covering, Membrane, Curing)
1000 – 1015 Break
Post-Installation (cont’d)
Application & Time Limits for Applying Membrane Curing Compounds ● Environmental
1015 – 1215 Conditions Required For Curing ● Heating Equipment, Methods & Procedures (E.G., Gas
Fired Burner, Stress Relieving Heating Elements) ● Placement of Temperature Sensing
Probes
1215 – 1230 Administer Quiz
1230 – 1330 Lunch
Post-Installation (cont’d)
Knowledge of Manufacturer’s Recommended Heatup & Cool Down Schedules ●
1330 – 1530
Applicable Heating Rates for Various Classes of Refractories ● Lining Integrity Inspection
Techniques
1530 – 1545 Break
1545 – 1630 Practice Exam
1630 – 1645 Course Conclusion
1645 – 1700 Presentation of Course Certificates
1700 End of Course

Practical Sessions
This hands-on, highly-interactive course includes real-life case studies and exercises:-

Course Coordinator
Cristy Mamisay, Tel: +971 2 30 91 714, Fax: +971 2 30 91 716, Email: [email protected]

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