Section 15 — Inspection

In-Plant Inspection of Refractories

IPE Engineering Practice IPE-EP-15-4-7

Document number: IPE-EP-15-4-7 · Section: 15 — Inspection

SCOPE

• This procedure defines the requirements and specifies responsibilities for the visual inspection of refractory linings in vessels, fired heaters, incinerators, and furnaces.
• Any deviation from this Practice must be approved by the procedure described in EP 1–1–3.
• An asterisk (*) indicates that an action by the Owner or the Stationary Equipment Inspection Authority is required.

2.0 REFERENCES

The latest edition of the following standards and publications are referred to herein:

STANDARDS AND PUBLICATIONS

DEFINITIONS

• Refractory External Inspection – Inspection of refractory conditions using visual or other means of examination or testing from outside the equipment while it is in or out of service.
• Refractory Internal Inspection – Inspection of refractory conditions using visual or other means of examination or testing from inside the equipment while it is out of service.
• Stationary Equipment Inspection Authority – For the purposes of this Practice the Stationary Equipment Inspection Authority is the Plant Chief Inspector, Inspection Supervisor, or Chief Inspection Engineer as defined by the Plant management.

INSPECTION PERSONNEL

• Personnel performing inspection of refractory shall be qualified in accordance with EP 15–3–1.

INSPECTION REQUIREMENTS

• A visual examination of the refractory shall be made to determine suitability for continued service.
• The refractory of lined vessels (including vessel nozzles), stacks, ducts, and fire boxes shall be inspected for evidence of:
• Extensive Cracking
• Refractory and Anchor Erosion
• Excessive Fluxing (Melting)

• Bulging
• Spalling
• Fall–out
• Voids
• A measurement shall be made of the depth, or thickness of remaining refractory where erosion, spalling, or fall–out have occurred.
• A hammer test shall be made of the lining by striking the lining with a ball peen hammer at one foot intervals.
• Refractory areas requiring repair shall be field marked using contrasting color spray paint. Care shall be taken to accurately define and paint the boundaries of the repair area.

REPAIR

• (*) Refractory linings shall be repaired or replaced under the following circumstances, unless otherwise approved by the Stationary Equipment Inspection Authority:
• Steerhorn or Vee anchors are exposed to the hot face.
• For erosion–resistant linings, areas of hex mesh are observed which have pulled away from the wall.
• For erosion–resistant linings, hex mesh and refractory cupping are observed which exceed 1/4 inch depth for 3/4 inch Hex mesh or 3/8 inch for 1 inch Hex mesh.
• Bulging or fallout have occurred extensively towards the bottom of the lining, leaving the upper lining unsupported.
• Erosion, fallout, or spalling has occurred near pressure parts or structural support members.
• Cracking is judged severe and/or is accompanied by fallout. Hairline cracking to 5/32 inch in width is generally acceptable.
• Cracking has occurred at locations that permit extensive air leakage.
• Evidence exists that shell or casing hot spots have developed.
• Hammer testing reveals a void or reveals refractory that has separated from the metal shell.
• Refractory repair shall be accomplished in strict conformance with the appropriate reference in Section 2.0.
• Inspection of the repair shall include:
• Verification of complete removal of defective refractory
• Examination of surface preparation
• Examination of anchor/hexmesh installation, including welding as follows:
• Ensure proper anchor pattern
• Bend test random anchors
• Visual and hammer test hex mesh welds
• Examination of prepared refractory materials including pre–qualification of materials and installers.
• Observation of application
• Measurement of depth of application
• Observation of curing operation
• Re–inspection of lining using hammer test and visual methods.

RECORDS AND DOCUMENTATION

• A permanent record of the lining inspection shall be made and the inspection findings shall be recorded in such a manner as to indicate any and all unusual conditions of the refractory and/or anchoring system and include their size and location(s).
• The drawing or sketch shall be updated as required to indicate the current status of any repair or replacement work in progress.

RESPONSIBILITIES

• The Stationary Equipment Inspection Authority or his delegate shall be responsible for:
• Serving as final authority on all matters concerning refractory inspection, including final acceptance.
• Assignment of personnel associated with the Inspection Operation
• Evaluating inspection findings, and approving repairs.
• Preparation of required inspection repair scopes.
• The Refractory Contractor or his delegate shall be responsible for:
• Supporting any required operations involving refractory repair as defined by the Inspection Repair Scope (IRS).
• Maintaining control and responsibility for all refractory repair and replacement work.
• The Inspection personnel shall be responsible for:
• Inspection of the refractory lining in accordance with this procedure.
• Providing a drawing or sketch of the lining marked to indicate inspection findings and the location of findings.
• Observing repairs that might be required.
• Updating lining sketches to show the status of repair and replacement work.
• Daily and final inspection reports.

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