A Refractory Inspectors Job

An Inspector has the primary responsibility to be one of clients specialists. We are hired because we can among other ensure standards & specifications as required are maintained. That said; we should be able to understand challenges, fairly evaluate competencies, establish parameters where required and, evaluate whether “less than perfect” by theoretical measure is acceptable. Because in the field it sometimes happens that a number of variable can potentially influence an outcome. However we have to ensure measures are in place to mitigate these risks. In the end we have to make informed decisions and be able to engage with our clients – and if required – their various role players such as OEM’s, design engineers, plant specialist (mechanical, operational, planning …) in order to add value, and aid progressive improvement.

Quality is our objective – not progress – but if there is poor or even no progress then there is nothing to inspect. A good inspector will not delay a job, a good inspector will make the appropriate assessment in good time and identify potential pitfalls or risks to schedule and costs. These can be raised and then driven or addressed by the relevant parties. It is important for an inspector to understand – we have a responsibility – because “guessing” when it comes to high value investments is not an option. Thus PBE Projects ensures that we always have experienced inspectors, and should an inspector encounter a unique challenge, we always have experienced backup engineers and consultant to verify and validate.

Here is API 936 Definition of a refractory inspector: The party or individual whom the owner has contracted or otherwise designated to monitor refractory testing and installation work performed by the contractor and refractory material manufacturer(s).

Section 5.3 of API936 clarifies the 8 main duties of an inspector – this article in part elaborates on these points.

Here are some do’s and don’ts for a competent refractory inspector.

Do’s

1. Get latest revision drawings, specifications, the planned scope of work, bill of materials, test certificates, data sheets, thermal scans, relevant history and list of concerns (if any) from the client.
2. Based on point 1 info: Be knowledgeable on the equipment, material and foreseeable challenges.
3. Get permission to take photos and have a laptop on site.
4. If no specification is available – decide on a standard ie: API936 and inform the installer to adopt it for their Quality plan.
5. Review and approve quality control documentation and method statement.
6. Ensure material installation instructions are available, if material is installer supplied their QC must present it. If the client issued material – get it.
7. Ensure supplier / manufacturer compliance to specifications and conduct product data verification with data sheet and batch test certificates.
8. Monitor material, equipment, operator, and applicator pre-qualifications – and document it.
9. Make sure material storage, handling, and logistics from (and between) warehouse, to plant, to installation area is sufficient.
10. Determine scope of work with client and contractor.
11. Verify B.O.Q and B.O.M. Carry out material quality and quantity verification.
12. Monitor installations and ensure contractor compliance to installation and material application instructions, method statement, quality control documentation, curing and dry out when the time comes.
13. Join or have toolbox talks daily.
14. Have correct inspection equipment.
15. Attend site meetings.
16. Oversee all quality requirements.
17. Inform your technician of relevant duties.
18. Verify your technicians work.
19. Verify test sampling is properly done and samples are managed.
20. Raise concerns in the same shift as noticed by using agreed method. Ensure to record and manage NCR’s.
21. Record and manage Concessions.
22. All conflicts with directives (ie: specs, drawings, standards), concerns and changes (points 19 & 20) shall be addressed to installer and owner and approved / resolved by owner.
23. Take responsibility for initial, progressive, invitation and final inspections. Do hammer tests pre- and if possible post dry out. Report anomalies.
24. Confirm inspection outcome and area specific duties with technicians.
25. Write the initial and final report without delay. Revisions to initial inspection reports as well. And sign your work. If approval signatures are required, then issue it with all signatures.
26. Ensure progressive on the job signing of quality documentation.
27. Accurate and progressive feedback to client. Complete daily logs with status report for detail shift handover.
28. Be pro-active, follow up.
29. Take responsibility for decisions, have insurance.
30. Make specific information requests available as required to design engineers, manufacturers, leads … timeously.
31. Attend technical and RCA’s sessions.
32. Identify and verify mark-up approved changes on drawings. Submit it to get stamped and re-approved for as new installed drawings to be drawn up.
33. Monitor dry-outs and ensure data capturing is accurate. I.o.w: thermocouple position and reading concurs and temperature hikes and holds are as per agreed strategy/schedule.
34. Audit completion data packs.

Don’ts

1. Don’t be late for an inspection. Don hold the job up.
2. Don’t give verbal instruction – only written instructions can be executed. Don’t say “but I told them”. It must be written and receipt signed.
3. Don’t consistently blame poor quality installation, document control, quality surveying or admin. on the QC. It is the inspector’s responsibility to add value and share knowledge. If anything stands out a as compromising concern, don’t delay reporting the issue constructively – do not complain – help.
4. Don’t make engineering decisions, design changes or material selections.
5. Don’t make compromising statements or comments that causes confusion or uncertainty.
6. Don’t be in the way – unless it is critical to indicate an obvious concern. Note that by invite (RFI / NOI) you are not in the way.
7. Don’t deviate from approved Quality plan, method statement or any technical instruction without concession and prior discussion with client.
8. Don’t ask your technician to do initial or final inspections.
9. Don’t rely on someone else ie: Supervisor or QC to witness or verify on your behalf.
10. Don’t run the job/project.
11. Don’t instruct the installers workforce or instill doubt in discussion that causes them to do re-work. Follow the organogram for communication.
12. Don’t commit to timelines.
13. Don’t commit to the ability of the contractor.
14. Don’t make uninformed decisions about quality or readiness.
15. Don’t expect the QC and technician to run the job after initial inspection.
16. Don’t assume, always verify your technician and the contractors work.
17. Don’t say you will sign something later. Sign it at the right time and don’t backdate signatures.

Note that this is a 1st revision and changes are likely, feel free to add comment’s or contact me direct

barnie@pbe-projects.com

Thank you.

Barnie Enslin