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API 936 Refractory Personnel Practice Test

API-936 exam Format | Course Contents | Course Outline | exam Syllabus | exam Objectives

Duration: 3 hours 15 minutes
Total Questions: 85 Questions
Question Details: 75 questions are scored- 10 questions are pretest
Question Type: 85 questions are multiple-choice and closed book
Passing Score: 70%

- Laboratory Testing Procedures
- Terms and definitions
- Test methods (e.g.- C704- CCS- PLC- Density) and related calculations
- Material Qualification
- Testingequipment- trial preparation techniques- dimensional requirements for test specimens
- Various materials utilized (for example- plastic- ceramic fiber- anchor- metal fiber- corrosion coatings- etc.)
- Curing and firing procedures
- Acceptance/rejection criteria
- Responsibilities of personnel and documentation requirements.

- Applicator and Material Qualification
- Installationmethods (e.g.- gunning- casting- ramming- and hand packing)
- Sampling and trial preparation procedures
- Terms and definitions
- Procedures for determining optimal water content and mixing
- Applicable formulation and manufacturing information
- Applicable knowledge of equipment and qualification process
- Applicable test panel/mockup requirements
- Applicable environmental controls
- Surface preparation requirements
- Responsibilities of personnel and documentation requirements

- Installation
- Terms and definitions
- Responsibilities of personnel and documentation requirements
- Knowledgeof detailedexecution planincluding design details and quality standards
- Packaging and storage requirements
- Surface preparation and cleanliness requirements
- Anchor: welding- layouts- patterns- materials
- Frequency andmethods of production sampling: gunning- casting- hand packing
- Water addition: quantity and temperature- mixing procedures
- Fiber addition: percentage- material- mixing
- Installation environmental controls (minimum and maximum temperatures)
- Gunite procedures and equipment- including variables that affect gunite quality (i.e.- air pressure- humidity- temperature- aging- water pressure- water purity- additives)
- Knowledge of flash set
- Casting procedures and equipment (e.g.- air vibrator- vibrator frequency- vibrator sizing- forming- setup)
- Ramming / Hand packed procedures and equipment

- Inspection
- Terminology- job specifications- application standards
- Inspection and data collection procedures
- Lining design and installation requirements
- Visual and nondestructive testmethodsand qualification testing methods
- Application/limitation for various inspection techniques (for example- hammer testing- sonic testing- radiography- core sampling- portable abrasion testing)
- Material verification and traceability
- Acceptance and rejection criteria
- Repair procedures
- Curing and dry out procedures
- Inspectors’ and contractors’ responsibilities
- Record keeping systems and requirements

- Post-Installation
- Terms and definitions
- Responsibilities of personnel and documentation requirements
- Knowledge of dryout requirements
- Sealing requirements (for example- water mist- covering- membrane- curing)
- Application and time limits for applying membrane curing compounds
- Environmental conditions required for curing
- Heatingequipment- methods and procedures (e.g.- gas fired burner- stress relievingheating elements)
- Placement of temperature sensing probes

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API 936 Refractory Personnel - 2026
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Question: 484
During material qualification, a refractory mix shows a cold crushing strength (CCS) of 12 MPa, below
the specified 15 MPa. The inspector suspects improper mixing. What is the minimum mixing time for a
low-cement castable per API 936?
A. 3 minutes
B. 4 minutes
C. 5 minutes
D. 6 minutes
Answer: C
Explanation: API 936 requires a minimum mixing time of 5 minutes for low-cement castables to ensure
homogeneity and proper binder distribution, which directly affects CCS. Shorter times result in
incomplete mixing, while 6 minutes exceeds the requirement without additional benefit.
Question: 485
While inspecting a refractory lining, you find that the contractor used a mix with a setting time of 6
hours, exceeding the specified 4 hours per ASTM C191. Per API STD 936, what is the potential issue,
and what should be done?
A. Reduced strength; reject mix and retest
B. Increased porosity; repair affected areas
C. No impact; document observation
D. Surface cracking; monitor during dry-out
Answer: A
Explanation: A longer setting time (6 hours vs. 4 hours) per ASTM C191 can reduce strength due to
improper hydration, per API STD 936, section 4.3.2. The mix should be rejected, and a new batch tested,
per section 4.4.3.
Question: 486
During a wet-gunning installation of a 70% alumina castable in a FCCU riser, the contractor observes
that the material is segregating at the nozzle, leading to inconsistent density. According to API 936, what
is the most critical parameter to adjust to mitigate this issue while maintaining compliance with the
execution plan?
A. Adjust the water content to exceed the manufacturer�s maximum limit by 0.5%
B. Increase the mix time by 30 seconds to ensure homogeneity before pumping
C. Decrease the pump pressure by 10% and increase the air velocity at the nozzle
D. Modify the nozzle angle to 45 degrees to enhance material flow
Answer: C
Explanation: Segregation during wet-gunning, as per API 936, is often caused by improper balance
between pump pressure and air velocity, leading to uneven material distribution. Decreasing the pump
pressure by 10% and increasing air velocity at the nozzle helps stabilize the material stream, ensuring
consistent density without violating the manufacturer�s water content limits, unnecessarily extending mix
time, or altering the nozzle angle, which is not specified in API 936 as a primary control.
Question: 487
During a hand-packing operation, the contractor prepares test specimens for a 1600 kg/m� plastic
refractory. Per API 936, what is the minimum curing time before testing compressive strength per ASTM
C133-97?
A. 12 hours
B. 48 hours
C. 36 hours
D. 24 hours
Answer: D
Explanation: API 936, referencing ASTM C133-97, requires a minimum curing time of 24 hours for
plastic refractory test specimens before compressive strength testing to ensure proper setting. Shorter
times (12 hours) risk inaccurate results, while 36 or 48 hours are unnecessary.
Question: 488
A refractory provider provides a certificate for a castable with a modulus of rupture (MOR) of 12 MPa
per ASTM C133. Core samples yield an MOR of 10 MPa. What is the maximum allowable deviation per
API STD 936, and what action is required?
A. �10%, accept material
B. �15%, reject material
C. �15%, accept material
D. �10%, reject material
Answer: D
Explanation: Per API STD 936, the maximum allowable deviation for physical properties like MOR is
�10%. The measured MOR (10 MPa) deviates by (12 - 10) / 12 x 100 = 16.67%, exceeding the
tolerance, so the material should be rejected. A �15% limit is not specified in API STD 936. Accepting
the material is incorrect due to non-compliance.
Question: 489
In a post-installation dry-out of a refractory lining, the contractor uses gas-fired burners with a maximum
flame temperature of 1200�C. The dry-out schedule requires a maximum refractory surface temperature
of 600�C. What control measure must be implemented to comply with API STD 936?
A. Use baffles to prevent direct flame contact
B. Maintain flame impingement on the refractory
C. Increase burner output to 1500�C
D. Ventilate the furnace to increase airflow
Answer: A
Explanation: API STD 936 prohibits direct flame impingement during dry-out to prevent localized
overheating, which could exceed the specified 600�C surface temperature and cause spalling. Using
baffles to diffuse the flame ensures indirect heating, maintaining uniform temperature control. Increasing
burner output or maintaining flame impingement violates the standard, and ventilation alone does not
address flame control.
Question: 490
A quality control inspector is reviewing the material qualification data for a phosphate-bonded plastic
refractory. According to API TR 980, what is the critical temperature range for forming a permanent
ceramic bond during initial heat-up?
A. 300�500�F (149�260�C)
B. 700�900�F (370�482�C)
C. 500�700�F (260�370�C)
D. 900�1100�F (482�593�C)
Answer: C
Explanation: API TR 980 specifies that phosphate-bonded plastic refractories form a permanent ceramic
bond during heat-up between 500�700�F (260�370�C). This temperature range is critical for ensuring the
material�s final bonding and structural integrity.
Question: 491
An inspector identifies a non-conformance in the curing process due to premature air drying. What is the
maximum allowable air-drying time before corrective action is needed, per API STD 936?
A. 1 hour
B. 2 hours
C. 3 hours
D. 4 hours
Answer: B
Explanation: API STD 936 specifies that hydraulic-bonded castable refractories must not air dry for more
than 2 hours before applying a curing compound. Premature drying beyond this requires corrective
action, such as rewetting or applying a curing compound.
Question: 492
During a laboratory test for abrasion resistance per ASTM C704-15, a refractory specimen is subjected to
a specific abrasive media under controlled conditions. If the initial weight of a specimen is 500.0 g, its
dimensions are 50 mm x 50 mm x 50 mm, and the weight after testing is 485.2 g, what is the abrasion
loss in cm�, given the initial bulk density is 2.5 g/cm�?
A. 6.32 cm�
B. 6.12 cm�
C. 5.92 cm�
D. 6.52 cm�
Answer: C
Explanation: To calculate abrasion loss per ASTM C704-15, the volume loss is determined using the
weight loss and initial bulk density. Weight loss = 500.0 g - 485.2 g = 14.8 g. Initial bulk density = 2.5
g/cm�. Volume loss = weight loss / density = 14.8 g / 2.5 g/cm� = 5.92 cm�. The answer is 5.92 cm�.
Question: 493
For a hydraulic-bonded castable refractory, what is the maximum allowable time for air drying before
applying a membrane curing compound, per API STD 936?
A. 1 hour
B. 2 hours
C. 4 hours
D. 6 hours
Answer: B
Explanation: API STD 936 requires that hydraulic-bonded castable refractories not be allowed to air dry
for more than 2 hours before applying a membrane curing compound to prevent premature drying, which
could impair the curing process and reduce lining strength.
Question: 494
In a refractory-lined reactor, you perform visual inspection and note spalling over a 0.4 m� area. Per API
STD 936, what is the maximum allowable spalled area, and which NDT method assesses subsurface
damage?
A. 0.2 m�, sonic testing
B. 0.4 m�, hammer testing
C. 0.2 m�, ultrasonic testing
D. 0.4 m�, radiographic testing
Answer: C
Explanation: Per API STD 936, the maximum allowable spalled area is 0.2 m� for critical linings. The
observed 0.4 m� exceeds this limit, requiring further evaluation. Ultrasonic testing is the most effective
NDT method to assess subsurface damage, such as delamination or cracking, beneath the spalled area.
Sonic testing lacks precision for subsurface defects. Hammer testing is limited to surface voids.
Radiographic testing is impractical for thick linings.
Question: 495
During a laboratory test for a high-alumina castable, the technician measures a permanent linear change
(PLC) of -0.4% after firing at 2912�F for 5 hours. The specification requires a PLC of -0.3% to +0.1%.
What is the correct action?
A. Reject the material and notify the manufacturer
B. Conduct a re-test at a lower firing temperature
C. Accept the material, as the PLC is within 0.1% of the limit
D. Request owner approval to adjust the specification
Answer: A
Explanation: API STD 936 requires compliance with specified PLC ranges per ASTM C113-14. A PLC
of -0.4% is outside the range of -0.3% to +0.1%, indicating non-compliance (Reject the material and
notify the manufacturer). A 0.1% tolerance is not permitted (ruling out Accept the material, as the PLC
is within 0.1% of the limit). Re-testing at a different temperature (Conduct a re-test at a lower firing
temperature) or adjusting specifications (Request owner approval to adjust the specification) is not
allowed without owner approval.
Question: 496
A refractory lining is being dried out using stress-relieving heating elements with a total output of 120
kW over a 25 m� surface. The schedule requires a hold at 450�C for 8 hours. What is the heat flux during
this hold?
A. 3.2 kW/m�
B. 4.8 kW/m�
C. 6.4 kW/m�
D. 8 kW/m�
Answer: B
Explanation: Heat flux is calculated as 120 kW � 25 m� = 4.8 kW/m�. This supports the 450�C hold per
API STD 936, ensuring uniform heating. Options like 3.2 kW/m� or 6.4 kW/m� do not match the
calculated value, and 8 kW/m� is too high.
Question: 497
For a gunning operation, API 936 requires a pre-installation mockup to qualify the applicator. The
mockup must be gunned to a panel size of 1 m x 1 m with a thickness of 100 mm. What is the minimum
number of test specimens required from this mockup for physical property testing?
A. 2 specimens
B. 5 specimens
C. 4 specimens
D. 3 specimens
Answer: D
Explanation: API 936 specifies that a minimum of three test specimens must be taken from a gunned
mockup panel for physical property testing (e.g., compressive strength, density) to qualify the applicator.
Options 2, 4, and 5 specimens do not meet the minimum requirement for ensuring consistent quality.
Question: 498
Which term, as defined in API STD 936, refers to the process of removing moisture from a newly
installed refractory lining to prepare it for service?
A. Curing
B. Firing
C. Dryout
D. Sealing
Answer: C
Explanation: API STD 936 defines �dryout� as the controlled process of removing moisture from a newly
installed refractory lining through heating to prepare it for service. Curing involves maintaining moisture
for hydration, firing refers to high-temperature processing, and sealing involves applying protective
compounds.
Question: 499
A refractory lining is tested for thermal shock resistance per ASTM C1100. The test requires cycling
between 1000�C and 20�C for 10 cycles. If the lining fails after 8 cycles with a 20% mass loss, what is
the minimum acceptable cycle count, and which inspection method verifies in-situ performance?
A. 5 cycles, core sampling
B. 5 cycles, infrared thermography
C. 10 cycles, core sampling
D. 10 cycles, ultrasonic testing
Answer: C
Explanation: Per ASTM C1100, the minimum acceptable cycle count for thermal shock resistance is 10
cycles with minimal mass loss. The lining�s failure at 8 cycles with 20% mass loss indicates non-
compliance, requiring verification. Core sampling is the best method to extract samples for ASTM
C1100 retesting to confirm in-situ performance. Infrared thermography detects temperature gradients, not
thermal shock resistance. Ultrasonic testing identifies internal flaws, not thermal shock performance.
Question: 500
A contractor is mixing a high-alumina castable with a specified water content of 5.5% � 0.5%. If 100 kg
of dry mix is used, what is the acceptable water volume range in liters? (Assume water density is 1
kg/L.)
A. 4.5�5.5 L
B. 5.5�6.5 L
C. 5.0�6.0 L
D. 6.0�7.0 L
Answer: C
Explanation: For 100 kg of dry mix, 5.5% � 0.5% water content translates to 5.0�6.0% by weight, or
5.0�6.0 kg. Since water density is 1 kg/L, this equals 5.0�6.0 L.
Question: 501
A castable installation in a heater uses a formwork with inadequate bracing, leading to bulging during
vibration. The castable density is 135 lb/ft�, and the vibrator force is 1,800 lbf. What is the best
corrective action per API 936?
A. Increase vibrator force to 2,000 lbf
B. Reduce castable density to 125 lb/ft�
C. Reinforce formwork with additional bracing
D. Use a lower frequency vibrator
Answer: C
Explanation: Reinforcing formwork with additional bracing prevents bulging, as API 936 requires rigid
formwork to withstand vibration forces. Increasing force worsens bulging. Reducing density is
impractical. Lowering frequency affects consolidation, not formwork stability.
Question: 502
For a refractory installation in a sulfur recovery unit, API STD 936 mandates strict environmental
controls. During mixing, the relative humidity exceeds 85%, risking excessive water absorption in the
dry castable mix. What is the applicator�s best action to mitigate this issue?
A. Add 2% extra water to the mix to compensate for absorption
B. Cover the dry mix with tarps and use dehumidifiers
C. Continue mixing but reduce the mixing time by 5 minutes
D. Store the mix in a heated warehouse for 24 hours
Answer: B
Explanation: API STD 936 requires controlling relative humidity to prevent water absorption in dry
refractory mixes, which can affect material properties. Adding extra water risks over-wetting the mix,
compromising strength. Reducing mixing time does not address humidity. Storing in a heated warehouse
may help but delays installation unnecessarily. Covering the mix and using dehumidifiers directly
mitigates high humidity, ensuring compliance with environmental controls.
Question: 503
A contractor adds 2% by weight of 310 stainless steel fibers to a 2200 kg batch of castable. The mixer
operates at 60 rpm for 4 minutes. What is the maximum allowable mixing time to avoid fiber damage per
API 936?
A. 3 minutes
B. 4 minutes
C. 5 minutes
D. 6 minutes
Answer: C
Explanation: API 936 recommends a maximum mixing time of 5 minutes for fiber-reinforced castables to
avoid fiber damage. Option 5 minutes is correct. The current 4 minutes is within limits, but exceeding 5
minutes risks damage.
Question: 504
During a flash set of a castable in a duct, the mix reaches 105�F with 7% water addition. The datasheet
specifies 6.5% water at 80�F. What is the most effective preventive measure per API 936?
A. Add a dispersant to the mix
B. Use a borate-based retarder
C. Reduce water addition to 6%
D. Cool the aggregate to 60�F
Answer: B
Explanation: Using a borate-based retarder controls rapid setting at high temperatures (105�F), per API
936. Adding a dispersant affects flow, not setting. Cooling aggregate is less practical. Reducing water
may compromise workability.
Question: 505
A refractory trial fails a cold crushing strength test with a result of 30 MPa, against a specification of
35 MPa minimum, per API STD 936. What should the inspector recommend?
A. Accept the trial if other properties meet specifications
B. Conduct a retest with a new sample
C. Request a variance from the owner
D. Reject the trial and investigate the cause
Answer: D
Explanation: A cold crushing strength of 30 MPa fails to meet the minimum specification of 35 MPa,
requiring rejection of the trial per API STD 936. Investigating the cause ensures quality control.
Accepting the trial violates the specification. Retesting is not appropriate without addressing the
failure�s cause. Requesting a variance is secondary to rejection and investigation.
Question: 506
During a dry-out procedure for a dense castable refractory, the contractor proposes a heating rate of
100�F/hr (56�C/hr) to 1000�F (538�C). What is the inspector�s action per API 936?
A. Approve the rate as it meets general guidelines
B. Verify the rate against the manufacturer�s data sheet
C. Request a revised schedule with hold points
D. Reject the rate and require a slower heating schedule
Answer: B
Explanation: API 936, Section 4.2.7, mandates that dry-out heating rates must follow the manufacturer�s
recommendations, as rates vary based on material composition and thickness. The inspector must verify
the proposed rate against the manufacturer�s data sheet. Approving without verification risks thermal
shock. Rejecting outright is premature without data. Requesting hold points is secondary to verifying the
rate.
Question: 507
During equipment qualification for a vibratable castable, the inspector observes segregation in the test
panel. What is the most likely cause per API 936?
A. Excessive vibration time exceeding 90 seconds
B. Inadequate mixing time below 3 minutes
C. Incorrect water content above 7%
D. Low-frequency vibration below 50 Hz
Answer: A
Explanation: API 936 notes that excessive vibration time can cause segregation in vibratable castables,
separating aggregates from the matrix. Inadequate mixing affects homogeneity but not segregation during
placement, incorrect water content impacts flowability, and low-frequency vibration is less likely to cause
segregation.
Question: 508
During a refractory installation, the inspector notes that the contractor�s mixing time exceeds the
manufacturer�s maximum by 30%. What is the inspector�s action?
A. Accept if the material appears uniform
B. Verify the mixing time with the owner
C. Request retesting of the mixed material
D. Reject the batch for non-compliance
Answer: D
Explanation: API 936, Section 4.2.3, requires mixing times to comply with the manufacturer�s
specifications to ensure material consistency. Exceeding the maximum by 30% is a non-conformance,
requiring batch rejection. Visual uniformity is insufficient. Retesting or owner verification does not
address the procedural violation.
Question: 509
During a post-installation inspection, the inspector finds that the contractor failed to maintain curing
records for a hydraulic-bonded castable. Per API 936, what is the consequence?
A. Reject the installation for non-compliance
B. Require retesting of physical properties
C. Accept the installation if visual inspection passes
D. Request retroactive documentation from the contractor
Answer: A
Explanation: API 936, Section 5.2.8, mandates that contractors maintain detailed curing records as part of
quality control documentation. Failure to provide these records is a non-conformance, leading to rejection
of the installation. Visual inspection cannot substitute for records. Retesting or retroactive documentation
does not address the procedural violation.
Question: 510
During a density test per ASTM C134, a refractory sample�s dimensions are 100 mm x 50 mm x 25 mm,
and its weight is 0.3125 kg. What is the density in lb/ft�, given 1 kg/m� = 0.06243 lb/ft�?
A. 156 lb/ft�
B. 100 lb/ft�
C. 150 lb/ft�
D. 175 lb/ft�
Answer: A
Explanation: Volume = 0.1 m x 0.05 m x 0.025 m = 0.000125 m�. Density = 0.3125 kg / 0.000125 m� =
2500 kg/m�. Convert to lb/ft�: 2500 x 0.06243 = 156.075 lb/ft�.
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API 936 Refractory Personnel Practice Test

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