File No. 10_API 936

API 936: Refractory Installation, Inspection and Testing

PART - VI QUESTION BANK FOR API 936 COURSE

QUESTION BANK FOR API 936 COURSE Q.1. API 936 deals with a)

Monolithic refractory

b)

Installations of refractory linings

c)

Installation, quality control procedures for monolithic refractory linings

d)

None of the above

Q.2. The term abrasion resistance means a)

effects of eroding particles for an extended period

b) thee ability to withstand effects of eroding particles for an extended period without significant loss of material or other damage c)

A measure of a refractory ability to resist failure

d) A non reactive coating applied to freely installed cementitious materials that aids the hydration process by retarding moisture loss Q.3. Metal fibers are usually made of a)

Austenitic Stainless Steel and 0.010 in to 0.0022 in ( 0.3 mm to 0.6 mm ) in length.

b)

Austenitic Stainless Steel and 0.010 in to 3/4 in ( 0.3 mm to 19 mm ) in length.

c)

Austenitic Stainless Steel and ¾ in to 1in ( 19 mm to 25mm) in length.

d)

None of the above.

Q.4. Hot wall means a thin refractory lining system with a)

metal shell temperature greater than 500degF(260degC)

b)

metal shell temperature greater than 700degF(370degC)

c)

metal shell temperature greater than 40degF to 100degF(5degC to 38degC)

d)

metal shell temperature greater than 1500degF(815degC)

Q.5. Chemical setting means a)

Developing a strong bond by chemical reaction

b)

Pre-set refractory installed by gunning method

c) A castable installation technique whereby refractory is sticky enough so that the lining formed is structurally homogeneous d) A non reactive coating applied to freshly installed cementitous materials that aids the hydration process by retarding moisture loss. Q.6. Hydro-setting refractories are commanly known as a)

castables

b)

monolithic lining

c)

erosion

d)

plastic refractory

Q.7. Testing of refractory materials sampled from the installation to confirm that they meet specified physical property standards mean a)

As-installed testing

b)

laboratory testing

c)

application qualification testing

d)

compliance data sheet

Q.8. Conventional refractories means a)

Castable refractories containing more than 2.5% CaO.

b)

Castable refractories containing less than 2.5% CaO.

c)

Castable refractories containing minimum 25% CaO.

d)

Castable refractories containing maximum 2.0% CaO.

Q.9.) a)

Specimen means individual used for physical property testing Cube

b)

Sphere

c)

Hexagon

d)

Cylinder

Q.10. Ramming means a)

the use of compressive force or impact to deform a stiff refractory mix.

b)

Castable installation technique by way of pumping castable to installation site

c)

A technique used with dry gunning machine

d) A castable installation technique by packing successive handfuls of material to the desired shape. Q.11. Flocculating agent means a)

A chemical additive causing rapid stiffening of fluid refractory castables

b)

A non reactive coating applied to freshly installed cementitous materials

c)

Phosphate bonded plastics

d)

None of the above.

Q.12. Temporary containments used in gunning that are set up and secured to provide a firm surface on which to make perpendicular cold joints at the termination of work areas is known as a)

Dry gunning

b)

Shot board

c)

Wet gunning

d)

Cut Back Effect

Q.13) The objective of the material qualification is a) Confirm that the specifications, good practice and installation procedures are followed. b)

Confirm that agreed procedure is followed.

c)

Confirm that the installed linings meet specification standards.

d) Confirm that materials manufactured for the job meet the specified physical property standards.

Q.14) Pyrometric cone is a three sided truncated pyramid has a)

Base 5/8 in ( 16 mm ) wide and 2 5/8 in ( 66 mm ) in height.

b)

Base 1 1/8 in ( 29 mm ) wide and 3/8 in ( 10 mm ) in height.

c)

Base 1 1/8 in ( 29 mm ) wide and 3/8 in ( 10 mm ) in height.

d)

None of above

Q.15) Semi Silica fire clay brick contains a)

27 % Silica maximum.

b)

Not less than 72% Silica.

c)

Maximum 58% Silica

d)

Maximum 45% Silica.

Q.16. Preparing detailed specification related to using products , thickness , etc is responsibility of_____ a) Owner

b) Contractor

c) Inspector

d) Manufacturer

Q.17. Sampling frequency as applicable for the products intended use in either erosion service or other service is responsibility of __ a) Contractor c) Inspector

b) Owner d) Manufacturer

Q.18. Deciding required lining thickness tolerances is responsibility of____ a) Contractor

b) Inspector

c) Owner

d ) Manufacturer

Q.19. Approval of engineering drawings & execution plan & dry out procedures is responsibility of_____ a)

Contractor

b)

Inspector

c)

Owner

d)Manufacturer

Q.20. Preparation & execution plan is responsibility of____ a) Owner

b) Contractor

c) Inspector

d) Manufacturer

Q.21. Execution plan should include____ a) Required lining thickness tolerance b) Cutting & dry out procedures c) Designation of inspection hold points & the required advanced notification to be given to the inspector d) Material and applicator qualification test results

Q.22. Documentation of material & applicator qualification test results is the responsibility of____ a) Owner

b) Contractor

c) Inspector

d) Manufacturer

Q.23. Submission to the owner of all exceptions ,substitutions & deviation of the requirements of execution plan, API 936 Standard &other referenced documents is the responsibility of____ a) Contractor

b)

Inspector

c) Owner

d) Manufacturer

Q.24. Providing inspector verified documentation of installation records is responsibility of____

a) Contractor

b) Inspector

c) Owner

d)

Manufacturer

Q.25. Deciding criteria for hammer testing & the extent of cracking & surface voids permitted is the responsibility of__ a) Owner

b) Contractor

c) Inspector

d) Manufacturer

Q.26. Specifying physical property requirement to be used for qualification & installation quality control by specific product installation method & location wherethe product will be utilized is the responsibility of____ a) Owner

b) Contractor

c) Inspector

d) Manufacturer

Q.27. Providing inspector verified documentation of installation records related to fibre & water percentage is responsibility of___ a) Contractor

b) Inspector

c) Owner

d) Manufacturer

Q.28. Submission of verified documentation of weather conditions & any other unusual conditions of occurrances & dry out records is responsibility of____ a) Owner

b) Contractor

c) Inspector

d) Manufacturer

Q.29. Providing a compliance data sheet in accordance with Annex C for each product is responsibility of____ a) Contractor

b) Inspector

c) Owner

d) Manufacturer

Q.30. Recording all non-conformances and/or potential problems is the responsibility of_____ a) Owner

b) Contractor

c) Inspector

d) Manufacturer

Q.31. Refractory material should be stored at temperature of____ a) 40degF to 100degF ( 5 DEG TO 38 DEG C ) b) 32degF to 40degF ( 0 DEG TO 5 DEG C ) c) 70degF ( 20 DEG C ) d) 65degF to 75degF ( 18 DEG TO 24 DEG C ) Q.32. For pneumatic gunning, test panel dimensions shall be____ a)

24in X 24in ( 600mm X 600mm )

b) 12in X 12in ( 300mm X 300mm ) c)

3/4in X 1in ( 19mm X 25mm )

d)

24in X 12in( 600mm X 300mm )

Q.33. For thick layer plastic installations {Greater than 50mm(2in)} the test panel shall be_____ a) 24in X 24in ( 600mm X 600mm ) b) 12in X 12in ( 300mm X 300mm ) c)

3/4in X 1in ( 19mm X 25mm )

d) 24in X 12in( 600mm X 300mm ) Q.34. For gunning using wire mesh basket the sample basket shall be_____ a) 24in X 12in( 600mm X 300mm ) b) 24in X 24in ( 600mm X 600mm ) c) 12in X 12in ( 300mm X 300mm ) d) none of the above Q.35. For gunning using wire mesh basket shall be constructed of wire mesh with)_____ a) 1/2in ( 13mm ) square openings

b) 3/4in ( 19mm ) square openings c) 1in ( 25mm ) square openings d)

none of the above

Q.36. In case of casting, the mock up should be cured for--------a) 12 hrs minimum prior to stripping the forms b) 24 hrs minimum prior to stripping the forms c) 8 hrs minimum prior to stripping the forms d) none of the above Q.37. In case of pneumatic gunning, the test panel shall be cured for atleast_____ a) 12hrs after completion of panel b) 24hrs after completion of panel c) 8hrs after completion of panel d) none of the above Q.38. In case of density calculation, the dimensions & weight shall be measured to_____ a) nearest 0.02in (0.5mm) & 0.002lb (1.0g) b) nearest 1in (25mm) & 0.010lb (5.0g) c) nearest 0.001in(0.0025mm) & 0.002lb (1.0g) d) none of the above Q.39. For PLC the length of each test specimen shall be measured to the a) nearest 0.001 in ( 0.025 mm ) along the 9 in dimension at each 4 edges of the specimen b) ) nearest 0.02 in ( 0.5 mm ) along the 9 in dimension at each 4 edges of the specimen c) nearest 0.002 in ( 0.05 mm ) along the 9 in dimension at each 4 edges of the specimen d) none of the above Q.40. In abrasion resistance(Erosion) the specimen shall be weighed to nearest_____

a)

0.1g

b) 0.002lb ( 1.0g ) c)

0.010lb ( 5.0g )

d) none of the above Q.41. In abrasion resistance the amount of redractory lost by abrasion shall be reported to the nearest____ a)

1cc

b)

10cc

c)

0.1cc

d)

0.5cc

Q.42. In abrasion resistance testing the refractory is fired to____ a) 1500 deg F ( 815 DEG C ) b) 1000 deg F to 1050 deg F ( 542 DEG TO 565 DEG C ) c ) 600 deg F to 700 deg F ( 318 DEG TO 374 DEG C ) d) 1300 DEG F ( 710 DWG C ) Q 43 . For drying out of conventional castable refractories, for arefractory density of 75 lbs/cu ft ( 1200 kg/cu mtr ) the drying out initial temperature to the first hold is at------------a) 250 deg F to 300 deg F ( 122 deg C to 150 deg C ) b) 600 deg F to 700 deg F ( 318 deg C to 374 deg C ) c) 1300 deg F to 1500 deg F ( 710 deg C to 815 deg C ) d) 1000 deg F to 1050 deg F ( 542 deg C to 565 deg C ) Q.44. drying out index for conventional castable refractories of density less than 75 lbs / cu ft ( 1200 kg / cu mtr ) is---------a) 23 Hours b) 31 Hours

c) 40 Hours d) none of the above Q.45. drying out of refractory the cooling down rates shall not exceed ----------a) 75 deg F / HR ( 42 DEG C / HR ) b) 50 deg F / HR ( 28 DEG C / HR ) c) 100 deg F / HR ( 56 DEG C / HR ) d) None of the above Q.46. For dry out of conventional castable refractories the-----a) dry out index increases with refractory density b) dry out index decreases with refractory index c) dry out index remains unchanged irrespective of refractory index d) none of the above Q.47. For deciding dry out index for a unit or vessel having multiple refractories the dry out should be based on_____ a) the refractory that has the longest duration requirement for the maximum thickness at each stage of dry out b) the refractory that has the shortest duration requirement for the maximum thickness at each stage of dry out c) the refractory that has the average duration requirement for the maximum thickness at each stage of dry out d) the manufacturer’s recommendations Q.48. Curing of refractory shall be done with manufacturer’s recommendation for minimum of 24 hrs__ a) At 50 deg F to 90 deg F ( 10 deg C to 32 deg C ) before moving the piece, stripping the form or heating b) At 150 deg F to 200 deg F( 65 deg C to 96 deg C) before moving the piece, stripping the form or heating

c) At 250 deg F to 300 deg F ( 122 deg C to 150 deg C ) before moving the piece, stripping the form or heating d) None of the above Q.49. For wet gunning water addition at mixer, mixing time and the rate of flocculating agent addition shall be in accordance with ____ a)

Owner’s recommendation

b) Contractor’s recommendation c)

Manufacturer’s recommendation

d) Inspector’s recommendation Q.50. For Dry gunning, optimum water addition at mixer, mixing time and aging of prewetted material shall be as per recommendations of ____ a)

Owner’s recommendation

b) Contractor’s recommendation c)

Manufacturer’s recommendation

d) Inspector’s recommendation Q.51. Temperature limits for refractory and mixed in absence of Manufacturer’s recommendation shall be between______ a) 60 deg F and 80 deg F ( 15 deg C and 27 deg C ) b) 50 deg F and 90 deg F ( 10 deg C and 32 deg C ) c) 250 deg F and 300 deg F ( 122 deg C and 150 deg C ) d) 200 deg F and 400 deg F ( 95 deg C and 200 deg C ) Q.52. Low duty fire clay brick means a fire clay brick with a PCE value not lower than___ a) cone 15 b) cone 29 c) cone 31 ½ d) None of the above

Q.53. Medium weight castable refractory have densities roughly in between____ a) 100 lb/cu ft and 150 lb/cu ft ( 1600 kg/cumtr and 2400 kg/cumtr ) b) 75 lb/cu ft and 100 lb/cu ft ( 1200 kg/cu mtr and 1600 kg/cu mtr ) c)

Less than 75 lb/cu ft ( Less than 1200kg/cu mtr )

d)

None of the above

Q. 54) Alumina – Zirconia – Silica refractories are used in a)

Insulating castables

b)

Erosion resistant castables and precast special shapes

c)

Neutral refractories

d)

Chemically bonded bricks.

Q. 55) A refractory lining that is abnormally soft and friable is called a)

Pores

b)

Punky

c)

Slagging refractories

d)

Spalling of refractories.

Q.56) Refractoriness is a)

The property of resistance to melting, softening or deformation at high temperature.

b)

The property of refractory from which porosity / voids are determined.

c)

The property of refractory from which CCS of refractory is decided.

d)

The property of refractory from which abrasion resistance can be known.

Q57) For Keolin,(While burning clay.) the PCE of the most commercial Kaolin ranges from ----a) cone 33 to cone 35

b) cone 29 to 31 1/2 c) cone 15 to 29. d) None of the above Q.58) Key in furnace construction is----------a) The uppermost or the closing brick of curved arch. b) A flat structure spanning an opening and supported by abutments at its extremities. c) The lower most brick of the curved arch. d) None of the above. Q.59) Alumina ( Al2O3) has melting point a)

2678 Deg F ( 1470 Deg C )

b)

3133 Deg F ( 1723 Deg C )

c)

3720 Deg F ( 2050 Deg C )

d)

1500 Deg F ( 815 Deg C )

Q.60) Perlite is a)

A Silicious glassy rock composed of small spheroids, varying in size from small shot to peas.

b)

A high alumina mineral, usually consisting of rounded concretionary grains embeded in clay like mass & believed to consists essentially of alumina tri hydrate(Al2O3-H2O) & alumina hydrate(Al2O3-H2O) in varying proportions.

c)

A natural or synthetic mineral theoritically consisting solely of alumina(Al2O3) having specific gravity 4.00 to 4.02, hardness 8.8 &melting point 3730degF(2050degC)

d)

None of the above.

Q.61) Reactor is a vessel in which a)

Cracking reaction occurs or is completed and product gases are separated from Coke.

b) Coke and residual hydrocarbons are burned off the catalyst and the flue gas is then separated from the catalyst.

c) By heat treatment the adjacent particles of the material cohere, at a temperature below that of complete melting. d)

None of the above.

Q.62) For erosion service abrasion resistance test need a)

2 no. specimens per sample.

b)

1 no. specimens per sample.

c)

3 no. specimens per sample.

d)

No specimen per sample.

Q.63) For erosion service - for permanent linear change a)

No. of specimens per sample required are 2 ( two.)

b) No. of specimens per sample required are 1 no. c) No. of specimens per sample required are 3 nos. d) No. of specimens per sample required are Nil Q.64) For erosion service – Abrasion resistance the size of the specimen is a)

4 ½ in x 4 ½ in x 1 in ( 114 mm x 114 mm x 25 mm )

b)

2 in x 2 in x 9 in ( 50 mm x 50 mm x 230 mm )

c)

2 in x 2 ni x 2 in ( 50 mm x 50 mm x 50 mm ).

d)

None of the above.

Q.65) For other service -- Cold Crushing Strength a)

No. of specimens per sample required are 2 (two.)

b)

No. of specimens per sample required are 3 no.

c)

No. of specimens per sample required are Nil.

d)

No. of specimens per sample required are 1 no.

Q.66) for physical properties and acceptable results for testing of as installed refractories for abrasion loss, range of acceptable result is --a)

Minimum None and maximum 120%

b)

Minimum None and maximum 120%

c)

Minimum None and maximum 120%

d)

None of the above.

Q. 67)

ASTM C 113 – 02 Standard deals with

a) The permanent linear change of refractory brick when heated under prescribed condition. b) Test methods of Cold Crushing Strength and Modulus of Rupture of refractories. c) Standard test method for abrasion resistance of refractory materials at room temperature. d) Q.68)

None of the above.

In abrasion test method it measures

a)

Volume of material in cubic centimeters abraded from a flat surface at right angles to a nozzle.

b)

the Modulus of Rupture of the refractory material in test

c)

the porosity & voids volume of the refractory material in test d) the PLC of the refractory material in test

Q.69) In abrasion test method the amount of size graded Silicon Carbide grain is ----a) 1000 grams b) 1500 grams c) 448 grams d) 1800 grams. Q.70) In abrasion test method the amount of air pressure used for blasting Silicon Carbide grain is ----a)

448 kpa ( 65 psi )

b)

100 kpa ( 14 psi )

c)

500 kpa ( 71 psi )

d)

1000 kpa ( 142 psi )

Q.71) In ASTM C 704 - 01 Abrasion resistance of refractory samples is worked out at a)

Room Temperature

b)

0 deg C ( 32 deg F )

c)

18 deg C ( 65 deg F )

d)

120 deg C ( 250 deg F )

Q.72. Abrasion resistance of material indicates a)

Its suitability for service in corrosive environment

b) Its suitability for service in high temperature c)

Its strength in cold crushing

d)

None of the above

Q.73. In test method for Abrasion resistance the nozzle size used is a)

115mm(4 ½ in) long X 7mm(1/4in) outside diameter XNominal 1.1mm (1/16in) wall

b)

70mm (1 3/4in) long X 9.53mm(3/8in) outside diameter X 1.19mm(0.05in) wall

c)

117mm(4.68in) long X 4.5mm(0.175in) outside diameter X 2mm(0.08in) wall

d)

None of the above

Q.74. For Abrasion media in ASTM C-704 is having screen analysis as shown in a)

Table 1

b)

Table 2

c)

No. 16 Grit silicon carbide

d)

No.30 Grit silicon carbide

Q.75. In test methods for cold crushing strength as per ASTM C 133 - 97 the test specimens are dried at a)

220 deg F to 230 deg F ( 105 deg C to 110 deg C )

b)

300 deg F to 320 deg F ( 180 deg C to 190 deg C )

c)

600degF to 650degF(315degC to 340degC)

d)

400 deg F to 450 deg F ( 204 deg C to 230 deg C )

Q.76. For refractory, the binder selection is primarily based on a)

the temperature desired for the refractory concrete

b)

Al2O3 content in refractory

c)

Lower iron content in binder

d)

None of the above

Q.77. For service temperature of 1340 deg C ( 2450 deg F ) The refractory used is a)

Trap rock, diahase

b)

Vermiculite

c)

Slag blast furnace(Air cooled)

d)

Perlite

Q.78. for temperature 1650 deg C ( 3000 deg F ) and Abrasive & corrosion atmosphere the refractory used is a)

Kaolin ( Calcined )

b)

Perlite ( Insulating )

c)

Slag Blast furnace( Air cooled )

d)

Dolomite limestone ( gravel )

API 936: Refractory Installation, Inspection and Testing

PART - VII STANDARD API 936 REFRACTORY INSTALLATION QUALITY CONTROL INSPECTION AND TESTING MONOLITHIC REFRACTORY LININGS AND MATERIALS