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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
Normative references............................................................................................................. 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
Linings ................................................................................................................................... 6
Anchoring .............................................................................................................................. 7
Dryout .................................................................................................................................... 8
10
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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.
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Refractory Inspection
Introduction
This GIS defines the roles and responsibilities of BPs 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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Scope
This GIS provides Group instructions for supply for inspection of refractory lining systems for
equipment operating above 480C (900F).
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 undated references, the latest edition (including any amendments) applies.
BP
GIS 72-001
GIS 72-002
GIS 72-003
GIS 72-110
5
5.1
PLC
PMI
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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Refractory Inspection
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.
5.4
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.
Linings
a.
Inspector shall have authority to determine whether refractory linings meet minimum
requirements.
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Refractory Inspection
b.
c.
A lining report that lists deviations from GIS 72-002 and reasons for deviations, along with
test results, shall be provided.
Anchoring
a.
b.
2.
3.
4.
5.
6.
7.
Refractory application
a.
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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Refractory Inspection
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.
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.
Dryout
Dryout of refractory linings, if required, shall be inspected and observed for compliance with
specification requirements identified in the following:
10
a.
GIS 72-003.
b.
c.
d.
Acceptance criteria
Acceptance criteria shall comply with GIS 72-002.
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