Ref Inspect

Module from the Refractory and Insulation Curriculum curriculum.

Module 4 - Refractory Inspection · Learning Objectives · 1. Conduct cold inspection during shutdown (VT, measured thickness) · 2. Conduct hot inspection during operation (IR thermography) · 3. Identify failure modes: spalling, cracking, erosion, alkali attack · 4. Classify findings and repair action by severity · 5. Maintain refractory map/drawing with condition history · Refractory Failure Modes

Mode	Cause	Indicator	Repair	Prevention	Ref
Thermal spalling	Rapid heat-up	Surface cracks, flakes	Patch or replace	Dry-out schedule	ASTM C1054
Mechanical spalling	Catalyst impact	Chunks	Replace section	Hex mesh design	Manufacturer
Chemical attack (alkali)	Alkali vapor	Surface melted zones	Replace with resistant	Upgrade material	Chemistry
Creep	High T, long-term	Sagging wall	Replace	Reduce load, upgrade	Material data
Cracking	Thermal cycling	Linear cracks	Patch	Expansion joints	Installation
Erosion	Flow + abrasion	Thinning	Replace	Hex mesh, upgrade	Service data
Anchor failure	Corrosion or fatigue	Loose panels	Replace anchors	Proper material	Anchor spec
Hot spots	Refractory loss	IR thermography	Identify and repair	Preventive	IR + planning

Source: Refractory_Insulation_Curriculum_v1.xlsx · Sheet: Ref Inspect

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