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Group Instruction for Supply
GIS 72-004 Refractory Inspection
14 December 2010 Engineering Technical Practice Engineering
Refractory Inspection
Table of Contents Page Foreword ........................................................................................................................................ 3 Introduction ..................................................................................................................................... 4 1
Scope .................................................................................................................................... 5
2
Normative references............................................................................................................. 5
3
Terms and definitions............................................................................................................. 5
4
Symbols and abbreviations .................................................................................................... 5
5
General.................................................................................................................................. 5 5.1 Inspection company/inspector..................................................................................... 5 5.2 Materials ..................................................................................................................... 6 5.3 Installation procedures................................................................................................ 6 5.4 Qualification of crew and installers.............................................................................. 6 Production................................................................................................................... 6 5.5 testing ......................................................................................................................... 6
6
Linings ................................................................................................................................... 6
7
Anchoring .............................................................................................................................. 7
8
Refractory application ............................................................................................................ 7
9
Dryout .................................................................................................................................... 8
10
Acceptance criteria ................................................................................................................ 8
Copyright © 2010 BP International Ltd. All rights reserved. This document and any data or information generated from its use are classified, as a minimum, BP Internal. Distribution is intended for BP authorized recipients only. The information contained in this document is subject to the terms and conditions of the agreement or contract under which this document was supplied to the recipient's organization. None of the information contained in this document shall be disclosed outside the recipient's own organization, unless the terms of such agreement or contract expressly allow, or unless disclosure is required by law. In the event of a conflict between this document and a relevant law or regulation, the relevant law or regulation shall be followed. If the document creates a higher obligation, it shall be followed as long as this also achieves full compliance with the law or regulation.
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Refractory Inspection
Foreword This is a revised issue of Engineering Technical Practice (ETP) GIS 72-004. This Group Instruction for Supply (GIS) incorporates the following changes: •Commentary added. •
Modifications to technical requirements for the inspector to enhance effectiveness of inspections.
Changes to this document are indicated by a bar in the left margin.
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Introduction This GIS defines the roles and responsibilities of BP’s authorised inspector (third party inspector in most instances) in projects that involve refractory linings. If plant or BP inspectors are used in refractory related projects, the same guidelines apply. The primary role of inspection is to ensure that appropriate specifications and approved procedures are followed in the design, selection, and installation of refractory materials. The inspector does not direct the crew of a refractory contractor and does not make exceptions to BP specifications. If the inspector observes deviation to the specifications or approved procedures, the inspector immediately notifies the BP responsible engineer of the deviations for resolution. Timely reporting is necessary to avoid costly repairs or delays to a project.
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1
Scope This GIS provides Group instructions for supply for inspection of refractory lining systems for equipment operating above 480ºC (900ºF).
2
Normative references The following referenced documents may, to the extent specified in subsequent clauses and normative annexes, be required for full compliance with this GIS: •
For dated references, only the edition cited applies.
•
For undated references, the latest edition (including any amendments) applies.
BP GIS 72-001 GIS 72-002 GIS 72-003 GIS 72-110
3
Procurement of Refractory - Firebrick, Insulating Firebrick, Ceramic Fibre (RCF), Alkaline Earth Silicate Wool (AESW), and Ferrules. Refractory Installation. Refractory Dryout. Procurement of Refractory - Monolithic.
Terms and definitions For the purpose of this GIS, the following terms and definitions apply: Inspector Person designated by BP to follow refractory application, including qualification of crew (procedure), anchor installation, and refractory lining installation, and ensure that minimum requirements of appropriate specifications are followed. Third party inspection company Company chosen by BP to furnish inspectors to follow refractory installation. Third party testing laboratory Company chosen by BP to provide testing of refractory in accordance with GIS 72-001, GIS 72-110, and GIS 72-002.
4
Symbols and abbreviations For the purpose of this GIS, the following symbols and abbreviations apply:
5 5.1
PLC
Permanent linear change.
PMI
Positive material identification.
General Inspection company/inspector Third party inspection company or inspector or both shall report directly to BP in accordance with GIS 72-002.
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5.2
Materials Verification shall be provided that refractory materials have been qualified (tested) by material vendor or independent laboratory prior to use in accordance with GIS 72-001, GIS 72-110, and GIS 72-002.
5.3
Installation procedures a.
Installation procedure for each application technique shall be reviewed and evaluated.
b.
Evaluation shall be subject to approval by the BP responsible engineer prior to qualification of crew and installers. Examining the contractor’s procedure provides BP confidence in the contractor’s skills and experience. The procedure also gives an opportunity for BP and the contractor to review the proposed work and correct any issues that arise. The procedure, once approved, also provides the inspector with guidelines for the application of refractory. Without an approved procedure, the contractor is free to make undisputable judgments about the installation and leaves the inspector ineffective.
5.4
Qualification of crew and installers Qualification of crew and installers shall comply with the qualification, inspection, testing, and repairs clause in GIS 72-002.
5.5
Production testing a.
Testing shall be performed in accordance with GIS 72-001, GIS 72-002, and GIS 72-110.
b.
Testing schedule shall be developed and shall be subject to approval by the BP responsible engineer. The production testing requirements are designed to have flexibility that provides the most cost effective testing program. The testing of production samples serves to confirm the quality of refractory linings and also to assess or evaluate the refractory contractor. This does not require testing of 100% of the samples taken. Sampling is well defined in GIS 72-002 and collecting the samples is a vital component of the quality control program. However, testing should be 25% to 40% of the samples taken. Selection of samples for testing depends on the type of material, type of equipment, and consequences of failure of the refractory lining. The testing schedule should maximise the number of installers tested along with a good cross section of the equipment. The plan should include testing of production samples for each day, each applicator, and each piece, at a minimum. In most instances, the number of samples will allow this, but review and approval is necessary by the BP responsible engineer. Samples need to be forwarded to a third party testing laboratory.
c.
Third party testing laboratory shall be subject to approval by the BP responsible engineer. The testing laboratory credentials are important and each lab needs to be approved by BP. Without this approval, test data and lining quality become compromised and consequences are potentially great. There are numerous labs currently approved by BP and their use is recommended. If other labs are considered, allow time for evaluation to avoid delays in the project.
d.
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PLC shall not be determined from production samples.
Linings a.
Inspector shall have authority to determine whether refractory linings meet minimum requirements. Page 6 of 8
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b.
Linings that do not meet minimum requirements shall be rejected. The role of the inspector is to ensure that the installed refractory linings meet all BP requirements. It is more valuable to BP and the installer for the inspector to witness all aspects of the work and become thoroughly familiar with the procedures, specifications, and work process. The inspector should anticipate problem situations and work toward resolution before mistakes are made. However, the inspector does not have authority to direct the work. The inspector has the authority to reject refractory linings that do not meet the minimum requirements of the specifications. However, the inspector needs to keep BP informed of any rejection in case other factors, such as schedule, are affected.
c.
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A lining report that lists deviations from GIS 72-002 and reasons for deviations, along with test results, shall be provided.
Anchoring a.
Anchor inspection shall comply with GIS 72-002.
b.
Inspection of anchoring systems shall include: 1.
Verifying correct anchoring type and metallurgy.
2.
Verifying correct alloy with PMI technique.
3.
Verifying that surface preparation meets requirements of GIS 72-002.
4.
Verifying proper anchor layout.
5.
Witnessing welding of anchors during first 15 min to 30 min (minimum) of installation procedure.
6.
Witnessing welding of anchors throughout application to verify pattern, welding, and surface cleanliness.
7.
Performing final inspection. The inspector needs to participate in all aspects of the anchor installation. Surface preparation should be a hold point for the inspector, and only after approval of the surface prep should the installation of anchors proceed. Approval of the anchor layout will reduce the risk of improper interpretation of the requirements and eliminate the need for compromise if improper layouts were used. The inspector also needs to witness the initial welding of anchors to ensure that the welder is consistent with qualification testing. After the initial inspection of anchor welding, the inspector should perform frequent spot checks on the anchor installation to avoid poor welding or anchor layout that will contribute to significant rework.
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Refractory application a.
Refractory application, in general and by individual installers, shall be inspected and techniques observed for compliance with specification requirements, approved engineering drawings, and generally accepted practices.
b.
Qualification and production sampling shall be observed for compliance with sampling requirements.
c.
Inspector shall have authority to determine whether individual installers comply with GIS 72-002.
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d.
Refractory installation times shall be monitored. If installation times exceed pot life or restrictions in GIS 72-002 (refer to the refractory application clause in GIS 72-002), refractory shall be rejected.
e.
Nozzlemen shall be subject to qualification. Nozzlemen who do not meet requirements of GIS 72-002 shall be rejected.
f.
Control plan that includes a checklist for each activity (i.e., cleaning, anchor layout and welding, forming, casting, form removal, and dryout) covered shall be developed, provided, and executed. The BP responsible engineer shall be notified of discrepancies discovered during execution of plan.
g.
Gunite, cast, cast vibration, and rammed applications shall be witnessed.
Dryout Dryout of refractory linings, if required, shall be inspected and observed for compliance with specification requirements identified in the following:
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a.
GIS 72-003.
b.
Approved engineering drawings.
c.
Approved written procedures.
d.
Generally accepted practices.
Acceptance criteria Acceptance criteria shall comply with GIS 72-002.
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