Upon completion of this course, participants will be able to:

• Identify and select appropriate refractory types (bricks, castables, fibers) for various high-temperature applications.
• Understand the installation and curing procedures for different refractory materials.
• Diagnose common refractory failure mechanisms (spalling, erosion, hot spots).
• Develop a comprehensive inspection and monitoring plan for refractory linings.
• Plan and execute quality control during refractory repair and replacement shutdowns.
• Calculate and manage the thermal efficiency implications of refractory performance.
• Understand the safety procedures associated with working on high-temperature systems.
• Utilize non-destructive testing (NDT) methods for refractory condition assessment.

• Maintenance Engineers in Power Generation, Cement, Steel, and Chemical plants
• Refractory Superintendents and Specialists
• Inspection and Integrity Engineers
• Maintenance Planners for turnaround and shutdown work
• Process Engineers managing high-heat systems
• Quality Control and Quality Assurance personnel

• Case studies on catastrophic refractory failure and the lessons learned
• Group workshop on designing a refractory QA/QC checklist for a shutdown
• Practical exercise in interpreting thermal images of a furnace or boiler shell
• Discussions on the selection of suitable anchors for different refractory types
• Individual assignment developing a refractory inspection plan for a high-heat asset.

Unit 1: Refractory Fundamentals and Selection

• Defining refractory materials and their key performance properties (e.g., thermal shock resistance, density).
• Classification of refractories: shaped (bricks) versus unshaped (castables, gunning mixes).
• Understanding insulation materials (ceramic fiber, insulating firebrick).
• Factors influencing refractory selection (temperature, atmosphere, chemical environment).

• The function and selection of refractory anchors.
• Best practices for installation of plastic, castable, and gunning refractories.
• Proper expansion joint design and placement.

Unit 2: Maintenance and Failure Mechanisms

• Diagnosing thermal spalling and mechanical damage.
• Identifying chemical attack mechanisms (slag penetration, alkali reaction).
• Understanding the role of creep and permanent linear change (PLC).

• Developing a structured visual inspection checklist for refractory linings.
• Using thermal imaging (thermography) to detect hot spots and lining degradation.
• Techniques for measuring remaining refractory thickness.

Unit 3: Installation and Curing Procedures

• The importance of proper drying and curing cycles for castable refractories.
• Understanding the risks associated with rapid heat-up (explosive spalling).
• Monitoring and controlling moisture removal during the dry-out process.

• Methods for patch repair and partial refractory replacement.
• Developing temporary repair strategies for minor defects.
• Gunning and shotcreting techniques for large area repairs.

Unit 4: Management and Quality Control

• Integrating refractory work into critical path shutdown planning.
• Specifying and procuring refractory materials (material certificates).
• Managing quality control during tear-out and installation (mixer water quality, mixing time).

• Tracking refractory life and developing accurate service life predictions.
• Analyzing the cost of refractory failure (downtime, energy loss).
• Optimizing inventory and storage of refractory spares.

Unit 5: Safety and Energy Efficiency

• Safety precautions for handling and installing refractory materials.
• Confined space entry procedures for high-heat enclosures.
• Lockout/Tagout (LOTO) protocols for furnace and boiler isolation.

• Calculating heat loss through refractory linings.
• Impact of lining degradation on furnace energy consumption.
• Strategies for improving overall thermal efficiency.