Section 11 — Refractory, Insulation & Fireproofing
Internal Insulation and Refractory Lining Inspection
IPE Engineering Practice IPE-EP-11-1-1C
Document number: IPE-EP-11-1-1C · Section: 11 — Refractory, Insulation & Fireproofing
THE MANUFACTURER OF EQUIPMENT PURCHASED BY INFLECTION POINT ENGINEERING, LLC SHALL BE RESPONSIBLE FOR MEETING ALL APPLICABLE REQUIREMENTS OF THE IPE ENGINEERING PRACTICES AND OTHER DOCUMENTS REFERENCED THEREIN REGARDLESS OF WHETHER THE ITEMS ARE INSPECTED BY A IPE REPRESENTATIVE.
REFERENCES
THE LATEST EDITION OF THE FOLLOWING STANDARDS AND PUBLICATIONS ARE REFERRED TO HEREIN.
IPE ENGINEERING PRACTICES
EP 11-1-1 INTERNAL INSULATING AND REFRACTORY LINING
ASTM SPECIFICATIONS
ASTM C133 COLD CRUSH STRENGTH AND MODULUS OF RUPTURE
ASTM C704-88 ABRASION RESISTANCE OF REFRACTORY MATERIALS AT ROOM TEMPERATURE ASTM C860 PRACTICES FOR DETERMINING CONSISTENCY IN REFRACTORY CONCRETES
STEEL STRUCTURES PAINTING COUNCIL
SSPC-SP6 COMMERCIAL BLAST CLEANING SSPC-SP10 NEAR WHITE BLAST CLEANING
FREQUENCY OF CONTACT BY THE INSPECTOR: (CHECK ONE)
LEVEL 1: ON CALL BY FABRICATOR LEVEL 2: ONCE EVERY TWO WEEKS LEVEL 3: EVERY WEEK
LEVEL 4: DAILY
LEVEL 5: RESIDENT LEVEL 6: OTHER, SPECIFY
LEVEL OF INSPECTION BY THE INSPECTOR: (CHECK ONE)
LEVEL 1: PREFABRICATION MEETING, DOCUMENT REVIEW, AND FINAL INSPECTION
LEVEL 2: PREFABRICATION MEETING, DOCUMENT REVIEW, REVIEW ITEMS, AND FINAL INSPECTION LEVEL 3: PREFABRICATION MEETING, DOCUMENT REVIEW, REVIEW ITEMS, WITNESS POINTS, AND FINAL
INSPECTION
LEVEL 4: PREFABRICATION MEETING, DOCUMENT REVIEW, REVIEW ITEMS, WITNESS POINTS, HOLD POINTS, AND FINAL INSPECTION
LEVEL 5: OTHER, SPECIFY
DOCUMENT REVIEW (SHOP INSPECTOR SHALL REVIEW):
| DOCUMENT DESCRIPTION | INSPECTOR'S INITIALS (REVIEW COMPLETE) | DATE | |
|---|---|---|---|
| IPE PURCHASE DOCUMENTS | |||
| DRAWINGS AND SPECIFICATIONS | |||
| DATA SHEETS (6.0) | |||
| CONTRACTOR SPECIFICATIONS (5.0) | |||
| QUALITY CONTROL PLAN | |||
| MATERIAL RECEIVING SIGN-OFF AND PMI | |||
| MATERIAL TEST REPORTS (19.1.5, 19.2, 19.3) | |||
| WELDING PROCEDURE SPECS. | |||
| WELDER QUALIFICATION RECORDS | |||
| WELDER TRACEABILITY DOCUMENT | |||
| FABRICATION PLAN/SHOP TRAVEL | |||
| IDENTIFICATION OF CRITICAL DIMENSONS | |||
| SUB-CONTRACTOR Q/C REPORTS | |||
| DRYOUT SCHEDULES AND THERMOCOUPLE PLACEMENT (18.0) | |||
| AUTHORIZED WAIVERS AND/OR DEVIATIONS REVIEW | |||
| REVIEW OF SUBORDERS OF UNPRICED PURCHASE ORDERS TO SUBVENDORS FOR COMPLIANCE WITH IPE ENGINEERING PRACTICES | |||
| EQUIPMENT ID | JOB NO. | DOCUMENT NO. | REV. |
|---|
GENERAL INSPECTION REQUIREMENTS
R CHECK: THE SHOP INSPECTOR SHALL REVIEW DOCUMENTED RESULTS OF INSPECTION PERFORMED BY VENDOR'S INSPFCTOR OR SUBCONTRACTED INSPECTOR.
W CHECK: INDICATES THE SHOP INSPECTOR SHALL WITNESS ITEMS DURING FABRICATION SHOP SHALL NOTIFY INSPECTOR 2 DAYS IN ADVANCE OF FABRICATION POINT BUT NEED NOT HOLD PRODUCTION FOR INSPECTION.
H CHECK: INDICATES THE SHOP INSPECTOR SHALL INSPECT ITEMS DURING HOLD ON FABRICATION. SHOP SHALL NOTIFY INSPECTOR FIVE DAYS IN ADVANCE OF FABRICATION POINT AND SHALL NOT CONTINUE AFFECTED PRODUCTION UNTIL INSPECTOR PERFORMS AND IMPROVES FABRICATION AFTER INDICATED INSPECTION.
| R | W | H | INSPECTION/TESTING ACTIVITY | INSPECTOR’S INITIALS (REVIEW COMPLETE) | DATE |
|---|---|---|---|---|---|
| MATERIAL QUALIFICATION | MATERIAL QUALIFICATION | MATERIAL QUALIFICATION | MATERIAL QUALIFICATION | MATERIAL QUALIFICATION | MATERIAL QUALIFICATION |
| REFRACTORY PREQUALIFICATION (19.2) | |||||
| ANCHORS (19.1.5) INCLUDING PMI CHECK | |||||
| PRODUCTION | |||||
| INSTALLATION QUALIFICATION | INSTALLATION QUALIFICATION | INSTALLATION QUALIFICATION | INSTALLATION QUALIFICATION | INSTALLATION QUALIFICATION | INSTALLATION QUALIFICATION |
| GUNITE (19.4.2) | |||||
| POURED/CAST (19.4.3) | |||||
| THIN EROSION RESISTANT LININGS (19.4.4) | |||||
| WELDING (13.1.3, 13.1.4, 13.2.1,13.2.2, 19.4.5) | |||||
| SHIPPING/HANDLING/MARKING/STORAGE | SHIPPING/HANDLING/MARKING/STORAGE | SHIPPING/HANDLING/MARKING/STORAGE | SHIPPING/HANDLING/MARKING/STORAGE | SHIPPING/HANDLING/MARKING/STORAGE | SHIPPING/HANDLING/MARKING/STORAGE |
| MATERIAL MARKING (14.3, 14.4, 15.1.2) | |||||
| MATERIAL AGE (14.1, 14.2, 14.8) | |||||
| PACKAGING (14.4, 14.5, 14.6, 14.7, 14.8) | |||||
| TEMPERATURE (15.2.1.7, 15.3.1.1, 15.4.1) | |||||
| HANDLING (15.1.1, 15.1.2, 15.4.15, 16.6) | |||||
| EQUIPMENT ID | JOB NO. | DOCUMENT NO. | REV. |
|---|
GENERAL INSPECTION REQUIREMENTS
R CHECK: THE SHOP INSPECTOR SHALL REVIEW DOCUMENTED RESULTS OF INSPECTION PERFORMED BY VENDOR'S INSPFCTOR OR SUBCONTRACTED INSPECTOR.
W CHECK: INDICATES THE SHOP INSPECTOR SHALL WITNESS ITEMS DURING FABRICATION SHOP SHALL NOTIFY INSPECTOR 2 DAYS IN ADVANCE OF FABRICATION POINT BUT NEED NOT HOLD PRODUCTION FOR INSPECTION.
H CHECK: INDICATES THE SHOP INSPECTOR SHALL INSPECT ITEMS DURING HOLD ON FABRICATION. SHOP SHALL NOTIFY INSPECTOR FIVE DAYS IN ADVANCE OF FABRICATION POINT AND SHALL NOT CONTINUE AFFECTED PRODUCTION UNTIL INSPECTOR PERFORMS AND IMPROVES FABRICATION AFTER INDICATED INSPECTION.
| R | W | H | INSPECTION/TESTING ACTIVITY | INSPECTOR’S INITIALS (REVIEW COMPLETE) | DATE |
|---|---|---|---|---|---|
| SURFACE PREPARATION/CLEANLINESS | SURFACE PREPARATION/CLEANLINESS | SURFACE PREPARATION/CLEANLINESS | SURFACE PREPARATION/CLEANLINESS | SURFACE PREPARATION/CLEANLINESS | SURFACE PREPARATION/CLEANLINESS |
| PRIOR TO WELDING (8.1.3, 8.1.4, 12.4.1, 12.5, 12.6, 12.7, 13.1.1) | |||||
| PRIOR TO COATING (12.2, 12.3, 12.7, 12.8) | |||||
| PRIOR TO REFRACTORY INSTALLATION (SEE DAILY LOG SHEET) | |||||
| EQUIPMENT CLEANLINESS (SEE DAILYLOG SHEET) | |||||
| DURING INSTALLATION (SEE DAILY LOG SHEET) | |||||
| ANCHOR INSTALLATION | ANCHOR INSTALLATION | ANCHOR INSTALLATION | ANCHOR INSTALLATION | ANCHOR INSTALLATION | ANCHOR INSTALLATION |
| MATERIAL (8.1.1, 8.3.1, 8.3.5, 8.6.2, 8.6.3, 19.1.5) | |||||
| DESIGN (8.2.1, 8.2.3, 8.3.2, 8.3.3, 8.3.5, 8.4.1, 9.0) | |||||
| SPACING (8.2.1, 8.2.4, 8.3.5, 8.4.2, 8.5.1, 8.5.2) | |||||
| WELDING (8.7.1, 8.7.2, 19.4.5) | |||||
| HEIGHT (8.1.3, 8.3.2, 8.4.3, 8.5.5) | |||||
| ADDITIONAL DIMENSIONAL CHECKS (8.2.2, 8.5.1, 13.1.5, 13.2.3, 13.2.7, 13.2.8) | |||||
| CURING AND DRYOUT (SEE SECTIONS 16.0 AND 18.0 FOR REQUIREMENTS) | CURING AND DRYOUT (SEE SECTIONS 16.0 AND 18.0 FOR REQUIREMENTS) | CURING AND DRYOUT (SEE SECTIONS 16.0 AND 18.0 FOR REQUIREMENTS) | CURING AND DRYOUT (SEE SECTIONS 16.0 AND 18.0 FOR REQUIREMENTS) | CURING AND DRYOUT (SEE SECTIONS 16.0 AND 18.0 FOR REQUIREMENTS) | CURING AND DRYOUT (SEE SECTIONS 16.0 AND 18.0 FOR REQUIREMENTS) |
| CASING TEMPERATURE | |||||
| CURING TIME | |||||
| CURING COMPOUND APPLICATION (SEE DAILY LOG SHEETS) | |||||
| DRYOUT | |||||
DAILY LOG SHEET
AS A MINIMUM, THE FOLLOWING LEVELS OF INSPECTION SHALL BE PERFORMED:
P CHECK: CHECK PRIOR TO STARTING WORK ON EACH SHIFT
R CHECK: IN ADDITION TO "P" CHECK, MAKE RANDOM CHECKS DURING SHIFT DATE: INSPECTOR’S NAME AND INITIALS:
| READINGS | READINGS | ||
|---|---|---|---|
| TIME | VALUE | ||
| R | CASING TEMPERATURES (15.2.1.4, 15.2.1.5, 15.3.1.4, 15.3.1.5, 15.4.6, 15.4.8, 16.2, 16.5, 16.7) |
||
| R | WATER TEMPERATURE (15.1.3) | ||
| R | WATER AMOUNT (15.2.1.1, 15.4.3, 15.4.4) | ||
| R | AMBIENT TEMPERATURE (15.3.1.6, 15.4.8) | ||
| R | MIX TEMPERATURE (15.2.1.2, 15.2.1.3, 15.4.5, 15.4.7) |
||
| R | MIXING TIME (15.4.11, 15.4.13) | ||
| R | LINING THICKNESS (15.1.12, 15.5.3) | ||
DAILY LOG SHEET
AS A MINIMUM, THE FOLLOWING LEVELS OF INSPECTION SHALL BE PERFORMED:
P CHECK: CHECK PRIOR TO STARTING WORK ON EACH SHIFT
R CHECK: IN ADDITION TO "P" CHECK, MAKE RANDOM CHECKS DURING SHIFT DATE: INSPECTOR’S NAME AND INITIALS:
| TIME | INSPECTOR’S INITIALS | ||
|---|---|---|---|
| P | WATER QUALITY (15.1.3, 15.1.4) | ||
| P | FIBER ADDITIONS (11.0, 15.1.10, 15.1.11) | ||
| R | CASTING DROP HEIGHT (15.2.2.5) | ||
| R | APPLICATION POSITION (15.2.2.6, 15.2.3.1, 15.2.3.2, 15.4.15) |
||
| R | GUNITE AREA (15.2.3d) | ||
| P | ROTATING/MOVING OF PARTS (15.1.1, 15.4.15) | ||
| R | CURING COMPOUND APPLICATION (15.2.1.14, 16.1, 16.4) | ||
| R | VIBRATOR PLACEMENT | ||
| R | FORMS (15.1.8, 15.3.1.3, 16.4) | ||
DAILY LOG SHEET
AS A MINIMUM, THE FOLLOWING LEVELS OF INSPECTION SHALL BE PERFORMED:
P CHECK: CHECK PRIOR TO STARTING WORK ON EACH SHIFT
R CHECK: IN ADDITION TO "P" CHECK, MAKE RANDOM CHECKS DURING SHIFT DATE: INSPECTOR’S NAME AND INITIALS:
| SURFACE PREPARATION/CLEANLINESS | TIME | INSPECTOR’S INITIALS |
|---|
| R | PRIOR TO REFRACTORY INSTALLATION (12.0, 15.1.8, 15.1.13, 15.1.14) | ||
|---|---|---|---|
| R | EQUIPMENT CLEANLINESS (15.1.6, 16.4.12, 15.4.16) |
||
| R | DURING INSTALLATION (15.2.1.h, 15.2.1.k, 15.2.1.l, 15.2.1.m, 15.2.2.d, 15.2.3.c, 15.3.1.l, 15.3.2.j, 15.3.2.k, 15.3.2.l, 15.3.2.m, 15.5.4, 15.5.5) |
||
PRODUCTION SAMPLES
| SAMPLE DESIGNATION | LOCATION | TIME | INSPECTOR'S INITIALS |
|---|---|---|---|
| INSPECTOR SIGN-OFF | INSPECTOR SIGN-OFF | INSPECTOR SIGN-OFF | INSPECTOR SIGN-OFF |
|---|---|---|---|
| INITIALS | NAME | COMPANY | SOCIAL SECURITY NUMBER |
| SUMMARY: |
|---|
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