API 936 study plan

Classify refractory classes (fireclay, high-alumina, basic, silica, alumina-silica, insulating) by chemistry and bond type, and state the service limits of each.

Build a property matrix comparing density, cold crushing strength, modulus of rupture, PLC, thermal conductivity, and abrasion resistance across at least 8 material types.

Explain the four damage mechanisms (thermal shock, chemical attack/slag corrosion, erosion, mechanical/structural) and match each to a plausible failure signature.

Solve 5 numeric problems covering thermal expansion, heat loss through a two-layer wall, and anchor/stud thermal load.

Select candidate lining materials for 4 different service environments (rotary kiln burning zone, FCC regenerator, steel ladle, reformer) and justify each choice against temperature, atmosphere, and slag chemistry.

Map common refractory test methods to the property they quantify and the units reported, without looking at notes.

Convert a set of service conditions into 10 quantitative specification clauses (thickness, density, strength, chemistry limits).

Identify where material selection interacts with design: anchor alloy grade, expansion joint allowance, and backup insulation.

Draft the installation-related sections of a lining specification covering surface prep, anchor spacing and pattern, expansion joints, and cure/dryout requirements.

Calculate lining thickness, anchor length and spacing, and expansion joint width for two vessel geometries.

Audit a sample specification and list at least 8 missing or ambiguous requirements.

Build a QC hold-point and witness-point list tied to design requirements.

Determine correct mixing water quantity, mixing sequence, and mix time for castables and ramming mixes, and state the consequences of over- and under-watering.

Compare placement methods (vibration casting, gunning, shotcrete, hand ramming) and select the right one for 5 given geometries.

Write a curing schedule that respects ambient and substrate temperature limits and addresses rapid moisture loss.

Sequence the installation steps for a vessel from anchor welding through final cure, including inspection points.

Describe sampling, specimen preparation, and curing of test pieces for castables, and list errors that invalidate results.

Interpret test results against acceptance criteria for density, CCS, MOR, PLC, and moisture content, and decide accept/reject/re-test.

Build an inspection and test plan with at least 10 hold points spanning incoming material, installation, and post-cure checks.

Outline the nonconformance process from detection through disposition and documentation.

Design a dryout heat-up curve (hold points, ramp rates, soak times) for a thick castable lining and justify each segment against steam migration and spalling risk.

Diagnose 5 lining failure case descriptions and prescribe a repair method (patch, hot repair, partial reline, full reline).

Plan a turnaround: scope definition, access, demolition, inspection of shell and anchors, and reinstallation sequence.

State the safety and quality checks required before returning a unit to service.

Re-test the two weakest domains identified by prior quiz scores and log each miss with its root cause.

Work 6 integrated case scenarios that each span selection, design, installation, and inspection.

Reduce the error log by re-deriving every missed concept from first principles rather than memorizing answers.

Time-box practice sets to exam pace to build stamina.

Complete two full-length timed practice exams under exam conditions.

Review every miss and re-verify the underlying fact in reference material before moving on.

Recite the key numbers (cure temperatures, ramp rates, water ratios, test tolerances) from memory.

Finalize a one-page summary sheet for last-minute review.