API 936 - Sect. 8.1 (QUALIFICATION & TESTING) 1, The laboratory conducting the test procedures shall be ‘subject to: ‘A) Audit and approval by the owner B) Audit and approval by the manufacturer C) Approval by the visiting Inspector D) None of these are correct, 2. Quality Control testing shall follow ASTM procedures as modified by API $36 and shall consist of all of the following except: A) Density and cold crushing strength (CCS) B) Workability index (This is applicable to plastics only) ) Permanent linear change (PLC) and Abrasion loss (when applicable) D) Other tests required by the owner as defined in the execution plan 3. Regarding Cold Crushing Strength (CCS) testing, which of these statements is NOT true? ‘A) Cube loading surfaces shall be parallel to within a tolerance of + 1/32 in. (£ 0.8 mm) and perpendicular to within a tolerance of + 1 degree, whether cast orgunned B) CCS shall be determined on samples that have been fired to 1500°F (815°C) C) Testing shall be in accordance with ASTM C133 and API 936 mo D) Green density shall be determined after drying or firing 4, Regarding Cold Crushing Strength (CCS) testing, which of these statements NOT true? A) The loading head of the test machine shall have a spherical bearing block B) For gunned specimens, load shall be applied paralletto the gunning direction C) For cast specimens, load shall be applied to either pair of faces cast against the side of mold D) For specimens cut from a larger cast panel, an open face shall not be used for top or bottom5, Regarding Cold Crushing Strength (CCS) testing, which of these statements is NOT true? 'A) Bedding material shall be non-cotrugated cardboard shims B) Bedding material shall be placed between the fest specimen and the loading surfaces ; ) New shims shall be_used for each test cube (dimensions = 75 mm * 75 mm 1.5 mm thick) : 5 4 D) Testing machine initial leading may be 30% of the expected load applied at convenient rate : 8.4 (QUALIFIGATION & TESTING) 6. Which of these statements is NOT true regarding Abrasion (Erosion) Resistance Testing? A) It shall be in accordance with ASTM C704 and additional modifications by AP! £36 8) Abrasion shall be to an original free (not troweled, molded, or cut) surface. ©) Fire to 1500°F (815°C) & weigh the specimens to the nearest 0.1 9 1D) Use the silicon carbide material for all specimens tested 7. Which of these statements is NOT true regarding Abrasion (Erosion) Resistance Testing? ‘A) Initial bulk density is calculated to the nearest 0.1 gicm3 8) Amount of refractory lost by abrasion must be calculated ‘C) From the intial volume, initia bulk density must be calculated D) Amount of refractory lost by abrasion must be reported in cm3 to the nearest 0.1 ce. 8, Which of these statements is NOT true regarding Density testing and determination? ‘A) Reporting is done in units of pounds per cubic foot or kilograms per cubic meter B) Density shall be determined at room temperature on specimens oven dried or fired ) Measure specimen dimensions to nearest 0.02 in. (0.6 mm) & determine specimen volume D) Weigh specimen to nearest 0.001 Ib (0.5 9) & calculate density by dividing weight by volume9. Which of these statements is NOT true regarding PLC testing? ‘A) The length of each test specimen shall be measured to the nearest 0.001 in, (0.025 mm) along the 9 in. (230 mm) dimension at each of the four edges of the specimen B) At room temperature, determine green refractory dimension by measuring specimen length, then oven dry specimens for 12 hrs minimum at 104°C to 110°C in a forced air, convection dryer : ©) After cooling to room temperature, measure the dried length of the specimen and then fire by heating at 300°F/h (170°C/h) maximum to 1800°F (815°C), hold for 12 hrs at 1500°F (815°C) D) After cooling to room temperature, measure the fired length of specimen. 40. Determine the green-to-dried and dried-to-fired and then report the PLC as: A) An average percent shrinkage in length for each specimen to + 0.05% B) An average percent shrinkage in length for each specimen to + 0.1% q C) Overall percent shrinkage jn length for each specimen to + 0.05% D) Overall percent shrinkage in length for each specimen to + 0.1% Section 8.2 (PRE-SHIPMENT REFRACTORY QUAL TESTING) 4, For Material Qualification Testing, subject to owner's approval, the contractor shall: - A) Direct the manufacturer to perform testing at the manufacturer's plant — B) Direct the manufacturer to perform testing at an independent laboratory C) Arrange for testing at an independent laboratory or at the manufacturer's plant D) None of these are correct 2. For Material Qualification Testing, which of these statements is NOT true? ‘A) Contractor shall inform owner of testing arrangements and timing B) Contractor may notify the inspector to witness or ‘spot check the testing C) When engaged as a witness, inspector shall select containers to be tested and ‘observe all sampling, specimen preparation, and testing D) In cases where an independent laboratory is utilized or the contractor assumes complete accountability for testing results, inspector participation may be waived or reduced by owner3. For Material Qualification Testing using pump cast installations, refractory ‘shall be: ‘A) Poured into forms B) Pumped into forms C) Either poured or pumped into forms: D) None of these are correct per API 936 4. Refractory shall be applied within what time limit from the initial qualification tests? 5 A) Within 2 months B) Within 3 months C) Within 4 months D) None of these are correct 5, During material qualification, when a sample fails to meet specified requirements, it may: ‘A) Never be accepted B) Retested once C) Retested twice D) None of these are c8.3 Qualification of installation procedure and crew/installers. 4. The pneumatic gunning test panel dimensions shall be: a) 12x12" b) 12°24" ©) 24"x24" d) Any of the above 2. The pneumatic test panel shall be inclined at: a) 45° above the horizontal b) 90° above the horizontal ©) 45° below the horizontal d) 60° above the vertical 3, The pneumatic test panel mid point should be: a) Approximately 1 feet above grade b) Approximately 6 feet above grade ©) Same as grade level =) None of the above “= se aaa 4, The pneumatic test panel inspection shall be carried out. a) After 12 hours completion b) After 6 hours completion ©) After 24 hours completion d) After 8 hours completion 5. For casting the mock up shall be prepared: a) Every day b) Yearly once ¢) Monthly once d) By each applicator.6. Refractory cast mock-up shall be cured for: a) 12Hours b) 8 Hours ©) 24 Hours d) No Curing required 7. Thin layer abrasion dimensions are: a) 12°X12"x3/4" by) 12"12"x1" ©) 24"x24"x1" 5 d) Either aorb 8. Thick Layer plastic installation test panel dimensions are: a) 12X"12" b) 24"X12" ©) 24°X 24" d) Any of the above 8.4 Production (as installed) Refractory sampling testing 4, Which of the following are the requirements for gunning? : a) Minimum one sample shall be gunned by each gunning crew per material per shift — —) Wire mesh basket should be used for gunning — ¢) The wire mesh basket dimensions are 12°X12'X4" with 1 ‘opening d) Allofthe above. square 2. Gunning panels dimensions should be: a) 24°X24"%x1" b) 12°X12"°x1" ©) 12"X12"K4" d) 18°X18°x4" 3.How many samples required for casting production testing? a) One sample by each mixing crew b) Two samples by each mixing crew c) -One sample by each mixing crew per material per shift <) None of the above4. The acceptance criteria for production testing is based on: a) Minimum physical properties b) Maximum physical properties c) Average physical properties d) Any of the above. 5. The Maximiim abrasion lost shall not exceed: a) 110% | b) 100% ©) 90% d) 105% 6. The Minimum CCS requirement is: a) 90% b) 110% ©) 105% d) 75% 7. The acceptable density range is a) #3 Ibft® b) +5 Ibi ©)” £10 Ibitt® d) None of the above 8.5 Test Specimen preparation 1. Air setting phosphate bonded refractories shall be air cured for minimum: a) 12 Hours b) 8 Hours c) 24 Hours d) 48 Hours 2. The standard PLC specimen dimensions are: a) 4X4 ¥xt" b) 2K 2"x" ©) 2°X2"x2" d) 2K2%4%"3. The standard CCS specimen dimensions are: a) 4%'X4 4"x1" b) 2°X2'x9" ©) 2"x2"x2" a) 2X2x4%" 4. For over dry the standard temperature is: a) 1500°F to 2000°F 7 b) 100° F TO200°F - ©) 220°F TO 230°F d) 250°F TO 400°F 5. For over fire heating and cooling rates are a) 300°F/Hr and 500°F/Hr b) 500°F/Hr and 500°F/Hr ¢) 500°F/Hr and 300°F/Hr 4d) None of the above 6. For over fire the holding temperature and time is: a) 1800°F and thr b) 1500°F and 2hrs ©) 1500°F and Shrs d) 1500°F and 30 minutes 9.Installation /Execution 4.Which of the following are surface cleaning requirements? a) Grid blasting to meet SSPC-SP-7/NACE NO:4 to remove rust, weld slag oil and dirt b) SPC SP-3 power tool cleaning for spot grinding ©) Vacuum cleaning to remove debris from grid blasted areas } d) Allofthe above 2. What should be the maximum chlorides of water used in stainless steel . | surface? a) 200 ppm b) 50 ppm ©) 100 ppm ~d) None of the abovey == ——— 3. Which of the following refractories shall-be discarded? a) Refractory containers exhibiting evidence of water contamination b) Refractory container with hard lumps ©) Both of the above 4) None of the above 4. If refractory installation take place before pressure testing: a) Welds shall be painted b) All pressure retaining welds shall oe covered c) All pressure retaining welds shall remain unlined d) None of the above 5. Plugs in the opening shall not be removed until at least for: a) 12Hrs | b) 24Hrs : c) 8Hrs | 1 d) 4Hrs ” 6. After nozzle packing the ceramic fiber density shall be at least | a) 8 Ibft? . b) 10 Ibft - co) 15 IbAt® « | d) 4 Ibe? . ___1. Equipment shail be cleaned a) Ateach material change b) Ateach shift change ©) If buildup of castable takes place d) Allofthe above 8. The temperature of air and shell at the installation site shall a) 60°F TO100°F } b) 50°F TO 90°F ©) 40°F TO 80°F : d) 40°F TO 90°F9. For cold weather conditions which of the following should be used to maintain temperature?. a) Heating b) External Insulation ©) cooling d) Onlyaandb, 10. For hot weather conditions which of the following should be used to be maintain temperature? a) Shading, r b) Water spraying ©) Airconditioning. d) Any of the above. : 11. Refractory mix temperatures shall be between: a) 50° F td 90°F. b) 60° F to 80° F. ¢) 70° F to 100°F d) 40° F to 80° F, 12. Dry gunning should begin from: a) Lower elevation. b) Middle elevation. = : | c) Higher elevation. d) Any of the above. 13. Down ward gunning beyond what degree is prohibited?. . | a) 45° b) 30° jis | ) 90° 14. What is the maximum stoppage time recommended for gunning ? a) 20 minutes. | b) 10 minutes. ) 1 hour. d) 2 hours.15. For casting the mixer capacity shall be sufficient to facilitate placement with no more than __minutes between succéssive mix batches. a) 10° b) 20 ©) 30 4)5 : 16. Which of the following are requirement for thin layer abrasion résistant linings? a) Water slicking of the lining is not permitted b) Water used to clean tools shall be dried off prior to use of the tools on the refractory. ) Over fill shall be removed flush with the tops of the hex metal or hexalt anchors, d) All of the above. 17. Which of the following applicable to plastic refractories? a) Field water addition or reconditioning is not permitted. b) Shall be removed from container/plastic wrap only when ready for application. : = i ©) Under no circumstances dry or crumbly material be installed d) All of this above. 18, Metal fiber reinforcement shall be used a) Under all circumstances. b) When specified by manufactures. c) When required by contractor. d) When specified by the owner. 19. organic fibers to facilitate moisture removal may be used: a) When required. b) With owner approval. c) When specified by manufacturer. 4) None of the above20. Material left this us the gun, hose, containers, and or mixers for more than 20 minutes shalt be: . a) Re used b) Re used after conditioning, ©) Discarded. d) None of the above. . 24. Which of the following should followed during application interruption a) Dislodged anchor leg coverings shall be replaced 'b) For less than 8 hours interruption of heat-setting refractories premoistened cloth or burlap shall be used to keep the mating surface hydrated. : ) If installation is halted for the day all openings in the item bein shall covered, closed and sealed. ) All of the above. 22. The curing temperature and duration is: a) 50° F to 90°F for 12 hours b) 50° F to 90°F for 24 hours. c) 60° F to 80°F for 12 hours. d) 60° F to 80°F for 24 hours. 23. The curing compound shalll burn off at a temperatures of / a) 50°F to 90° F. —_ 'b) 120°F to 150°F. ©) 150" F to 200° F. 4) 40° F to 100° F. 24, Plastic Refractories: a) Require air curing. b) Kept dry and protected from freezing condition. e ) Kept moistened. d) All of the above.10.DRYOUT 1. Who will develop the ‘dry out procedure? a) Owner b) Contractor .¢) Manufactures. @) Supplier: 2. For dry out of complex vessels with more than one burner, more than two flue gas exit points or eight or more thermocouples the procedure shall be reviewed by: a) Owner. : b) Engineer. ) Inspector. 4) Contractor. 3. Flame Impingement and radiant heating : ‘ a) Shall be approved by owner. b) Shall be avoided. ¢) Shall be carried out according to the procedure, 4d) None of the above. cS 4. Which of the following is nota Dry out requirement? . a) Heating rate shall be monitored by thermocouples closest to ——“the:heat source. —_——— 'b) Cooling rates shall not exceed 100° F /1tr. c) Thermocouples shall be located within ‘" of the refractory surface. d) Initial heating by portable bumers are not permitted. 5. Which of the following statement is not true? a) For refractory density less 76 Ib/f® heating rate is 100° Fihour. b) For refractory density less 75'Ib/f” heating rate is 75° F/hour. ¢) For 101 Ibiff*to 140 Ib/ft? heating rate is 50°F /hour. d) Dry out index is 40 hours for all densities.ANNEX B. 4. Who will provide compliance data sheet? ° a) Refractory manufacturer. * by Owner., ©) Supplier 4) Contractor. 2. Bulk density shall be taken at : a) 70° F and 1500° F. b) 70° F and 200° F. ¢) 200°F and 1500° F d) None of the above. 3. Apparent pordsity shall be measured : a) After drying at 220° F. b) After drying at 70° F. ©) After firing at 1500° F. ¢) Only aand c. 4. Workability index temperature range is: 1a) 70° F to 1500° F. b) 65° F to 75°F. c) 800° F to 1000° F : d) 220° F to 1500° F. ANNEX C: 4. The refractory inspectors: a) Must achieve and demoristrate minimum competency. b) Certified to API 936. ¢) Minimum 3 years’ experience. d) Onlyaandb