Section 11 — Refractory, Insulation & Fireproofing

Fired Heater Refractory Inspection Checklist

IPE Engineering Practice IPE-EP-11-1-2C

Document number: IPE-EP-11-1-2C · Section: 11 — Refractory, Insulation & Fireproofing

Equipment Job No. Document No. Rev.

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 C27 FIRECLAY AND HIGH ALUMINA REFRACTORY BRICK ASTM C113 REHEAT CHANGE OF REFACTORY BRICK

ASTM C133 COLD RUSH STRENGTH AND MODULUS OF RUPTURE REFRACTORY BRICKS AND SHAPES ASTM C155, GROUP 23 CLASSIFICATION FOR INSULATING FIREBRICK

ASTM C201 THERMAL CONDUCTIVITY OF REFRACTORIES

ASTM C860 PRACTICES FOR DETERMINING CONSISTENCY IN REFRACTORY CONCRETE ASTM C892 HIGH TEMPERTURE FIBER BLANKET THERMAL INSULATION

STEEL STRUCTURES PAINTING COUNCIL

SSPC-SP6 COMMERCIAL 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

Equipment Job No. Document No. Rev.

DOCUMENT REVIEW (SHOP INSPECTOR SHALL REVIEW):

	DOCUMENT DESCRIPTION	INSPECTOR'S INITIALS (REVIEW COMPLETE)	DATE
	IPE PURCHASE DOCUMENTS
	DRAWINGS AND SPECIFICATIONS
	DATA SHEETS (6.4, 6.5)
	CONTRACTOR SPECIFICATIONS (5.0)
	QUALITY CONTROL PLAN
	MATERIAL RECEIVING SIGN-OFF AND PMI RESULTS
	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 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	INSPECTION/TESTING ACTIVITY	INSPECTION/TESTING ACTIVITY	INSPECTION/TESTING ACTIVITY	INSPECTOR’S INITIALS (REVIEW COMPLETE)	DATE
MATERIAL QUALIFICATION	MATERIAL QUALIFICATION	MATERIAL QUALIFICATION	MATERIAL QUALIFICATION	MATERIAL QUALIFICATION	MATERIAL QUALIFICATION	MATERIAL QUALIFICATION	MATERIAL QUALIFICATION	MATERIAL QUALIFICATION
			REFRACTORY PREQUALIFICATION (11.1, 12.7, 12.9, 13.1,19.2)	REFRACTORY PREQUALIFICATION (11.1, 12.7, 12.9, 13.1,19.2)	REFRACTORY PREQUALIFICATION (11.1, 12.7, 12.9, 13.1,19.2)	REFRACTORY PREQUALIFICATION (11.1, 12.7, 12.9, 13.1,19.2)
			ANCHORS (19.1.5) INCLUDING PMI CHECK	ANCHORS (19.1.5) INCLUDING PMI CHECK	ANCHORS (19.1.5) INCLUDING PMI CHECK	ANCHORS (19.1.5) INCLUDING PMI CHECK
			PRODUCTION (19.3)	PRODUCTION (19.3)	PRODUCTION (19.3)	PRODUCTION (19.3)



INSTALLATION QUALIFICATION	INSTALLATION QUALIFICATION	INSTALLATION QUALIFICATION	INSTALLATION QUALIFICATION	INSTALLATION QUALIFICATION	INSTALLATION QUALIFICATION	INSTALLATION QUALIFICATION	INSTALLATION QUALIFICATION	INSTALLATION QUALIFICATION
			GUNITE (19.4.2)	GUNITE (19.4.2)	GUNITE (19.4.2)	GUNITE (19.4.2)
			POURED/CAST (19.4.3)	POURED/CAST (19.4.3)	POURED/CAST (19.4.3)	POURED/CAST (19.4.3)
			THIN EROSION RESISTANT LININGS	THIN EROSION RESISTANT LININGS	THIN EROSION RESISTANT LININGS	THIN EROSION RESISTANT LININGS
			WELDING (8.7.1, 8.7.2, 19.4.4, 19.4.5)	WELDING (8.7.1, 8.7.2, 19.4.4, 19.4.5)	WELDING (8.7.1, 8.7.2, 19.4.4, 19.4.5)	WELDING (8.7.1, 8.7.2, 19.4.4, 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	SHIPPING/HANDLING/MARKING/STORAGE	SHIPPING/HANDLING/MARKING/STORAGE	SHIPPING/HANDLING/MARKING/STORAGE
						MATERIAL MARKING (10.2)
						MATERIAL AGE (10.1, 10.5)
						PACKAGING (10.3, 10.4, 10.5, 10.6, 16.1.21)
						TEMPERATURE (16.1.6)
						HANDLING (16.1.1, 16.4.4)

Equipment Job No. Document No. Rev.

GENERAL INSPECTION REQUIREMENTS

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, 8.7.4, 9.4.1, 9.5, 9.6, 9.7)
			PRIOR TO COATING (9.2, 9.3, 9.7, 9.8)
			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, 8.4.2, 8.5.1, 19.1.5)
			DESIGN (8.2.1, 8.2.3, 8.3.1, 8.4.1, 8.4.2, 8.5.4, 8.6.3, 12.1, 12.2)
			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, 8.2.2)
			ADDITIONAL DIMENSIONAL CHECKS (8.3.2, 8.4.2, 8.7.3)



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 (16.1.9, 16.4.2, 18.2)
			CURING TIME (16.4.2)
			CURING COMPOUND APPLICATION (SEE DAILY LOG SHEETS)
			DRYOUT



FINISHING DETAILS	FINISHING DETAILS	FINISHING DETAILS	FINISHING DETAILS	FINISHING DETAILS	FINISHING DETAILS
			EXPANSION JOINTS (7.3, 7.13, 12.3, 12.4)
			GASKETING (7.4, 7.12, 9.10)
			ANCHORS (8.5.3)

Equipment Job No. Document No. Rev.

DAILY LOG SHEET (ALL APPLICATIONS)

VERIFY THE FOLLOWING PARAMETERS COMPLY WITH THE REQUIREMENTS OF EP 11-1-1.

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	SURFACE PREPARATION/CLEANLINESS	TIME	INSPECTOR’S INITIALS
R	PRIOR TO REFRACTORY INSTALLATION (9.0, 16.1.3, 16.1.4, 16.1.16.1)



R	EQUIPMENT CLEANLINESS (16.1.2)



R	DURING INSTALLATION (11.2, 12.5, 13.13, 13.15.1, 13.15.9, 14.4, 16.1.17, 16.1.22, 16.1.23, 16.1.25, 16.2.1, 16.3.3)

PRODUCTION SAMPLES

SAMPLE DESIGNATION	LOCATION	TIME	INSPECTOR'S INITIALS

Equipment Job No. Document No. Rev.

DAILY LOG SHEET CASTABLE INSTALLATION

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 (16.1.6, 16.1.8, 16.4.2)



R	WATER TEMPERATURE (16.1.11)



R	WATER AMOUNT (16.1.10)



R	AMBIENT TEMPERATURE



R	MIX TEMPERATURE (16.1.13, 16.1.14)



R	MIXING TIME


R	LINING THICKNESS (16.1.5)

Equipment Job No. Document No. Rev.

DAILY LOG SHEET CASTABLE INSTALLATION

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:

Equipment Job No. Document No. Rev.

DAILY LOG SHEET BRICK AND BLOCK

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 TEMPERATURE


R	AMBIENT TEMPERATURE


P	LINING THICKNESS
WHEN FIELD MIXING MOTOR OR ADHESIVES THE FOLLOWING SHALL BE VERIFIED, AS COMPLYING WITH THE MANUFACTURER'S RECOMMENDATIONS	WHEN FIELD MIXING MOTOR OR ADHESIVES THE FOLLOWING SHALL BE VERIFIED, AS COMPLYING WITH THE MANUFACTURER'S RECOMMENDATIONS	WHEN FIELD MIXING MOTOR OR ADHESIVES THE FOLLOWING SHALL BE VERIFIED, AS COMPLYING WITH THE MANUFACTURER'S RECOMMENDATIONS	WHEN FIELD MIXING MOTOR OR ADHESIVES THE FOLLOWING SHALL BE VERIFIED, AS COMPLYING WITH THE MANUFACTURER'S RECOMMENDATIONS
R	WATER TEMPERATURE

R	WATER MOUNT

P	MIXING TIME


P	WATER QUALITY (WATER QUALITIES SHALL COMPLY WITH THE REQUIREMENTS OF EP 11-1-2: 16.1.11 & 16.1.12
R	JOINT CONSTRUCTION (11.6, 12.3, 12.4)


R	EXPANSION JOINTS (7.13, 12.3, 12.4)


P	DIMENSION CHECK (12.5)
R	ANCHOR CHECKS (11.5, 12.1)

Equipment Job No. Document No. Rev.

DAILY LOG SHEET CERAMIC FIBERS

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 TEMPERATURE


R	AMBIENT TEMPERATURE


P	LINING THICKNESS
P	DIMENSIONAL CHECKS (EP 11-1-2; 13.10, 13.15.4, 13.15.5, 13.15.7)

FIELD VERIFY THAT THE FOLLOWING MEET THE REQUIREMENTS OF EP 11-1-2	FIELD VERIFY THAT THE FOLLOWING MEET THE REQUIREMENTS OF EP 11-1-2	FIELD VERIFY THAT THE FOLLOWING MEET THE REQUIREMENTS OF EP 11-1-2	FIELD VERIFY THAT THE FOLLOWING MEET THE REQUIREMENTS OF EP 11-1-2
R	JOINT CONSTRUCTION (13.8, 13.15.3, 13.15.6, 13.15.9, 13.15.10)

INSPECTOR SIGN-OFF	INSPECTOR SIGN-OFF	INSPECTOR SIGN-OFF	INSPECTOR SIGN-OFF
INITIALS	NAME	COMPANY	SOCIAL SECURITY NUMBER

Equipment Job No. Document No. Rev.

SUMMARY:

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