Refractory Systems Fundamentals Training 27th – 31st Jan 2025 (Weekdays)

Course Description

This course covers key concepts related to the design, installation, inspection, and testing of refractory systems. The courses will equip delegates with the necessary skills to assess the RISK of Refractory Failure and to examine Design Concepts. The courses cover the life of refractory linings from raw materials, purchase specifications, manufacturing, installation, heat-up and operation. Refractories are a critical part ofthe facility’s operation of most high temperature processes and play an essentialrole inmany otherindustries. They are frequently amajor costitemboth in general maintenance and also in the unscheduled downtime of production units arisingfrompremature refractory failure.

Who this course is for:

This trainingis will be beneficial for:
Refractory Operations Crew
Maintenance Engineers
Metallurgists
Refractory Supervisors

Course Outline

1. Introductionto Refractories in Gas-to-Liquids (GTL)Projects:
   –   Importance ofrefractory systems in GTL processes like those at Escravos.
   –   Overview of the GTL process: converting natural gas to liquid hydrocarbons via Fischer-Tropschsynthesis.
   –   High-temperature applications in GTL plants that rely on refractories, such as reformers andreactors.
2. API936 Overview for GTLProjects
   –   Overview of API936andits relevance to the GTL industry.
   –   Specific guidelines from API 936 that apply to refractory selection, installation, andquality control in GTL facilities.
   –   Compliance with API 936 for refractory systems in high-temperature reactors, reformers, andheat exchangers.
3. Refractory Materials in Gas-to-Liquids Applications
   –    Selection of refractory materials suitable for GTL processes, including:
   –    Chrome-alumina and high-alumina refractories for reactors.
   –    Silica and ceramic materials for insulation and heat recovery systems.
   –    Specialized refractories resistant to chemical attacks from catalysts, synthesis gases, and hydrocarbons.
   –    Performance properties needed for GTL processes, including chemical stability, thermal conductivity, and resistance to thermal shock.
4. Detailed Description and analysis of the Key components of a refractory system

   i.   –    Refractory Lining
              Types of refractory linings used in GTL plants:
            –  Dense refractory linings:
            – Insulating refractory linings:
            – Ceramic fiber linings: 
   ii. Anchors and Studs
   iii. Metallic or ceramic anchors
   iv. Expansion Joints
        – Flexible joints
   v. Castable Refractory
   vi. Refractory Bricks
   vii. Mortar – Refractory mortar
   viii. Ceramic Fiber Modules
   ix. Protective Coatings
   x. Insulating Backing Materials
   xi. Thermal Barriers
   xii. Fiber-Reinforced Concrete
   xiii. Sealants
   xiv. Heat Shields
   xv.  Monolithic Linings

5. Detailed Description and analysis of the Instrumentation and Control system for a Refractory System of Gas-to-Liquids (EGTL) facility
   i. Field Instruments
   · Pressure Transmitters and Gauges
   · Temperature Sensors
   · Flow Meters:
   · Level Transmitters
   · Gas Analyzers

   ii. Control Valves and Actuators
   · Control Valves
   – Globe valves, ball valves, and butterfly valves are typical in GTL applications, handling high pressures and temperatures.
   · Actuators:
   – Pneumatic actuators
   – Electric actuators
   – Hydraulic actuators

   iii. Programmable Logic Controllers (PLCs)

   iv. Distributed Control System (DCS)
   – Describe how the DCS receives data from PLCs, field instruments, and analyzers to provide real-time process monitoring and control of critical units like:
   – Fischer-Tropsch reactors, syngas reformers, gas purification units, and heat exchangers.

   v. Human-Machine Interface (HMI)

   vi. Safety Instrumented Systems (SIS) – Emergency shutdown (ESD) systems – Fire and Gas Detection Systems

   vii. Supervisory Control and Data Acquisition (SCADA)

   viii. Advanced Process Control (APC)

   ix. Gas Chromatographs and Online Analyzers

   x. Vibration Monitoring and Condition Monitoring Systems
   · Vibration sensors
   · Condition monitoring systems

   xi. Power Management and Monitoring Systems
        · Power distribution and control systems
        · Power monitoring systems

   xii. Alarm Management System

   xiii. Data Historian

   xiv. Networking and Communication Infrastructure

   xv. Calibration and Testing Equipment 

6. Description and analysis of typical operating parameters for a Refractory System of Gas-to-Liquids (EGTL) facility.
   i. Temperature
   · Operating Temperature Range:
   · Thermal Cycling

   ii. Thermal Conductivity
   · Low Thermal Conductivity
   · Target Values

   iii. Thermal Expansion
   · Controlled Thermal Expansion
   · Coefficient of Thermal Expansion (CTE)

   iv. Chemical Resistance
   · Resistance to Syngas (Synthesis Gas)
   · Fischer-Tropsch Catalyst Exposure .
   · Alkali Resistance

   v. Mechanical Strength
   · Cold Crushing Strength (CCS)
   · Hot Modulus of Rupture (HMOR)
   · Abrasion Resistance

   vi. Porosity
   · Low Porosity

   vii. Heat-up Rate and Curing Time
   · Heat-up Rate
   · Curing and Drying Time

   viii. Gas Permeability
   · Low Gas Permeability

   ix. Thermal Shock Resistance
   · High Thermal Shock Resistance

   x. Erosion and Abrasion Resistance
   · Erosion Resistance

   xi. Refractoriness Under Load (RUL)

   xii. Anchoring System Performance

   xiii. Hydration Resistance (for Castable Refractories)

   xiv. Refractory Lining Thickness
   · Lining Thickness

   xv. Insulation Efficiency
   · Thermal Insulation Efficiency 

7. Refractory Lining Design for GTL Equipment
   · Designing refractory linings for high-temperature reactors, reformers, and syngas production units.
   · Consideration of thermal stresses, mechanical loads, and chemical exposure in GTL operations.
   · Expansion joints, anchor design, and refractory thickness calculations for GTLspecific equipment.
8. Installation Techniques for Refractories in GTL Plants
   · API 936-compliant installation methods for castable, brick, and gunned refractories in GTL facilities.
   · Challenges in installing refractories in complex geometries and high-stress zones of GTL reactors and heat exchangers.
   · Best practices for ensuring the integrity and longevity of refractory linings in continuous high-temperature environments.
9. Curing and Drying of Refractories in GTL Facilities
   · Procedures for the proper curing and drying of refractory linings in GTL units to avoid cracking and premature failure.
   · API 936-recommended heat-up schedules, tailored to GTL processes.
   · Preventing thermal shock and steam explosions during startup in gas processing environments.
10. Inspection and Testing of Refractories in GTL Projects
    · API 936-compliant inspection techniques for refractory linings in critical GTL equipment.
    · Non-destructive and destructive testing methods:
        – Cold crushing strength (CCS) and hot modulus of rupture (MOR) for reactors and reformers.
        – Chemical resistance tests for environments with high levels of synthesis gas (syngas) and catalysts.
    · Conducting regular inspections during unit turnarounds and maintenance shutdowns.
11. Refractory Failure Mechanisms in GTL Plants
    · Identifying and analyzing common refractory failure modes in GTL applications:
    – Chemical corrosion from syngas and Fischer-Tropsch catalysts.
    – Erosion and abrasion in high-velocity syngas and gas-reforming units.
    – Thermal shock and spalling due to temperature fluctuations during startup and shutdown.
    · Techniques for conducting root cause analysis and preventive maintenance based on failure analysis.
12. Refractory Maintenance and Repair in GTL Facilities
    · Strategies for maintaining refractory integrity in continuous operation GTL units.
    · Best practices for emergency repairs and patching of refractory linings in reactors and heat exchangers.
    · Extending refractory life through proper operational practices, maintenance planning, and timely inspections.
13. Quality Assurance and Quality Control (QA/QC) in GTL Refractory Projects
    · Implementing API 936 QA/QC protocols during refractory installation and maintenance in GTL projects.
    · Documentation and reporting for regulatory and operational compliance.
    · Ensuring material traceability and installation quality in GTL projects through checklists and on-site testing.
14. Case Studies: Refractory Applications in GTL Projects
    · Examples from real GTL projects, focusing on refractory installations and performance in syngas reactors, reformers, and heat exchangers.
    · Lessons learned from refractory failures and successes in similar gas-to-liquids facilities, including Escravos GTL. 14. API 936 Certification Preparation (Optional)
    · Review of key topics for API 936 certification specific to GTL operations.
    · Practice questions and strategies for individuals seeking API 936 certification in refractory quality control.

    This course would be beneficial for engineers, maintenance personnel, and quality control staff involved in the refractory systems for the Escravos GTL project. The course focuses on ensuring long-term reliability and compliance with API 936 standards in high-temperature and chemically aggressive environments unique to the GTL industry.