Robert J Jenkins and Co

Robert J Jenkins and Co Refractory

"It's What's Inside that Counts"

Robert J.

Jenkins & Company was established in 1977 in order to provide refractory quality control services based on hands-on installation experience.

03/01/2019

February 2019 Newsletter
Industry Issues with Laboratory Testing

In today’s industry, equipment owners cannot rely on the accuracy of refractory material test data. Accurate unbiased test data is critical for successful unit operation. When the accuracy of test data cannot be relied upon, the owner’s interest is put at risk, and the owner loses the ability to make sound engineering decisions. The source of the problem is the manner in which refractory material testing is performed. The solution to the problem is not complicated, requiring only a minor shift in existing procedures.

The majority of laboratory testing consists of the pre-qualification testing of refractory materials, and the testing of field samples. Pre-qualification testing is performed prior to refractory installation, and is intended to ensure the use of high quality refractory materials. Field sample testing is designed to measure the quality of installed refractory.

Pre-qualification testing is usually performed by the material manufacturer, who is employed by the refractory installer. It is in the manufacturer’s best interest to achieve laboratory results that promote the sale of product. Pre-qualification testing is rarely witnessed by a representative of the owner. Without oversight of both sample preparation and testing procedures, the test results may not accurately predict the quality of the installed lining.

Field sample testing is usually performed by an independent laboratory selected by the refractory installer. It is in the refractory installer’s best interest to use a testing laboratory that achieves the most favorable results. The installer and the laboratory depend on each other for success.

In both cases the laboratory works for and owes allegiance to the installer. The owner is left out. Financial ties exist between the installer, the manufacturer, and the laboratory. This creates a situation with potential bias and conflict of interest. It is for this reason that the refractory inspector would never be permitted to work directly for the refractory installer. Using the same reasoning, the manufacturer and the laboratory should not be permitted to work directly for the installer, and the manufacturer should not be permitted to test its own materials unless an owner representative is present. How is this potential for bias and conflict of interest best addressed? The following approach accomplishes that end.

Material Pre-qualification Testing
• Manufacturer sample preparation and testing procedures witnessed by a representative of the owner
• Testing performed by an independent laboratory selected by the owner
• Testing charges are to the owner or the installer as the owner directs
• Test reports transmitted directly to the owner by the owner representative or the independent laboratory

Field Sample Testing
• Testing performed by an independent laboratory selected by the owner
• Testing charges are to the owner or the installer as the owner directs
• Test reports transmitted directly to the owner by the independent laboratory

The owner, who ultimately lives with the end result, whether good or bad, deserves the quality that has been paid for. The owner’s best interest must be preserved. This simple approach is a big step towards accomplishing that end.

01/07/2019

What is refractory installer certification? Installer certification is a process by which an installer demonstrates his ability to perform the work as specified. Why certify a refractory installer? The refractory installer may not be competent to perform the work even if similar work has been per

11/29/2018

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11/12/2018

What does it take to organize and execute a quality refractory installation?

Achieving a successful refractory installation involves many important activities that must be addressed if the desired goal is to be met. The desired goal is to achieve high quality refractory on the wall, where it counts! If it’s not good on the wall, it’s not good!

Following are the steps that lead to high quality in refractory systems. While the requirements are extensive, the payoff is well worth the effort.

Before the Bidding Process
* Review Scope of Work
* Review drawings, specifications and refractory details
* Review installer bid requirements
* Prepare refractory documentation
Installation procedure: guidelines
Inspection & test plans
* Material test reports
* Project inspection status
* Quality control / refractory mix log
* Non-compliance
* Acceptance / rejection
* Material class selection
* Required property ranges
* Refractory design assistance

During the Bidding Process: Document Review
* Installer proposal
* Installation procedures
* Installation plans
* Installer QA/QC plans
* Thermal dryout procedures
* Repair procedures
* Inspector resumes

Following the Bid Award
* Pre-job meetings to discuss refractory Scope of Work
* General meetings with engineers, fabricators, dryout contractors, installers
* Pre-inspection meetings prior to the start of work
* Material selection for prequalification testing
* Material prequalification testing
* Installer certification
* Mock ups
* Nozzleman qualification
* Rammer qualification
* Vibration casting qualification
* Expedite testing of prequalification samples
* Review installer equipment and personnel

Onsite Management
* Daily site meetings
* Prepare daily inspection plan
* Execute inspection plan
* Organization and verification of refractory inspection activities
* Organization and verification of refractory installation activities
* Check staging areas for materials and equipment
* Verify installer staffing
* Review refractory inspection reports
* Verify daily collection of test samples
* Expedite sample shipping to the laboratory
* Review laboratory test reports for compliance
* Consult / assist on issues that arise during the project

Project Follow-up
* Compile refractory data book
* Discuss project successes and shortcomings
* Plan for future projects

The extensive list of activities noted above testifies to the amount of time, effort and experience necessary to achieve refractory quality on the wall. It is because the list is so extensive and complicated that plant and engineering personnel frequently do not have the time, and in many instances do not have the technical background, necessary to manage refractory quality as it should be managed. Jenkins has the ability to fill this gap. When Jenkins provides refractory consulting services to your project, more concentration is placed on refractory quality, and plant and engineering personnel have more time to devote to other important activities. The result is better refractory quality, and better quality all around, which leads to better equipment operation.

When you plan your next refractory project, consider Jenkins as your refractory consultant.

Best regards,
Bob Jenkins
Donavin Duhon

11/05/2018

November 2018 Newsletter
Refractory Material: Prequalification Testing



A refractory material is not of good quality merely because it is new. It is of good quality only when proven to be so.

Today’s industry demands that refractory materials be prequalified prior to installation. Although a material may be new, it is not necessarily of good quality. When refractory materials are not properly prequalified, it becomes open season on refractory quality. It is the equipment owner who ultimately pays the price when refractory quality is poor.

Cost and safety are the primary concerns of the equipment owner. Safety is the ultimate concern, and is specifically addressed in equipment design. Cost can be the cost of the new equipment, the cost of maintenance, and the cost of downtime.

High quality refractory systems run longer and require less maintenance. Extensive refractory maintenance can extend the length of an outage. The installation of inferior refractory materials can result in refractory failure and unplanned outages. It can also push the equipment owner into a corner where he must make the engineering decision to go on line with inferior refractory systems, knowing that the result will be problems that must be faced in the future. An inferior installation will almost certainly increase future maintenance cost and possibly maintenance downtime. When equipment is out of service, the daily cost can be substantial.

Prequalifying refractory material is the first of many steps towards ensuring refractory system quality, and promotes successful equipment operation. If a refractory material has not been proven to be of good quality, the life of the equipment may be placed in jeopardy even before the work has started. It is important to keep in mind that a good refractory installer cannot install bad refractory material and make it good. The prequalification of refractory materials is essential for ensuring the quality of refractory systems.

Refractory prequalification testing should be performed far enough in advance of the start of refractory installation to provide sufficient time to prequalify replacement material in the event of poor test results. If prequalification for a shutdown is performed too close to the start of the work, and the material tests poorly, there may not be sufficient time to prequalify replacement material. The result could be the installation of inferior material and/or a negative impact on project schedule.

Refractory material prequalification testing is generally performed by the material manufacturer, where the manufacturer’s client is the refractory installer. This testing is rarely confirmed through outside surveillance that represents the equipment owner. Test results are accepted based on faith and convenience. The API 936 Body of Knowledge originally stated that a refractory inspector may not have any commercial affiliations with the contractor or installer. Following that same logic, the refractory testing laboratory should have no commercial affiliations with the contractor or the installer as well.

The cost of proper prequalification testing is insignificant when compared to the cost of failure. The issue is whether material manufacturers should be given the responsibility to judge the quality of their own materials with impartiality, such that any suggestion of conflict of interest is eliminated.



Your Independent Source of Quality Refractory Services

906 Medical Center Blvd, Webster, Texas 77598
[email protected]


When refractory material prequalification testing is properly performed, the owner is rewarded with reliable equipment operation, predictable refractory maintenance, and reduced maintenance cost. When refractory material prequalification testing is not properly performed, the owner is the recipient of the costs associated with poor equipment reliability. Relaxing a quality standard for convenience sake leads to an increase of headaches not a reduction. When a unit fails, the question of “why” must be addressed. With the cost of failure so high, every action must be reviewed and judged. Relaxing quality requirements is dangerous to say the least, and is an invitation to disaster. There is no profit when the equipment is down. Equipment reliability depends on quality.

Owners need to take charge of refractory prequalification testing! Quality depends on it! The prequalification testing of refractory material should be placed into the hands of independent owner approved refractory testing laboratories. While this approach results in increased material handling cost, the added cost fades into insignificance when compared to the cost of equipment maintenance, and sometimes equipment failure. The cost saving of a single unit failure would probably finance the cost of material prequalification testing for the life of the equipment. Proper material prequalification testing is an investment in quality and reliability.


Bob Jenkins

10/26/2018

Refractory Documentation is Important

October 22, 2018

What is the Real Cost of Quality?
The real cost of quality is what you end up with when quality is lacking. It’s what’s on the wall that counts. In refractory, that is the only thing that counts. When quality is low, maintenance costs rise, production time is shortened, and profits are unnecessarily compromised.

Quality Starts with a Detailed Quality Plan
Quality must be demanded. Quality is not a request. Proper refractory documentation is an essential element of the success of a refractory installation. It is a system of demands that leads to quality on the wall. It is critical during both the design and the installation phases of a project. Inadequate or non-existent documentation puts refractory system in jeopardy, and adversely affects its ability to serve. This is especially important to the equipment owner who pays dearly when refractory quality is poor, because run time and maintenance costs have been compromised.

What Good is a Quality Plan if it is not Executed?
Good documentation, when properly applied, provides a system of checks and balances that keeps everyone on the project alert to quality expectations. The objective is to execute the project in a way that produces quality results on the wall, where it counts. If the demands of the documents are not enforced, it is open season on quality, all at the owner’s expense. Quality is an investment that pays off. Good refractory quality leads to good equipment service. Bad quality benefits no one.

Robert J. Jenkins & Company can provide the documentation needed to assure refractory quality on the wall. We also review client, manufacturer and installer documentation for accuracy and completeness, to assure it is clear and descriptive, and that it provides for the high quality standards demanded by the industry.

Examples of this documentation are as follows:

Refractory Documentation/What the Documentation Provides:
• Refractory specifications
Specific to the work being performed; accurate and complete
• Refractory details
Clear details show how the refractory system is built; describes
materials and anchoring systems
• Installation procedures
Specifically details how the refractory installation will be performed, and how quality expectations will be maintained
• Inspection & test plans (ITP)
The hold and check point path that leads to quality
• Material test reports (MTR)
Formal documentation of tested material properties
• Refractory inspection
Provides for accurate and detailed inspection reporting
• Inspection status
Tracks the day-by-day status of project refractory operations

• Quality control
A record of all pertinent quality data during refractory installation
• Material pre-qualification
Assures material testing is properly performed and data accurately recorded
• Installer certification
Assures the installer is competent and qualified to do the work
• Field sample testing
A record of physical properties on the wall, where it counts
• Material compliance data
Physical property requirements upon which quality will be judged
• High temperature dryout
Layout sketches and dryout details

Refractory quality must be demanded. It does not come by accident. Proper documentation is a major step toward achieving that goal. Jenkins can help.

Best regards,
Bob Jenkins

11/02/2010

Our new website is up and running please feel free to visit at www.rjjenkins.com

Address

906 W Medical Center Boulevard
Webster, TX
77598

Opening Hours

Monday 8am - 5pm
Tuesday 8am - 5pm
Wednesday 8am - 5pm
Thursday 8am - 5pm
Friday 8am - 5pm

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