CONTRACTOR JOB NO. PROJECT NAME 1736 Doc No : PR-7736-CO-486 apsawigsoy El Refractory Dry-out Procedure |>°°N°” f thet for : ene - 7 |Page : 10f18 , GSCA SRU Train 5 (MC-P06) [ate t8uy, 2011 Refractory Dry-out Procedure for SRU Train 5 (MC-P06) CONTRACT NO. 6600020932 (OOK) & 6600010932 (IK) Manifa Gas Facilities (MGF) Project COMPANY SAUDI ARABIAN OIL COMPANY SITE Khursaniyah Gas Plant, Saudi Arabia i = ; | isk | byl A | 16 July.11 Issued For Review | K'H.Choil B.Y.Kim |O.K.Kwon] G.J.Ahn REVD | DATE Rev.| DATE DESCRIPTION prepp| ceo | aa | ERD (SM) | comPANY > GS Construction Arabia Co., itdRefractory Dry-out Procedure | 20° No: PR-7736-Co-486 ones Rev. A ana for |Page : 20118, w GSCA SRU Train 5 (MC-P06) |oate + t6auiy,_ 2011 TABLE OF CONTENTS 1. PURPOSE SCOPE 3. REFERENCE INTRODUCTION 5. RESPONSIBILITIES SAFETY PRECAUTIONS ACTIVITIES BEFORE DRY-OUT OUTLINE of MC-P06 PACKAGE DRY-OUT WORK DETAILED PROCEDURES Attachments moo Refractory Dry-out Fiow Chart Refractory Dry-out Curves B-1) Air Preheater Furnace B-2) Reaction Furnace / Combustion Chamber B-3) Converters B-4) Sulfur Condensers B-5) Thermal Oxidizer ‘Temporary Preheat Gun Operation P&ID Extracted Literature from vendors’ OIMs Checklist and Report Form (Saudi Aramco) SATIP-N-110-01 SAIC-N-2030 SAIC-N-2031 SATIP-F-001-01 SAIC-F-2007 SAIC-F-2008 Castable Refractory Installation Perform Inspection of Dryout (Furnace, etc.) Final Inspection & Punchlisting of Castable Refractories Fired Heaters ~ Field Installation Heater Box Closure Inspection Final Inspection of Fired Heater & Components (Re-instatement) Marked -up P&IDsRefractory Dry-out Procedure | 2°°Ne : PR-7736-co-486 Soke eae ts ~ aoe Page : 30f18 w, GSCA SRU Train 5 (MC-P06) Date: 16July, 2011 1, PURPOSE The purpose of this document is to provide the procedure for the dry-out of refractory lined equipment and pipelines at MC-P06 Package in SRU Train 5, which will be carried out as a post-MCC activity. 2. SCOPE The related equipment to be dried out according to this procedure is as follows. (1) Ke4-F-578 Air Pre-heater Furnace (2) K64-F-571/872/573 Reaction Furnace (Burner/Combustion Chamber/Steam Generator) (3) K84-E-573/575/577/579 Sulfur Condensers (4) K84-D-578/580582 Converters (5) K84-F-574/576 Thermal Oxidizer and its bumer (6) K84-F-579 HP Steam Superheater (7) Ke4-F-575 SRU Stack (8) Including all refractory lined piping Note: HTO of MC-P11-2 Package in SRU 500 will be dried out independently in accordance with a separate dry-out procedure. 3. REFERENCE Documents referenced are: - RE-474034 Mechanical Completion and Acceptance Requirements - GI.2.710 Mechanical Completion and Performance Acceptance of Facilities - SAES-N-110 _ Installation Requirements - Castable Refractories - SAES-N-120 _ Installation Requirements-Extreme Erosion Resistant Refractories - RE-473698 Operating Manual for Sulfur Recovery Plant K84 Unit 500 - RE-473692 Description of Logic System for Start-up and Shut-down Operation SRU Unit 500 - Vendors’ Operation Manuals 4. INTRODUCTION Itis not uncommon for moisture to be absorbed by the refractory during final stages of in-shop fabrication. Therefore, residual moisture and any absorbed moisture must be removed after installation but prior to commencement of start-up operations. Otherwise, trapped moisture willDoe No: PR-7T36-CO-486 semua Refractory Dry-out Procedure |20°Ne: F soak for s | Page: 40f18 <, GSCA SRU Train 5 (MC-P06) Date: 16July, 2011 steam, causing cracking, and in many cases, the refractory will separate from the metal in large pieces. Prior to the initial start-up phase of SRU Train 500, it is necessary to perform a complete dry- out of all the installed equipment containing refractory lining according to the procedures and temperature profiles recommended by the equipment manufacturers. Allactivities need to be described in detail and in sequential order to ensure @ successful and expedient execution of the work while maintaining the highest level of safety. During the work, several organizations have to be coordinated with good communication. The followings are parties at the minimum that must be involved in this work. (1) HSE (2) Operation (3) Engineering (4) Maintenance (Mechanical, Instrument and Electrical) (8) SAPMT (6) Inspection (7) CONTRACTOR GSCA (8) VENDORS 5. RESPONSIBILITIES 5.1 COMPANY shall have the overall responsibility for this work. 5.2 COMPANY shall review and approve the dry-out procedure. 5.3 COMPANY shall operate the facilities to dry out the equipment. 5.4 COMPANY shall inspect before/during/after the dry-out according to the relevant SATIP/SAIC/SATR. 5.5 CONTRACTOR shall prepare the procedures. 5.6 CONTRACTOR shall assist in the dry-out operation, inspection, and repair. 5.7 CONTRACTOR shall communicate and coordinate with the equipment vendors. 6. SAFETY PRECAUTIONS During dry-out, proper measures shall be taken to safeguard personnel and prevent environmental pollution. The following represents minimum precautions (1) Observe and enforce all local codes and regulations to safeguard plant, personnel and the environment. (2) Place warning signs and fence the entire area with strips of color distinguishable from those used for construction activities, (3) Instruct involved personnel in how to monitor dry out operation and to stop the activity When required (4) Ensure personnel involved in dry-out operation to wear protective clothing, gloves, boots, helmets, ear protection and goggles.1 Doe No : PR-7736-CO-486 ona go Refractory a ‘out Procedure = a _ a or Page : Sof 18 , GSCA SRU Train 5 (MC-P06) meee an (5) Hand tools shall always be kept in safe position and stored in a toolbox if possible. (6) Any activity must be stopped if the safety is not guaranteed and maintained before and during the execution of it (7) Before entering the vessel, oxygen content inside the vessel should be more than 19.8 %. 7. ACTIVITIES BEFORE DRY-OUT 7.1. The following operations must be carried out before dry-out takes place: (1) All parts involved must be mechanically tested and cleaned (2) Alllines involved must be steam or air blown to remove welding slag and scales which may damage valve internals and affect flow meters. (3) Allinstruments involved must be available and control loops checked. (4) Emergency Shut-down (ESD) system must be functioning and trip settings checked. Ensure that the emergency shut-down switches are not actuated (HS-5010A/B/C/ E HS-5170, HS-5167A/B, and HS-5165) (6) Allvaives must be mounted according to the flow direction, control valves stroked and relief valves settings checked (6) Allservices i. utility air, instrument air, steam, fuel gas, nitrogen, boiler feed water, and demineralized water must be available. (7) The area must be cleaned and all non-essential items like ladders, scaffolding, etc. be removed. (8) Fuel gas system must be leak tested and inerted. (9) Acertificate of acceptance of refractory lining is signed by all parties involved 7.2. The following final checks before dry-out must be performed: Check the installation of the bumer piping. (1) (2) Check the operability of all valves connected to the burner system. (3) Check refractory lining for any damage. (4) Check burner tips for correct installation, (5) Check the absence of dirt or foreign material which may have accumulated during construction. (6) Check the operability of the air dampers and louvers over full travel. (7) Check if access doors and peep holes can close securely. (8) Check if all relevant instruments have been installed and calibrated. (9) Check clearance for thermal expansion. 7.3. The following instrument should be on hand (1) An RTD for measuring the temperature in the steam reheaters via the test well. (2) Portable infrared pyrometer to check the temperature at the point not easy to access .Doc No : PR-7T36-CO-486 Refractory Dry-out Procedure Spgnuull gSob 7 [Rev A Sees or » Page 6 of 18 ,, GSCA SRU Train 5 (MC-P06) Date. 16 July, 2011 OUTLINE of MC-P06 PACKAGE DRY-OUT WORK Refer to Attachment A ‘MC-P06 Refractory Dry-out Flow Chart’ The whole works of refractory dry-out for MC-P06 Package is divided into 11 Steps as follows, for the convenience of procedure description as well as for the smooth and sequential proceeding of dry-out operation. Step-1 Step- 2 Step- 3 Step- 4 Step-5 Step-6 Step-7 Step-8 Step-9 Step- 10 Step- 11 Initiating Dry-out Dry-out of Air Preheater Furnace Dry-out of Thermal Oxidizer Prepare for Blow-through Heating and Dr Initial Heating up of Sulfur Condensers Ignition of Preheat Burner and Reaction Fumace Burner Main Bumer Ignition Dry-out of Condensers and Converters Heating of SUPERCLAUS stage and 4" Sulfur Condenser Further Heating to Maximum Operating Temperature (Main Burner) Dry-out Completion and Inspection (using K84-K-571B)Doc No : PR-7T36-CO-486 Refractory Dry-out Procedure Span goth Hs Rev. 2A ~ ; Page: 70f 18 e,GSCA SRU Train 5 (MC-P06) Date: 16 July, 2011 DETAILED PROCEDURES 9.1 STEP-1 Initiating Dry-out The following P&IDs are ferenced in this step: RA-859481 005 (Combustion Air Blower K-571B/C) RA-859481 007 (Combustion Air Heating/Control) RA-859481 021 (Thermal Oxidizer) RA-859481 008 (Air Preheater Furnace) RA-859481 025 (LLP Fuel Gas KO Drum) RA-859481 022 (HP Steam Superheater) (1) Ensure that the HV-5050 and AOV-5062 for SRU 500 are open. (2) Commission the instrument air supply for purging to prevent possible sooting at the flame scanners and sight glasses. (3) Start airflow through the train by means of electrical driven blower K-571B. * Start "Blow-through" operation via BHS-5075B. * Confirm the blower vents properly to atmosphere to prevent surging. + Ensure that the pressure in the combustion air header is above the set point of PAL-5070, (4) Ensure that K84-K-571C is commissioned as it may be required to achieve the excess air in the dry-out. (5) Check the permissive to start the Thermal Oxidizer burner: (F-576) + Ensure that fuel gas for the Thermal Oxidizer bumer is available (PALL-5252 is not active (LLP fuel gas supply pressure) + Ensure that the louvers are fully open (controlled by the BMS) (6) Ensure that HP steam is routing through the coils for the superheater to prevent dry running during start up + Open the valve in the bypass line (12-HHP-5030) + Close the valve in the HP steam inlet ine (12-600S-5032) *Close the ESD valve AOV-5255 in the HP steam line to the header by actuating AHS-5255 [if it is not already closed by the safeguarding). +The pressure is controlled by PDC-5175 (set to 15 psig) and steam will be vented to the LP Steam header. (7)Keep the blowers on for at least 24 hours (temperature 176°F) before commencing with the next step and running for the duration of the dry-out. (8) Ensure that Combustion Air can bypass the Air Preheater Furnace (HV-5243) is. open.Refractory Dry-out Procedure 2° No: PR:7T36-CO-486 spouts) ; Rev A sel! or e Page: Bof 18 GSCA SRU Train 5 (MC-P06) Sl 9.2 STEP2 — Dry-out of the Air Preheater Furnace The following P&IDs are referenced in this step: RA-859481 008 (Air Preheater Furnace SRU Train 5) NOTE: Dry-out of the Air Preheat Furnace shall be performed in isolation of the unit. No process air shall be passed through as per the recommended procedure in the vendor OIM. The 30” 300# Spectacle Blinds should be used for isolation of the Air Preheater Furnace. For startup of the Main Burner K84-F-571 via the BMS logic it is required that the Air Preheater Furnace be shut off, therefore it is required that the dry-out of the Air Preheater Furnace is completed before the Main Burner requires to be started up. As per the OIM section 3, the Air Preheater furnace must be pre-commissioned before dry-out to ensure the possibility of using the main burners to reach the required temperature. (Air Preheater Furnace OIM 7T36-MFO02-009) The dry-out shall adhere to the Air Preheater Furnace OIM Section 4. The initial heater firing shall take place on the pilots only. These should be ignited and allowed to bum for a period of 24 hours minimum. The stack damper and bummer air registers should be partly open during this operation. As per the following dry-out curve, dry-out can now commence. During the dry-out readings shall be taken every 60 minutes at the following locations: @ Flue gas temperature at the Arch (TI-5248) @ Flue gas temperature at the Stack(TI-5245) © Tube skin Thermocouple (TI-5243, 5244, 5246, and 5247) @ Heater draft at the Arch (PI-5745) @ Oxygen (Al-5240) To accomplish the dry-out in full agreement with the Vendor's dry-out curve, proceed as follows. (Note : Temperatures indicated are flue gas temperatures recorded at the hottest, point - normally arch roof) (1) Increase F-578 temperature 257°F at a rate of 36°F per hour, (2) Maintain F-578 temperature at 257°F (10°F) for 30 hours; (3) Increase F-578 temperature up to 527°F at a rate of 36°F per hour; (4) Maintain 527°F (10°F) in F-578 for 20 hours;Doc No : PR-7T36-CO-486 | sopcuuigsut Refractory Dry-out Procedure as a | e ne _for Page : 9of 18 | <, GSCA SRU Train 5 (MC-P06) Date: 16 July, 2011 (5) Increase F-578 temperature up to operating value 887°F at a rate of 36°F per hour; (TI-5245,5247 and 5248 monitored) (6) Maintain F-578 temperature at 87°F(#10°F) for 24 hours. NOTE: The stainless steel process tube temperature should not exceed 887 *F. (7)When F-578 dry-out is completed, gradually reduce the fuel gas flow and decrease F-578 temperature at a rate of 90°F per hour. Then switch off the main bumers and pilots. The fumace shall not be opened until it is totally cooled down, thatis, the inside temperature is below 30°F for at least 4 hours. (8) Once the internal temperature is acceptable, inspect the refractory in the Air Preheat Furnace. (Refer to the section 4.7 of the vendor OIM) 93 STEP3 — Dry-out of the Thermal Oxidizer The following P&IDs are referenced in this step: RA-859481 021 (Thermal Oxidizer, SRU Train 5) RA-859481 022 (HP Steam Superheater, SRU Train 5) RA-859481 023 (Vent Stack, SRU Train 5) RA-859481 025 (LLP Fuel Gas KO Drum, SRU Train 5) NOTE: Thermal Oxidizer dry-out procedure shall be done in parallel with the entire unit dry out. The dry-out shall be performed in accordance to the curve in referenced in the Thermal Oxidizer_ vendor HAMWORTHY OIM 7T36-MFO01-02- 124(Section 7.0) Before attempting any burner ignition, it is mandatory to have HP Steam Superheater ready to receive the gas. The dry-out shall be performed in manual mode in order to be able to strictly follow the dry-out curve, especially during the starting phase which is the most difficult, due to the low temperature inside the chamber and low temperature rise during the first § hours of drying-out. It is recommended to have refractory supplier's (Gouda) specialist attend and supervise the drying-out operation because it is of critical importance to execute a uniform and graduated drying-out procedure in accordance with professional standard and practice, During the dry-out readings shall be taken at the following locations: *Flue Gas temperature in the duct by TE-5166/5167 * Temperature in the stack by means of TI-5162/5163/5164/5 165. (1) Light the pilot burners of the Thermal Oxidizer F-576. Use pilot burners only until ‘a temperature rise inside the combustion chamber is observed (2)Proceed with drying-out, starting to run the bummer with the dry-out gun, atRefractory Dry-out Procedure |20°No: PR:7736-Co-486 ; Rev. 2 A _for Page : 100f18 SRU Train 5 (MC-P06) Date: 16 July, 2011 minimum firing (3) Increase progressively the heat liberation, strictly following the dry-out curve. (4) Increase the temperature from ambient to 248°F (+5°F) at a rate 27°F /hour. (5) Hold at 248°F(25°F) for 14 hours. (6) Increase the temperature to 302°F(£5°F) at a rate 27°F/hour. (7) Hold at 302°F(#5°F) for 14 hours. (8) Increase the temperature to 572°F at a rate of 27°F /hour. (8) Maintain 572°F (45°F) for 24 hours. (10)Gradually increase the temperature up to 1004°F at the rate of 27°F per hour. (11)Hold 1004°F (25°F) for 24 hours. (12)ncrease the temperature to 1112°F at a rate of 27°F/hour. (13)Maintain 1112°F(45°F) for 24 hours. (14)Increase the temperature up to the operating value 1580°F at a rate of 36°F per hour. Although it is instructed in the vendor OIM to increase the temperature up to 1652 "F, final temperature will be limited at 1580°F because of the tolerable limit at the tube of Superheater, which is made of SS321 material. Maintain the operating temperature for at least 12 hours. (15)For safety reason, the thermal oxidizer will be kept working for the entire duration of the dry-out procedure (minimum 1200°F). Once the dry-out is fully completed, the thermal oxidizer is the last furnace to be switched off. (16)During the operation the maximum heat fluctuating rate is 90 °F/hour when the temperature is higher than 572 °F. (17) The furnacelstack shall not be opened until it is totally cooled down, i.e. means that the inside temperature is maintained below 302 °F for at least 4 hours. 9.4 STEP 4 Prepare for Blow-through Heating and Drying (using K84-K-571B) The following P&lDs are referenced in this step: RA-859481 010 (Reaction Furnace Thermal Stage, SRU Train 5) RA-B59481 012 (1* Converter & 2 Sulfur Condenser, SRU Train 5) RA-859481 014 (2™ Converter & 3rd Sulfur Condenser, SRU Train 5) RA-859481 017 (4 Sulfur Condenser & Coalescer, SRU Train 5)Refractory Dry-out Procedure | 0°°No : PR-7736-co-486 i Rev. A plot Page : 110/18 SRU Train 5 (MC-P06) Date: 16July, 2011 RA-859481 015 (3° Stage Steam Reheater & Condensate Drum) RA-859481 024 (LP Fuel Gas KO Drum, SRU Train 5) RA-859481 033 (Burner Management System, SRU Train 5) (1) Ensure that fuel gas is available (PALL-5194 is not tripped). (2) Ensure the SUPERCLAUS® stage (K84-D-582) bypass line is also open (ZV- 5111 open) for blow through only. (3) Open the air vent on top of the Waste heat boiler steam drum (K84-D-576) and fill the drum with boiler feed water to normal operating level (However, follow the chemical cleaning procedure if the HP Steam Generation System is chemical cleaned during refractory dry-out period.). Leave the vent open for initial venting and put FC-5082 in AUTO mode. (4) Open air vents on all the condensers (E-573, E-575, -577 and E-579) for initial venting. Check that all condensers are filled to the normal level (However, follow the chemical cleaning procedure if the Sulfur Condensers are chemical cleaned during refractory dry-out period) and put their level controllers, LC-5081, LC- 5092 and LC-5103 on AUTO. Check that the block valves in the BFW to the sulfur condensers (E-573, E-575 and E-577) are fully open (8) Check BHS-5075B operation is enabled via the commissioning override, and that SUPERCLAUS® stage is open (ZV-5111 is closed) to receive the complete hot air blow through from the Claus section. 9.5 STEP5 _ Initial Heating up of the Sulfur Condensers The following P&IDs are referenced in this step: RA-859481 010 (Reaction Furnace Thermal Stage, SRU Train 5) RA-859481 012 (1"' Converter & 2™ Sulfur Condenser, SRU Train 5) RA-859481 014 (2™ Converter & 3rd Sulfur Condenser, SRU Train 5) RA-859481 017 (4" Sulfur Condenser & Coalescer, SRU Train 5) RA-859481 015 (3” Stage Steam Reheater & Condensate Drum) Start the condensers: initial heating up of the condensers may be assisted using steam from the LP steam distribution. This is done as follows: For E-573, E-575 and E-577 perform the following in sequence: (1) Slightly open the check valve by-pass in the steam line from each condenser, thus supplying a flow of steam to each condenser to gradually heat up the boiler water, until normal boiling temperature is reached, Ensure that the by-pass valves aren't open too much, as this could lower the pressure in the LP distribution and affect the supply to other users. (2) As the BFW starts boiling in each condenser, steam will be seen venting from the air vent valves. Allow a large excess of steam to vent and thus, effectively purge all the air out, before closing the vent.Doc No : PR-7T36-CO-486 somgsou! Refractory Dry-out Procedure ae A we er for ® . Page : 120f18 <, GSCA SRU Train 5 (MC-P06) Date: 16 July, 2011 (3)Close the check valve by-pass in the LP steam line and open the downstream block valve, thus allowing steam to be exported to the LP distribution. For the SUPERCLAUS® condenser, E-579: (1) Gradually open LP steam to the bottom steam inlet (N16), to heat up the boiler water until normal boiling temperature is reached. (2) Start the air fin fan of the 15 psig Steam Condenser (K84-E-580) (3)As the BFW starts boiling in the condenser, steam will be seen venting from the air vent valve. Allow a large excess of steam to vent and thus, effectively purge all the air out, before closing the vent. (4) Switch the SUPERCLAUS® stage back to by-pass mode, via BHS-5075B to permit ignition of the Reaction Fumace Burner. (Open ZV-5111) 9.6 STEP6 Ignition of the Pilot Burner and Reaction Furnace Burner: NOTE: Step 8 and 9 are done simultaneously with the dry-out of the Reaction Furnace (Step 6-7) The following P&IDs are referenced in this step: RA-859481 007 (Combustion Air Heating/Control, SRU Train 5) RA-859481 009 (Reaction Furnace Burner, SRU Train 5) RA-850481 033 (BMS, SRU Train 5) Temporary P&iD for Preheat Gun for Dry-out (1) Commission the instrument purges to prevent possible sooting on the flame scanners and sight glasses. (2) Reset the logic sequence for the Reaction Furnace via HS-5070 (refer to BMS). (3) Start the Ne purge via HS-5073. Ensure that the nitrogen flow rate is above the setting of FALL-5073B (predefined position at 2248 SCFM). The purge is completed after 30 minutes to check No (Refer to attached ‘Temporary Preheat Gun P&ID for Dry-out’ for identification of the manual valves) (4) Initially ensure that all Fuel Gas Valves are closed including BV-5072, BV-5073, FGHV-1 (8° valve before N3 nozzle on K84-F-571), FGHV-2 and FGHV-3. During the preheat gun operation, force close FCV-5070; the flow indicator FIT- 5070A should be used to allow manual control via PCV-5574 for fuel gas. Pilot Burner operation : NOTE: Ensure that there is a minimum of 0.1 kpa (0.0145 psi) pressure across the burner face to protect against backfiring. (PDIT-5078) SAFETY NOTE: An Emergency Stop Button is located on the platform which willagai gsob) ‘sms <=, GSCA Refractory Dry-out Procedure for SRU Train 5 (MC-P06) Doc No Rev. Page Date PR-7T36-CO-486 A 13 of 18 16 July, 2011 automatically shut all Fuel Gas Valve to the Burner when triggered. (1)Ensure that Instrument Air is being supplied to the Pilot Burner 1/2” Nozzle at 1 Bar via a temporary installed pressure regulator valve (one on the main Instrument air header) (2)Once the burner is fully purged with Nitrogen open PAHV-1 on the Process Air line to the preheat gun. The combustion air should be introduced at a minimum level of 50 SCFM using the PAHV-1 of the preheat gun. (3) BV-5072 and BV-5073 can now be opened. Using the PCV-5574 set the pressure to 1 bar. (There should be no flow of Fuel Gas until the next step) (4) Check that the Pilot Bumer Ignition control box is energized. (5) Manually open the valves FGHV-3 on the Fuel Gas line to the Pilot Bumer and check the Pl shows a reading of 1 bar flow. On the control box, push the ignition button; a pilot flame should be lit immediately. (6)A light on the Control Box of the igniter will turn ON as the ionization rod on the Preheat Gun tip will determine if a pilot flame is present. (7) Open FGHV-2 manually. Using the PCV-5574, introduce fuel gas at a minimum 3.15 SCFM (monitored at FIT-5070A) (8) Increase the flow of fuel gas with PCV-5574 and combustion air via the manual globe valve PAHV-1 on the air line to raise the temperature of the Combustion Chamber to 248°F ata rate of 27°F per hour. Hold this temperature for 14 hours. This temperature will be monitored by TI-5071, TI-5073 and TI-5074, NOTE: When the Reaction Furnace temperatures are in excess of at least 250°F, steam will be seen venting from the Waster Heat Boiler steam drum. The generation of steam will increase with increasing heat input. Allow a large amount of steam to exhaust and thus purge all the air out, before closing the vent valve. (9) Increase the flow rate of the Process air and Fuel gas gradually so that the temperature increases to 302°F at a rate of 27°F per hour. Hold this temperature for 14 hours, (10) Increase the flow rate of the Process air and Fuel gas gradually so that the temperature increases to 572°F at a rate of 27°F per hour. Hold this temperature for 24 hours. (11)Increase the flow rate of the Process air and Fuel gas to raise the temperature up to 1004 °F at a rate of 27°F per hour. It needs to hold this temperature for 24 hours. However, it is expected that the Preheat Gun will be limited to a temperature between 752°F and 1172°F. When this temperature is reached the fuel gas must be shut down temporarily to start the Main Bumer. Both valve connecting Process Air and Fuel Gas to the Preheat Gun shall first be manually closed. (FGHV-2, FGHV-3, PAHV-1)Doc No : PR-7T36-CO-486 &panuull gSol) Refractory Dry-out Procedure nanan coal for age: 140f8 <<, GSCA SRU Train 5 (MC-P06) De een (12)Shut down the air blowers. Ensure that all fuel gas valves are closed. (BV-5072, BV-5073) (13)Qpen the 8" manual fuel gas valve (FGHV-1) at N3 nozzle to allow for a normal start up of the main Bumer using the BMS system as follows. 9.7 STEP7 Main Burner Ignition The following P&IDs are referenced in this step: RA-859481 007 (Combustion Air Heating/Control, SRU Train 5) RA-859481 008 (Air Preheater Furnace, SRU Train 5) RA-859481 009 (Reaction Furnace Burner, SRU Train 5) RA-859481 032 (Advanced Burner Control, SRU Train 5) RA-859481 033 (BMS, SRU Train 5) The BMS system can bring the Air Preheater Fumace into operation to raise the temperature of the Reaction Furnace. The Air bypass valve HV-5243 should be closed to allow the preheated air to the Reaction Furnace through the Air Preheater Furnace. The spectacle blinds (30") on either side of the Air Preheater Furnace should be opened to allow air through. (1) Start the ignition procedure by actuating HS-5076A. The Air Preheat Fumace must restarted for this operation, thus it is important that the Air Preheater furnace is available for this section. (2)The igniter is inserted, the combustion air supply is started, the igniter is energized and the fuel gas valves are opened. Within 5 seconds ignition should be obtained, otherwise the unit is tripped. The fuel gas stoichiometry settings are determined empirically by the Advanced Burner Control system. The excess air should be set to 300% to start the curve at a temperature near 720°F. In addition, the fuel gas flow (FC-5070A) can be manually adjusted within a certain range. The following table summarizes some of the estimated temperatures that can be obtained from stoichiometry. Excess Air ‘Temperature 300% eel ~120°F 220% E 1472°F 90%" without Nitrogen purge/ Steam Po injection * This substoichiometry is not recommended (3) One minute after ignition, the following controllers are accessible for the operator. + FC-5063AC{in Advanced Burner Control), acting on the trim air valve. + FC-5070A, fuel gas. (4)After establishing a stable flame pattern, the size of the flame is restricted by adjusting the stoichiometry of the Advanced Burner Control to 300% excess air. (8) Switch FC-5070A (fuel gas) and FC-5063AC (total air) to AUTO mode. AfterDoc No : PR-7T36-CO-486 ppnuigsol I Refractory Dry-out Procedure = A nde He " ; ; Page : 150f 18 w, GSCA SRU Train 5 (MC-P06) Beat eetaelioon switching FC-5063AC to CASCADE, the ratio between fuel gas and air can be adjusted with HC-5070. FC-5061A can be taken into operation to allow the ‘operator to increase the air flow during warming up. Note: In case of dry-out interruptions such as burner failure, heating shall recommence and continue from the point of interruption. ‘The Dry-out of the Reaction Furnace is continued in STEP 10. 9.8 STEP8 — Dry-out of Condensers and Converters The following P&IDs are referenced in this step: RA-B59481 009 (Reaction Furnace Burner, SRU Train 5) RA-859481 010 (Reaction Furnace Thermal Stage, SRU Train 5) RA-859481 011 (1st Stage STM Reheater & COND. Drum, SRU Train 5) RA-859481 012 (1st Converter /2nd Sulfur Condenser, SRU Train 5) RA-859481 013 (2nd Stage STM Reheater & COND. Drum, SRU Train 5) RA-859481 014 (2nd Converter! 3rd Sulfur Condenser, SRU Train 5) Check the temperature every 30 minutes during holding period after raising the temperature. Heating of the 1st Sulfur Condenser (K84-E-573) & Tail end of Steam Generator Section/Piping. (1) The first condenser will receive air directly from the Reaction Fumace Package (K84-F-572). The temperature of the first condenser will be controlled by the Steam Generator. (8 Boiler Feed Water increase via FCV-5082 and the increased steam production will cool the air across the Generator) (2) Increase the temperature at TI-5083 from ambient to 230°F at a rate of 50°F per hour. (3) Keep the temperature for 8.5 hours, then gradually increase up to 608°F at the heating rate 50°F per hour. (4) Keep the temperature steady for 12 hour and then start decreasing with the rate 100°F per hour until not reaching the ambient temperature. Heating of the 1st Claus Converter (D-578)/ 2nd Sulfur Condenser (K84-E-575): (1)Commission HP steam to the first steam reheater E-574A/B and also commission its condensate system. Ensure that control valve TCV-5095 is fully closed. Put the reheater carefully into operation by slowly admitting steam via the 3” control valve bypass. Do not open the control valve until the reheater is sufficiently heated to a temperature that ensures the Converter can reach the highest point on the dry-out curve. A handheld temperature gauge or RTD can be inserted into the test well to get a reading, (2)Commission the automatic temperature control system (TC-5095). In order to] Refractory Dry-out Procedure |00°N°: PR-7TS6-co-486 Sgn gsob) He Rov. 2A = , Page : 160f18 <, GSCA SRU Train 5 (MC-P06) Date: 16 July, 2011 obtain a gradual heating-up of the Converter, increase the temperature at TC- 5095 from ambient to 230°F at a rate of 50°F per hour. The Condenser temperature will follow that of the Converter. (3) Keep the temperature for 8.5 hours, then gradually increase up to 608°F at the heating rate 50°F per hour. (4) Keep the temperature steady for 12 hours and then start decreasing with the rate 100°F per hour until not reaching the ambient temperature. Heating of the 2nd Claus Converter (D-580) / 3rd Sulfur Condenser (K84-E-577) (1)Commission HP steam to the second steam reheater E-576A/B and also commission its condensate system. Ensure that control valve TCV-5105 is fully closed, Put the reheater carefully into operation by admitting slowly steam via the 3" control valve bypass. Do not open the control valve until the reheater is sufficiently heated to a temperature that ensures the Converter can reach the highest point on the dry-out curve. A handheld temperature gauge or RTD can be inserted into the test well to get a reading, (2)Commission the automatic temperature control system (TC-5105). In order to obtain a gradual heating-up of the converter, increase the temperature at TC- 5105 from ambient to 230°F at a rate of 50°F per hour. The Condenser temperature will follow that of the converter. (3) Keep the temperature steady for 8.5 hours, then gradually increase up to 608"F at the heating rate 68°F per hour. (4) Keep the temperature steady for 12 hours and then start decreasing with the rate of 100 °F per hour until not reaching the ambient temperature. 9.9 STEP 9 Heating the SUPERCLAUS® stage / Fourth Sulfur Condenser (K84-E- 579) The following P&IDs are referenced in this step: RA-859481 015 (3 Stage STM Reheater & COND. Drum, SRU Train 5) RA-859481 016 (3" Converter Stage, SRU Train 5) RA-859481 017 (4” Sulfur Condenser & Coalescer, SRU Train 5) {1)Commission HP steam to third steam reheater E-578 A/B and also commission its condensate system. Ensure that control valve TCV-5115 is fully closed. Put the reheater carefully into operation by admitting slowly steam via the 3° control valve bypass. Do not open the control valve until the reheater is sufficiently heated to a temperature that ensures the Converter can reach the highest point on the dry-out curve. A handheld temperature gauge or RTD can be inserted into the test well to get a reading, (2) Supply heating air at maximum flow via the start-up line (FO-5614) and the 3% steam reheater to the SUPRTCLAUS® Converter. The Condenser temperature will follow that of the converter.Doc No : PR-7T36-CO-486 Rev. A bod Page 17 of 18 , GSCA SRU Train 5 (MC-P06) Date: 16July, 2011 pqnuull gSoy) | Refractory Dry-out Procedure smo for (3)Commission the automatic temperature control system (TC-5115). In order to obtain a gradual heating-up of the Converter, keep the temperature at TC-5115 between 302°F and 356°F during the first six(6) hours, (4) Keep the temperature for 8.5 hours, then gradually increase up to 608°F at the heating rate 50°F per hour. (5) Keep the temperature steady for 12 hours and then start decreasing with the rate 100°F per hour until not reaching the ambient temperature. 9.10 STEP 10 Further Heating to Maximum Operation Temperatures (Main Burner): (1) Increase F-572 temperature from 1004 °F up to 1112°F at a rate of 27°F per hour and hold this temperature for 24 hours; (2) Reach the operating temperature 1652°F at a rate of 36°F per hour and hold this temperature for at least 10 hours; (3) Once the dry-out procedure for F-572 has been completed, gradually reduce the fuel gas flow and decrease the temperature at a rate not exceeding 90°F per hour, 9.11 STEP 11 Dry-out Completion and Inspection (1)In case of dry-out interruption such as burner failure, heating shall recommence and continue from the point of interruption. (2)Upon completion of the refractory dry out, the 600 psig steam to the reheaters shall be gradually reduced to obtain a cooling down rate of 70°F ihr. (3) Shut-off the burners of the reaction furnace, thermal oxidizer and Air Preheater. ‘Also, 600 psig steam to the reheaters shall be isolated. (4)Keep the combustion air blowers on until the system temperature becomes steady. (5) Shut down the combustion air blowers. (6) Physically isolate the fuel gas. (7) Open the following equipment for final internal inspection: SAIC inspection checklists (refer to attachment E) are to be used. - Reaction Furnace Combustion Chamber F-572 - Reaction Furnace Steam Generation Section F-573 - Reaction Furnace Bumer F-571 - Condensers E-573/575/577/579 - Converters D-578/580/582Doc No : PR-7T36-CO-486 eo Refractory Dry-out Procedure |°2°N°: * eae He ~ A Page : 180f 18 @ GSCA SRU Train 5 (MC-P06) Date + 16suy, 2011 (8) Once the inspection has been completed, and the refractory installation and dry- out is determined to be successful on all the equipment, take out the pilot bumer ‘and the pilot ignition & ionization rod, and then install the end blind flange at N15 nozzle flange. Attachments ‘A. Refractory Dry-out Flow Chart B. Refractory Dry-out Curves B-1) Air Preheater Fumace B-2) Reaction Furnace / Combustion Chamber B-3) Converters B-4) Sulfur Condensers B-5) Thermal Oxidizer Temporary Preheat Gun Operation P&ID Extracted Literature from vendors’ OIMs- Checklist and Report Form (Saudi Aramco) SATIP-N-110-01 Castable Refractory Installation SAIC-N-2030 Perform Inspection of Dryout (Furnace, etc.) SAIC-N-2031 Final Inspection & Punchiisting of Castable Refractories SATIP-F-001-01 Fired Heaters — Field Installation SAIC-F-2007, Heater Box Closure Inspection SAIC-F-2008 Final Inspection of Fired Heater & Components (Re-instatement) F. Marked —up P&lDs mooAttachment A (MC-PO6 REFRACTORY DRY OUT FLOW CHART ‘ir Praheater dry out done in isolation Tgnite the Thermal Oxaser raure | [Star the Air Bower (Approximately 176) as ‘te Ar Pehester Furnace 8 ary out ‘eam avaiable fr HP Steam teteenced is ry out procedure step? Lo gd 0 step? of dy oul procedure Superneatr as referenced in dy out cae] he Baer hace ry ot n ‘Procedure step? step 3) ‘Once the dry outs completed switch of the ‘Cooldown the Ar PreeaterFursace Combest enprte ioet he ehacry (Note 2) Anti! heating of Condenser) Dry ut the Thermal Oxiiser to ‘manimur temperature of 1580°F according to sep:3 (Refer to dry out proceaure). Thermal Onder shal be n operation troughout the ory ‘out ofall other equipments oar pale q ‘Once the Thermal Oiler cry out “completed (rau thatthe Theta! ‘Ones needs to run with 2 ‘minum temperature of 1200°F nt the end of erator dry out ‘operation ofall equipments) shut ‘the Thermal Onciser Note 1: When the Reaction furnace main burr is igeited the combustion ait from the Ar Blowers fow to Reaction funace though Av Peheater to facta further heating of Reaction furnace Note 2: Ar preheater furnace wil be brought into operation (manually not using BMS) at requred belore initon of the Reacbon Furnace Shut down the Ai lower & isolate Note 3:Soi-out and Acid cleaning operation fox Steam Generator and Sulfur the fuel ga line as reorenced in dry ‘Condensers may be cared cut in paral! wih dy-out operation out procedure stp 2 T Equipment tgs ravesTiNnc we ‘Open he Thermal Oxdses HP aH) 7 texto aa Canaan steam Superbater Terma Onder Chante / Seon ger Stace Reaction Face comaston aa = Chante Condenser & Converters tmanvaye 3300 beg ferns | []- Main operation rors “ern On Sack “eter nd iarepecan os | (EE rail opeaton ab Te i re Hee Face eerenced mn ry out procedure or ieseae stp Ghat aeriacanyan | C—]- tees oreaton re ana [sat Ema 0578/0 Clos Cars wise Supe ComeAttachment B-1 EP.027 (ISSUE 0 REV 0.) NoTes BOUSTEAD INTERNATIONAL HEATERS LIMITEC APPENDIX | - REFRACTORY DRYING OUT PROCEDURE CUSTOMERS NAME: GS / SAUDI ARAMCO_ BOUSTEAD JOB NO:__611 CUSTOMERS JOB NO:_7T36-PO-M-F-002 HEATER ITEM NO: ~KBO--478/575 4 ENSURE STACK DAMPER IS OPEN DURING DRY OUT OPERATION. 2 TEMPERATURES INDICATED ARE FLUE GAS TEMPERATURES RECORDED AT HOTTEST POINT - NORMALLY ARCH ROOF 3 HOLD TEMPERATURE MAY DEVIATE BY 10 DEG.C. 4 AFTER THE TEMPERATURE HOLD TIME AT 475 DEG.C. IS COMPLETE IT IS ACCEPTABLE THAT THE HEATER MAY BE PLACED INTO OPERATION TO ACHIEVE THE OPERATING TEMPERATURE PROVIDED THE PROCESS FLUID FLOW IS NOW ACTIVATED INTO THE COIL. HOWEVER, CARE MUST BE TAKEN TO ENSURE PROCESS FLUID CAN TOLLERATE A FILM TEMP.OF 475 DEG.C. IF INTRODUCED AT THIS STAGE. IF NOT COIL MUST BE ALLOWED TO COOL DOWN TO AN ACCEPTABLE LEVEL. IF PROCESS CAN TOLERATE INTRODUCTION AT 450 DEG.C. THEN THE RISE TO OPERATING TEMPERATURE MUST BE TAKEN AT STEPS OF 25 DEG.C. PER HOUR. 8 TEWeERATUREC 88 (MAXIMUM TUBE WALL [TEMPERATURE MUST NOT IEXGEED 475°C Hoare]Attachment B-2 GOUDA GOUDA wane: cient Duar CE esting up schedule: Manite ges plant 0 8 % MBM & HB 2 HH 95 104 112 120 128 19S me Ow ‘me pierd Bomar 1 De oe catia sey arin erat sy ure 6 Pou ec ConpY me wae Sor a! Tee surtce oP ant poo sno oa st arp rw ect St hua neta far) By Sing ‘th aun nan forme boy ob aang em ty ha Ra wih wary aca be ‘hoc at ety, Ate 2 hous dying cana hr tog foie wom pan Ceara * Wii Pater anvcare wih ons rt low be vrs cca easy. fo tnly areas paras ay ‘Sen sae mone sure a ho sane tur serge lees hom sree bar oe Oo (Benen etn vrs ost aan a ay ecace 1+ Tamera ing rcs meeniced nth matics oe: menos partes re SY + nisetentealivenanc stesso nto det rg eat peescie econ wi ess ence ‘reac ven ete Be weg mean nh gap a ma By cag ‘Sgegnooun Hoare: BY ty Mat somata you scat ah ae sazcae epee. Te tress Soy rs on rina ayy ttm rn eng yo pd hy ‘eesonal roy ager asst oe aces oa toe uncnGna Rerasonee BV dis 3,Attachment B-3 boobong REFRACTORY LINING DOC NO | —_ 7736-MVO01-029 PROCEDURE WITH ITP PAGE WO) /EERORNCEIECS 66) Thermocouple gly & location : Three (3) thermocoupleat refractory surface 7) Check outlet temperature per the 30 minutes intorval during the holding time, £8) Dryout shall be performed by electric heating system with air circulation, r2HisHoldeg 20 Lower Temp. 100 | 350 he Natural Curing over Time (Hour) 26 hours a 128 20 32 10. TESTING 1) Alltests shall be witnessed and approved in writing by purchaser or their authorized person prior to acceptance of the refractory installation. 2) All laboratory tests shall be performed by a authorized laboratory acceptable to purchaser, ‘and certified by third party inspection authority. 3) All qualification tests must be approved by purchaser or their authorized person. 4) Mill certificate issued by material manufacturer shall be submitted. 2) Minimum two samples shall be taken from the refractory material supplied forthe job. ) Examination and test shall be made as per ASTM standards as follows: ‘DAEBONG ACROTEC. CO. LTD.Attachment B-4 7736-ME002-024 CERA - SEWON - £298-S1 Owner's Do < CERA | REFRACTORY LINING PROCEDURE | Vendor's Doc.No PAGE 1 OF 15 9 DRY-OUT 1) Raise temperature to 110T at a rate of 28 per hour. 2) Hold at. 110% for 8.Shours. 3) Ralse temperature to 320U ata rate of 28 per hour. 4) Hold at $20 for 12 hours. 5) Lower to ambient temp. at arate 55 por hour. 6) Thermocouple qty & Location = three(@) thermocouple at refractory surface 7) Check outlet temperature per the 30 minutes interval during the holding time. TEMP(T)47 ‘Owner no.: 7736-MFO01-02-124 ICE no, 1620-1124 ROOA HCE no. SPECIFICATION ‘Thermal Oxidizer Package - Train 5 KB4-F-574 / 575 / 576/579) INSTALLATION, OPERATION & MAINTENANCE MANUAL SL yl SEL Bet Oet Busooye fg jenbos uadn ampovord ino Bafip © Yas anoove o Buys! Ag sove}2e}e4 epnoD eofeNd pue SPIeDUeIS euo!ssoyoud yen aouepso%0e U1 sunpsoo.d ino Burkyp pajenpelb pus uo\Un @ =yn2x9 0} soueoduA JeDIUD 4051, 969 # a1e soimperodwe) pouoguow 1 ‘249 40 oes oxy uo pasnseawy saunjesodwo} Butuy are seumerodwwas ‘edense Aise0 ue0 snaden see 24) 1841 8 Papiiord 29 pynoys UoejAUaN warsyNs BuyBayaLd Buung “syoei0 sojpue soeyins ay) way s12h@}J0 Bugred Bust ‘oli arnyesodute) paseascun fipide! 00} y_fse9 edeose 0} 18700 saqeise9 Krojoexj9y ‘aimesaduse} ay) 12n0 Jayjuca poob 2 YuM pue g:sSod se AyIOIS Se mo paLUED 24 PINOUS BUTEAYAe aud yo pauen 2 uani6 ayp 19pun ayqissod se Bucy se soy 18/8 wea Burip se sinoy pe Jey ‘o0e,ns o19 yo Bujees Attachment B-5 Manifa Gas Facilities ~ Saudi Arabia .] due, SESRERSRRESAttachment C repos — IN PEUD FOR PEFRACTOR 'Y DRY-OUT(SRU TRAIN 5) zu TT rescue INSTRUMENT AR pat hay {_} 1 yee _ Osea PERMANENT CONNECTION FOR NORMAL OPERATION. =: TEMPORARY CONNECTION FOR REFRACTORY DRY-OUT = GS Const uction Arabia Cc td. MGF Project Pre-commissi jing Team Date 13 July, 2011Attachment D FOR APPROVAL Vendor Document Review ‘Action Code Description ‘Approved wihout comment ‘Vendor to submit Fr Final oe “Approved with comment ‘Vendor fo amend ard submit For Final > ‘Approved wih comment, 3 ‘Vendor to amend and o-submit For Approval D Not ReviewediConsired unaosoplabie v Quality, Re- submit For Review By Date Equipment No. 7736 PO M F 002 (P0No,| PREFIX PLANTNO. MATERIAL GLASS INCREMENTNO SUFFIX NO. (a0cNo,] KPcl M98 32 x01 DA SAUDI ARABIAN Oil COMPANY SEOUL, KOREA 0A S070 ISSUED FOR APPROVAL RR SF. KL REV, DATE STATUS PREPARED | CHECKED] APPROVED EQUIPMENT "AIR PREHEATERS [rime (BIH 611-£T0-0708.0) (OPERATION & MAINTENANCE MANUAL, items KO4-F-47B & KB4-F-578 NO. 7T36-MF002-009 BOUSTEAD INTERNATIONAL HEATERS GD Take] rare = zea [a | 097 mec REVSON TD Sate | 408 —] — oreOPERATION & MAINTENANCE INSTRUCTION MANUAL SECTION 4 CASTABLE REFRACTORY DRYING OUT PROCEDURE CONTRACTOR: ‘GS ENGINEERING & CONSTRUCTION PURCHASE ORDER NO: 7736-PO.M-F.002 PROJECT NUMBER: 611-£70.0708 REVO PROJECT: MANIFA GAS FACILITIES PLANT LOCATION: KHURSANIYAH, SAUDI ARABIA END USER: SAUDI ARAMGO PLANT (Tog No Kea-F-4781578 BIH JOB No: yop ettSection 4. Refractory Drying Out Procedure 4.1, This section provides guidelines for the drying out the heater internal refractory linings. ‘All checks listed within section 3 must be completed prior to commencing with this section The Heater is now ready for drying out. Please follow the steps detailed within section 5 for starting up the heater. 4.2, The drying out of the refractory is a very important procedure for a new Heater, as all refractories contain moisture, some in the form of absorption moisture and part in the form of crystallization, If the following precautions are taken when first firing up the Heater, i.e. to use a slow heat, this will ensure a long Heater life and low maintenance costs. 4.3. Before any drying-out takes place, the following should be noted : 43.1. The Stainless Steel process tube temperatures should not exceed 475°C. 4.3.2. The temperature in the Heater during drying out is regulated by pilot operation and varying the size of the main flame. This operation should only be carried out by experienced operators or under full time supervision of an experienced heater commissioning engineer. 4.3.3 Itis not recommended that any process fluid be circulated in the process tubes during rying out as this will absorb the heat from the burners and reduce the temperature of the refractory 4.4. The initial Heater fring should take place on the pilots only. These should be ignited (refer to section 5) and allowed to burn for a period of 24 hours minimum. The stack damper and Burner air registers should be partly open during this operation, Drying-out, as per the Appendix | graph, can now commence. During the dry out phase records should be kept of the following we would recommend that the following readings be taken every 60 minutes curing the dry out phase, + Flue Gas Temperature at the Arch * Flue Gas Temperature at the Stack * Heater Draft at the Arch + Oxygen * Tube Skin Thermocouple Readings 4.5. Should the main Burner have to be it to achieve these temperatures, then minimum fring is recommended, with the stack and Burner dampers fully open For this operation the burners may have to be throttled using the manual valves to restrict the gas flow to the burner. This operation should only be done with ful time monitoring by an experienced operator or heater commissioning engineer.4.6 In multi-Burner installations all Burners may not be required at any one time, but as many as possible should be used to ensure an even heat. If the main flame is used it should only ever be at a low firing rate. if all Burners are not needed then they should be fired alternately to ensure an even heating during the holding phases. For this operation the burners may have to be throttled using the manual valves to restrict the gas flow to the burner. This operation should only be done by an experienced operator or under the full time supervision of an experienced heater commissioning engineer. 4.7. Once the Heater has been properly dried out, it should be shutdown and allowed to cool. All access doors must be removed t00 allow complete access to all sections of the heater for inspection of the refractories. A permit for entry to the heater should be obtained prior to entry, Its quite normal for the castable refractories to have very fine oracks such that the face lobks like crazy paving, these are due to the permanent linear change (shrinkage) of the castable after drying these cracks will close up once the refractory is heated up again. Upon successful inspection of the refractories the access doors should be re installed. The heater ‘can now be brought on stream in accordance with the start-up procedures detailed in section 5 of this manual. Alternatively the heater can be bought on stream upon completion of the dry out period however care must be taken too ensure that the process fluid can tolerate the tube metal temperature of 475° C. Refer to note 4 of the attached Dry Out Curve. Itis vital that no Heater be put onto full capacity for at least 48 hours after drying out has been completed. Once the heater has been on full process load, it will not be necessary to go through the crying out procedure again, uniess the Heater has been out of service for a considerable amount of time and moisture has been absorbed by the refractory from the atmosphere. This is exiremely unlikely on a process line Heater but is not an uncommon situation on @ start-up service where the Heater may be used only two or three times a year.EP.027 (ISSUE 0 REV 0.) BOUSTEAD INTERNATIONAL HEATERS LIMITEC APPENDIX I - REFRACTORY DRYING OUT PROCEDURE CUSTOMERS NAME: GS / SAUDI ARAMCO. BOUSTEADJOBNO:____611 (CUSTOMERS JOB NO:_7T36-PO-M-F-002 HEATER ITEM NO: —KBALF-478I675 NoTes 4 ENSURE STACK DAMPER IS OPEN DURING DRY OUT OPERATION. 2 TEMPERATURES INDICATED ARE FLUE GAS TEMPERATURES RECORDED AT HOTTEST POINT - NORMALLY ARCH ROOF 3 HOLD TEMPERATURE MAY DEVIATE BY 10 DEG.C. 4 AFTER THE TEMPERATURE HOLD TIME AT 475 DEG.C. IS COMPLETE IT IS ACCEPTABLE THAT THE HEATER MAY BE PLACED INTO ‘OPERATION TO ACHIEVE THE OPERATING TEMPERATURE PROVIDED THE PROCESS FLUID FLOW IS NOW ACTIVATED INTO THE COIL. HOWEVER, CARE MUST BE TAKEN TO ENSURE PROCESS FLUID CAN TOLERATE A FILM TEMP.OF 475 DEG.C. IF INTRODUCED [AT THIS STAGE. IF NOT COIL MUST BE ALLOWED TO COOL DOWN TO AN ACCEPTABLE LEVEL. IF PROCESS CAN TOLERATE INTRODUCTION AT 450 DEG.C. THEN THE RISE TO OPERATING TEMPERATURE MUST BE TAKEN AT STEPS OF 25 DEG.C. PER HOUR, 0 peg - fee 2 me ¥ [srrcmiR go [MAXIMUM TUBE WALL 5 0 REE ECR TOROUES TEMPERATURE MUST NOT 5 ea Excery arc =| G3] ° 025 3825 a8 78 rai 778 107.26OPERATION & MAINTENANCE INSTRUCTION MANUAL SECTION 5 START UP PROCEDURE ‘CONTRACTOR: GS ENGINEERING & CONSTRUCTION PURCHASE ORDER NO’ 7136-PO-M-F-002 PROJECT NUMBER: 611-£T0-0708 REVO PROJECT: MANIFA GAS FACILITIES PLANT LOCATION: KHURSANIVAH, SAUD! ARABIA END USER: SAUDI ARAMCO PLANT (Teg No}: Kea-F-£78)878 BIH JOB No: yopett5 Start-Up Procedure Fired heaters involve the combustion of large quantities of fuel. The initial start up is a critical period and it is essential that these instructions are fully understood before attempting to start up the heater. In addition the operators should be familiar with section 6 which includes the specific information on the burners installed. 5.1 The start up of the heater is controlled by the Burner Management System (BMS) system Which is provided by others. This ensures that the correct sequence is followed for the start up of the heaters. The start up sequence and operator inputs for start up are detailed in the control philosophy document no 611-ETD-164AA. This document is contained within section 12.0 of this manual. The start up of the heater is controlled by a BMS system provided by others, The operating instructions for the BMS should be consulted prior to start up. 5.2 Set the Burner registers in accordance with Burner manufacturer's instructions. Please refer to section 6. Since this Is a natural draft heater the setting of the burner air registers will be used to provide overall capacity control for the heater. 5.3 Ensure that the flow control loops controling the process flow to each pass are functioning correcily. Prior to fring the process should be circulated through the Heater coils above the minimum flow trip setting, 5.4 Ensure that the stack damper is fully open The stack damper can be opened by adjusting the Pneumatic Cylinder Actuator which are located at the stack of the heater. 5.5 Open all air purge isolation valves to the main flame scanners and to the burner pilots, 8.6 Before introducing a source of ignition into the heater to light the pilot burners it is necessary to ensure that the firebox is vented of any gas that may have accumulated and could be ignited and cause an explosion. For this heater the BMS system has a programmed purge time detailed in the control philosophy document no 611-ETD-164AA. This document is contained within section 12.0 of this manual. Use of a portable gas detector prior to ignition is recommended, 5.7 Provision should be made to ensure that the fuel gas will be maintained constant at the light up pressure. This pressure will normally correspond to the minimum fuel gas pressure indicated on the burner liberation curves included in section 6 of this manual. Burners should not be lit at higher gas pressures in order to avoid pressure pulses within the firebox on ignition and to minimize the possible discharge of un-bumt gas within the firebox. 5.8 Start the heater following the steps laid out in the control philosophy document no. 611-ETD- 164AA. This document Is contained within section 12.0 of this manual. It is necessary to ensure that the pilot burners are it first followed by the main burners. Fuel should be shut off within Ssec if any pilot burner or main burners fails to light. 5.9 After ignition, trim flames and adjust for capacity refers to sections 6 & 10.1 of this manual, 5.10 On no account should flames impinge on any part of the Heater coil or refractory.5.11 Should impingement take place due to flame instability, trim immediately. It is common fault for instability to be caused by lack of air. 5.12 The heater fuel gas pressure should be kept constant until all the burners are lit. The Heater ‘should not be put into feed back contro! on outlet temperature until all burners are lit and stable conditions have been Details on how this is done can be found in the philosophy document no 611-ETD-164AA contained within section 12.0 of this manual 5.13 During initial start-up the Heater will be cold and the operations of Burner should be carefully ‘checked through the observation doors. Please note precautions when use doors as noted in section 2. 5.14 The rate of temperature increase of the furnace should be controlled. The rate for the first light up after dry out is given in section 4, Best practice is to allow a gradual rise the flue gas temperature leaving the radiant section for each start (eg 100c per hour) as rapid temperature rises can cause damage to the refractory ining,Attachment D FINAL Vendor Document Review 7 ‘Action Code Description ‘Approved without comment, 4 Vendor to submit For Final ‘Approved with comment, 2 Vendor to amend and submit For Final ‘Approved with comment, 3 Vendor to amend and re-submit For Approval Not Reviewed/Considared unacceptable 4 Quality, Re-submit For Review By: Date: Equipment No.: Common To TKT Supply t [Ts PO MF OOF (PONG) [PREF PLANT NO. MATERIAL INCREWENTNO.—_ SUFFOENO. (ROE WO} | 3S KTPCTi[M[9]8] 3 |2] xX 0/0]; D[A SAUDI ARABIAN OIL COMPANY j | | @ GS Engineering & Construction L SEOUL, KOREA 1 005 BATT Final GR tea PE 0A, 0406-70 For Approval | GR Tea PE rev. | DATE starus | prerareD | cHecKeD | Airronuey DOCUMENT TITLE GS NO. | 7T36-MF001-232 TKT VR CODE. A5001/2/4/5/8/10 ME\ reconeDUIKER Combustion Engineers b.v, Wateringen - Holand TITLE. REFRACTORY LINING INSTALLATION PROCEDURE DUIKER DOC 30.672-RIP. PURCHASER SCAINONT RT ORDER + 30631 / 40002 ITEM : REACT, FURN, BURNERS TYPE 2500, K84-F-471/571 : REACT, FURN, COMB. CHAMBERS, K&4-F-472/572 PLANT : MANIPA GAS PROJECT, SRU LOCATION : KHURSANIYAH, SAUDI ARABIA CUSTOMER : SAUDI ARAMCO REQUISITION 2 MR 0132.01 DUIKER ORDER 0.572 [veNooR DOCUMENT REviEW AFA rusinen et loa revise ano nesuneat PRO: 3063 2 ro ne ssutD as Fnat PROVIDED COMMENTS lcusromen: 5— Marfa Korsaniah Gas Proje {ARE INCORPORATED far ws 013201 {fe no commen = na. sue Po 30683 / aoa? be ronsvonaToW om (NTERNALUS rem: @e-f74/ 571) 672/572 luo ofeaneaB en lv Doe. Code: ‘85001 /2/4 /5 (8/10 owl pare AP S FINAL vi ‘A _|ORIGINAL ISSUE FOR APPROVAL Gx | Leg | o4junio Iss ‘DESCRIPTION BY | RVD | DATEGOUDA 9, DRYING OUT. ea 22 Preparation betore operation. Prior to drying-out 2 certiicate of acceptance of refractory lining shall be signed by al partes involved. Temperature recores shall be made during the drying out ‘= Each time-step Inthe drying-out procedure shall be considered as a minimum and Is ment fo tne dryng-out othe castable and the setting ofall ricimork layers. +» The maximum dry-out tomparature must be controlled so as not to reduce the ‘mechanical properies or chemical composition ofthe material of the ines equipment. Drying out. Before operating the unlts the must be dried out, the crying out must be done to teontorm withthe folowing schedule as given on the next page. “The maximum dry-oul temperature must be controlled 60 as not 0 reduce the ‘mechanical properties or chemical composition of the material ofthe ined ‘equipment.GOUDA GOUDA vues tient : Dulker CE ‘eating up sohediie: Manita gas plant 1000 > ee : - a wot sat Sot ™ E col Fs) po — wot sao = zt 00 0 0 8 1% Mh 4 HB BB 72 MB OS IO 112 12 128 105 104 182 Tepid Pee ir ol te cst fy snctun cement uy once hous rat colt th mae big ‘od Ths sure eens be sano ao Bows smart) 8) Sala ‘in autas we laa et ape oy ern re uta vey ha xt mira mtr gah nd a propery. Air ere yg ca at srs esse ander en Sean + Prteatng shat cared ono oa rdw ged art ve tmeerae taco caries ‘itive gabe scr wach Sat rl abv mtr tape say hoo aby rrasec rere ay ‘Sep cnc ftenon nine sue extse or user aes ame sracs sso. Oe) ‘Fatocg slic omian shoud Se poveanas Pa waa ccs coi eco + Tampere 2 neg perce maser enh ute fe kg A menos porns > 5% 1+ tis ofoeatireonrce assum ae pads reg eu rece ascordoce wih esl arcs ‘TEZSEics onaceees B0 bra pov yous ft obtdied wai pce steed Teizigy ace waa winut nary oy hal am psa eeceg erg au posscve sty ‘Serre ry Samages eso ane acon oor snr tctoua Roaee BY ame 9000.GOUDA 10, OPERATION Explosions, overheating and thermal shock shail always be avoided ‘The fumacelstack shall never be cooled with water or steam on the stool casing or ‘any other forced cooling metho. “The furmaceyetack shall never excesd the maximum operating temperature as given nthe ora ‘To prevent chemical attack tothe refractory no other chemical compositions than ‘specifically agreed upon in tne order shall be processed. ‘The temperature during the heating up and cooling down will be measured on REFRACTORY LINING PROCEDURE | Vendor's Doc.No PAGE 1 OF 15 9 DRY-OUT 1) Raise temperature to 110T ata rate of 28 per hour. 2) Hold at. 110% for 8.Shours. 3) Ralse temperature to 320 at arate of 28 per hour. 4) Hold at $20 for 12 hours. '5) Lower to ambient temp. at a rate 55 per hour. 8) Thermocouple qty & Location - three(3) thermocouple at refractory surface AS Hn Hing 7) Check outlet temperature per the 30 minutes interval during the holding time.Attachment D FINAL Vendor Document Review ‘Action Code Description a ‘Approved without comment, Vendor to submit For Final —- ‘Approved with comment, Vendor to amend and submit For Final A “Approved with comment, . Vendor to amend and re-submit For Approval ay ‘Not Reviewed/Considered unacceptable 7 Quality, Re- submit For Review By: Date : Equioment No. : 7736 PO M F 001-2 (PONO,)| PREFIX PLANTNO. MATERIAL CLASS INCREMENTNO — SUFFIXNO. (AOC NO.}| KPC] M98 32 X010 DA SAUDI ARABIAN OIL COMPANY ww, GS Engineering & Construction SEOUL, KOREA 0A Oct 10, 2010 : FINAL A AN EG REV. _DATE STATUS PREPARE CHECKEDAPPROVED INSTALLATION, OPERATION & MAINTENANCE MANUAL FOR TO PACKAGE (TRAIN 5) NO 7736-MF001-02-124 UT HAMWORTHYHCE no. 1620-1124 ROOA. SPECIFICATION | owner no.: 7736-MFO01-02-124 |" to oxi Pcape Tans 2 KB4-F-574 / 575 / 576/579 Deer eon net INSTALLATION, OPERATION & MAINTENANCE Saudi Arabia MANUAL K-84-F574 / 575 / 576/579 THERMAL OXIDIZER PACKAGE INSTALLATION, OPERATION & MAINTENANCE MANUALHCE no. 1620-1124 RODA SPECIFICATION | Owner no.: 7T36-MFO01-02-124 ‘Thermal Oxidizer Package ~ Train 5 415 KB4-F-574 / 575 / 576/579 Manifa Gas Feciliies— = [frm INSTALLATION, OPERATION & MAINTENANCE Saudi Arabia MaaNiAit 7.0 Dry-Out Activities Thermal Oxidizer lining shall be installed at site by others. Only SSH will be supplied already refractory lined at shop. Refractory installation procedure shall consider the following sequence: 1) Installation of Anti-acid internal Coating (please refer to datasheet reported below) 2) Installation of Refractory material (see doc No. 7T36-MF001-02-130) 3) Installation of external ceramic fiber on the Thermal Incinerator Stack. For refractory installation purposes, please also refer to following drawings: Document No. Desertption T736-K84F576- DWG- 028 Refractory Lining arrangement Plenum Chamber Train 5 Refractory Lining Plenum Chamber ~ Burner Mounting Plate Train 5 Refractory Lining Arrangement Combustion Chamber Train 5 7736-KB4F576- DWG- 027 TT36-KB4F574- DW. 035 T726-K64F574- DWG- 036 Refractory Lining Combustion Chamber Sections Train 5 7736-K84F574- OWG- 037 Refractory Lining Combustion Chamber Details Train 5 TT36-KB4F575- DWG- 040 Reractory Lining Slack Train 5 TT36-KB4F575- DWG- 041 Refractory Lining Stack Train 5 7736-K84F575- DWG- 045 Refractory Lining Duct between Stack and SSH Train 5 This paragraph gives detalled explanation of the dry-out procedures to be performed at site, during commissioning. Before commissioning Dry-Out must be performed strictly in accordance to the curve given in this paragraph. ‘The following dry-out curve is extracted from Doc. No. 7T36-MF001-02-130, also attached to this Manual, as Attachment #4. For more information, please refer to the recommendations from the original vendor.7 i TEEEEEGELE HCE no, 1620-1124 ROOA creel SPECIFICATION | owner no. 7T36-MFOOT-02-124 HAMWORTHY P= COMBUSTION ‘Thermal Oxidizer Package - Train 5 16 K84-F.574 /575 | 576 / 579 Manifa Gas Faciliies- [7 INSTALLATION, OPERATION & MAINTENANCE ‘Saudi Arabia MANUAL Moreover to this, before to attempt any bumer ignition is mandatory to have the SSH ready to receive the gas, as explained in paragraph 3. For reference see the Operation Manual of the SHH Vendor (Attachment #3). The dry-out phase shall be performed in manual mode, in order to be able to strictly follow the dry- out curve, especially during the starting phase which is the most difficult, due to the low temperature inside the chamber and low temperature rise during the first 5 hours of drying-out. It must be also considered that the TO must be operated firing fuel gas only, without process gas. To manually operate the thermal incinerator the following actions are generally requested: ‘a, Fuel gas pressure to main burner controlled by means of the control valve, whose controller FC-4165 shall be put in manual mode. Please note that also plenum dampers control shall be put in manual mode (HC-4162) in order to obtain a visually stable flame during dryout and to regulate combustion air flow. It is advisable during start up to maximize dampers opening in order to minimize adiabatic flame temperature. AA direct reading of the Gas Pressure on relevant pressure gauge shall allow the operator to determine burner liberation by means of bumer curve for dry-out operation. Due to low fuel flows needed for intial dry out phases, PA\ iqnal shall be overridde: b. Start drying-out using pilot burners only, until a temperature rise inside the combustion chamber is observable. ©. Proceed drying-out, starting to run the burner with the dry-out gun, at minimum firing. d. Increase progressively the heat liberation, strictly following the dry-out curve of the refractory manufacturer (see below).7 HCE no. 1620-1124 ROOA ‘Owner no.: 7T38-MFO01-02-124 Thermal Oxidizer Package - Train 5 KB4-F-574 / 575/576 | 579 SPECIFICATION INSTALLATION, OPERATION & MAINTENANCE, MANUAL 21)8e4 EpnOgYOIYN 40} Swe} J04710 10 Se o}Buynsas sabewep Sue soy aj'suodsos 1Aup ay) Buynnaxe uosied so wy 41 pup} Aue jo Aueuem nou aygepere apew AyBups0s0e u pajeioosse syst 18 ideaae nos “asocind yey) 10} ig] SBUO}De¥ey epMoDeBEGU oF OU 96 @ = eve saumresedkue; pauoguow yy Guay 19 40 eeuns ayr Vo pemnseow Sainjerodwo) Bun are Soseodo, = ‘adeass fysee eo snoden jeu au yeu) 08 papinord 89 Pinoys woge|quaN jwar=yns Buneayard 4 F2seyy fuedax! Ino powwed 29 veo 79) 20se wim Boeuns a yo Buyeos ay Jo soe 3 asejerous ‘appe ‘sug soyou oi) ent otro oes! Sindy Sounder dens GuaseD unulrye MpSou) 3yeeS09 OY s064Ra UL Sey fino] uy, GL vel SCL GL OZ Zit vol GB 9B OB WZ Ww OS B OP @ w 8 O Manifa Gas Facilities ~ ‘Saudi Arabia Taber snows sig snouoon st Tot era BEBRSRSRREO bd duaa TUELLEEELEEEE HCE no. 1620-1126 ROA ELEECAULEEELE | speciricaion | oymermno.: 7736-MF00%-02-124 HAMWORTHY = COMBUSTION | Thermel OxdzerPackage Train a urna 578/516 679 Manifa Gas Facilities — ane INSTALLATION, OPERATION & MAINTENANCE Soust abla fae NOTES: 4) PLEASE NOTE THAT SINCE FUEL GAS CONTROL VALVE CANNOT SUSTAIN TOO LOW FUEL FLOWS, REQUESTED FUEL FLOW RATE FOR DRY OUT MUST BE INITIALLY CONTROLLED USING BYPASS PCV-4177 UNTIL REACHING A TOTAL LIBERATION OF ABOUT 4 - 5 MMBTUIH, AFTER THAT FUEL GAS CONTROL VALVE FCV-8165 CAN BE USED FOR FLOW CONTROL. IN ORDER TO REACH LOW FUEL FLOWS DURING FIRST PHASE OF DRY OUT PROCEDURE IT COULD BE NECESSARY TO PARTIALLY CLOSE DEDICATED BURNERS MANUAL BLOCK VALVES. IT IS IN ANY CASE ADVISABLE TO START DRY OUT PROCEDURE WITH AT LEAST TWO (2) BURNERS ON AT MINIMUM FIRING, CAREFULLY CHECKING TEMPERATURE RISE INSIDE COMBUSTION CHAMBER (AND INCREASING TOTAL LIBERATION STRICTLY FOLLOWING REFRACTORY SUPPLIER DRY OUT CURVE) ACTING WHEN NECESSARY ON BURNERS AIR REGISTER AND ON PLENUM CHAMBER AIR DAMPERS IN ORDER TO MAXIMIZE AIR SUPPLY LOWERING ADIABATIC FLAME TEMPERATURE. 2) For specific recommendations from Refractory supplier, please see Original Vendor operation ‘manual, doc No. 7T36-MF001-02-130. 3) In case of any doubt, please contact Hamworthy Combustion.Attachment E [SAUDI ARAMCO TYPICAL INSPECTION PLAN fester PPROTEDOATE OBOE [Castable Refractory Installation SATIP-N-110-01 | 01-Jun-09 MECHANICAL INSPECTION RESPONSIGNTY new QUALITY | QUALITY ‘ASSIGNMENTS TM | PROJECT PHASE TASK ACTIVITY CURLIN | CUAL, ae en Pesan) 1.0 DOCUMENT REVIEW Refractory Installation fsa Special Construction Process per Contract Schedule Q (Attachment VI) 1 aslable Reactor Insaation Poe 12 Castle Retactry Oryout Procedure 13 WPS & PARR for Welding of anchor, | supports end hexsieol. See Remark. 14 ct eee eames 20. MATERIAL RECEIVING \Veriteation of refractory raw mati, a anchors, supports & Hexsteets. 22 ‘atl Storage, Handling & Preservation 3.0 INSTALLATION a \Welding* anchors/supportsihexstee! or CCattable Retactory Appealons a2 ‘PreQual Test (Applicator & Procedure) 33 ‘Pre-Application Inspection In-Process inspection/Testing: 'Pneumatically Applied Refractory as In-Process inspection Testing: | (Casting Application I Hl SACN2018 ‘sAICN-2030 SAC-N2022 SACN2019 SAIC-N-2020 SAICN-2021 Hl ‘SAIGN-2022 ‘SAIGN-2025, SAC-N2024 SAIC-N2028 SAC-N2026 SACN2018 RH SAIC-N2020 | RH SACN2022 Re SNCN2019 RH ‘SAIC-N-2020 w | SAIGN-2021 w SAIC-N2022 4" SAC-N2023 4 SAICN2024 4 | SAICN2025 4 SAICN.2026 H Page 1 of 2 2011-07-16 2:49 PM RH RH RH RH | Spec Process pera \Use SAIC-W.2036, Tie checklat i @ stand alone (document. Welders have a vad JCC card ‘SA authorizes crews & Inspectors BEFORE work Note: Error exists in Sh, Q, Attachment VI, Table |see Note 1 - General Notes for SA inspection ‘See Note 1 - General Notes for SA inspection Includes Detaled Inspection & Bend Testing reqmis {Use SATR.N-2001 - See Note 1 General Notes for SA Inspection (Use SATR-N-2001 -See Note 1 General Notes for SA inspection[SAUDI ARAMCO TYPICAL INSPECTION PLAN cae ov aan [eres ore [Castable Refractory installation saTipn-t10.01 | otJuno9 MECHANICAL TSPECTION RESPONSE MEM pposecr PASE askizcrmy | QUALITY guatiy Cae as Me lepocmshapecenein, | gactzer| SACN227 wlw Ue SATR AEDS He Can ae SA a Pest apetzatonmapecon-Cna. | sica.2028 wilow Use SATRN2001 ae poke of Castabio Reacory snesi202 | swon2020 w|ow 449. PRE-couMISIONING a Dy-utinspectonFumece, ete) SAIC N00 | SAIC 2090 How ‘See ato G12. 710 fo deta Wokscope rams a Fal nepecton and este or snenzoat | sxcnoat nol 4 see aso 12.710 for dlaled Woscope reams ——— representative in attendance. ‘GENERAL NOTES 2. Surellance: QA/OC organization lo monitor workin progress without noice from Construction Organization \wiiness: GNC organization shal be noted ofthe timing of Inepaction or test in advance. Howe "Tho fel ee inoonts ofeach Inopecton or fesing adiviy lated requre 100 % parlclpaton by Saudi Aramco Sie Inepecion Personnel” Aer Wis period, Saudi Aramco Inspection ay sajit We levels of Saud! Aramco parteipaton based upon the Contractor's performance, the inspection or ost sha be performed as scheduled ifthe QAIOC Hote: {QAQC organization shal be notified of the timing of Inspection or test in advance, Inspection o test shall not be cared out without the QAVQC organization ‘5 the Main Contractor delegates the atigned responsibilty to the Subcontractor, then the Main Contractor will have the same degre of responsibilty 2s assigned to Saudi Aramco LEGEND Told Porn for 6 inepocton Test Witness inspecton/Test ‘Surveillance eed Re Revew of Bocumenis RH Review and Approval of Documents 1_ 100% Contactor Iepection Page 2 of 2 2011-07-16 2:50 PMsuo ARACOIPD-16UAY.05-REV (uc Ca 206 rea sono SAUDI ARAMCO INSPECTION CHECKLIST SRONAIER DRTEAPPROVED "GRNUMEER [Perform inspection of Dryout (Furnace, etc) 2030 15-Dec-09 = MECH- JsSvenuTannarECnGWONTE ewe ACTUAL KSPECTON DATE THE ORNATE —— as SPT Ta a -_ _ 'SAUDIARANGO USE ONLY 7 ACCEPTANCE GRITERIA REFERENCE PASS FAL NIA. REINSPOATE "A. General Requirements (SAES-N-110 & SAES.N-20 Applications, See Note 1) Alm tnng ced & eon ere Retecn Manfocuars — SAEST [At recommendations or standard procedures of SAES-N-110 Sec. 10.8 Seeento see 1 SASH 120 ‘az checklists SAIG-N-2028, SAIC-N.2026 & SAIG-N-2027, SAICN-2028 8. sjeoncog 1 Bz B3 Bs 88 87 co 2 3 ‘SAIC-N-2020 a'8 complete including in-process inspection/samaling Dryout by Fumace use is ita controled nesting of rfracory Bnings raised o lomporatures nea hei service temperature afer curing to ‘Scheve required physical properties of lining ats service temperature Furnace Dryout Specific Requirements (SAES-N-110 & SAES. During yout. the equipments properly supported to prevent damage the tring and equipment (at elevated temperatures). Adequately calorated temperature measuring deviees are installed to monitor tne temperature ‘When dryouts by ausliry bumers, temperature monitoring is provided ‘on the gas outlet and bumer areas. “The maximum dryout temperature fs controled on ined equipment ‘See Note 2. ‘wmen dryout i done in furnace, the temperature measuring devices ‘are intaled on te refractory side & on extemal surfaces of equipment (kin to indicte efferantle Betweon metal & refactor temperatures, Unies otherwise specified by he Refractory Manufacturer, minimum hold times during dryout are 1 hour per 25 mm of rerectry thickness. Dryout inspection (SAES-N-110, Figure 1 Checkist) areas flows: ‘A) Fring equipment used isin good condition & meets procedure ) Burner locations spacing relative to refactor is checked C) Dryout schedule is avaliable & meets procedure ) Thermocouple locations are idenitied & meet the procedure E)Reconing equipment i avaiable &calbrated & meets procedure Ingpection Requirements After Dryout (SAES-N-110 or SAES-N-120 Procedure, Attachment 1) ‘All Inapection i performed per Seusi Aramco Inspection Requirement Form 175-3281 10 & SAES-N-110)120 procedure.See Attachment 1. Viva examination (Cracking evaluation) & Hammer Test # performed after the fumace dryout per SA Form 175-328110, Line tem 26. Lining cracks found AFTER DRYOUT are repsired when they are 3 mm ‘wide and lager ané when the depth exceeds 20% refractory thickness. 1-120 Procedure, See Note 1) SAES.N-t10/120, See. 4, Definition SAESNA10, Pra. 10.1.2 SAES.N-110, Para. 10.3.1 ‘SAES-N-10, Pra. 10.3.1 SAES.N-110, Para. 10.32 SAESN-110, Para. 10.33) SAES-N-110, Para, 10.3.4 SAES-N-110, Para. 11.8 SAES.N-110, Para, 11.1.1 SAES-N-110, Para. 11.1.1 SAES-N-110, Para. 11.5.4 Page 1 of 1SAUDI ARAMCO INSPECTION CHECKLIST eats eee = ACCEPTANCE GRITERIA REFERENCE PASS FAL NA REANSPDATE "See Note 3, D. _Inapecton of Exterr Surfaces Aer Dryout py Tenpory suppor are emoved afer Dyout &suacat rave robes SAES-NA10, duton sr mechanal danape om te Dy opeatons Pao. 012 Inspector checks all heated exterior surfaces closely for evidence of hot 7 2 spo doron'nequpmentsufaces,anéotherieltedhest Gamage, SAESNATO, er rout operons have uot conoiaas Rena REFERENCE DOCOWENTS: 1, SAES-N-100 ~ Refractory Systems (30 Jan 2007) 2. SAES-N-110 ~ Instalaton Requirerants-Castable Refractories (90 Jan 2007) ls. SAES--120 ~ Instalaton Requlrarants-Exrome Erosion Resistant Refractories (90 Jan 2007) Js API RP936.Retacior Installaton Qualiy Conrl Guidelines inspection and Testing Monolithic Retactory Linings and Materials (Now08) (ATTACHMENTS: I. Attachment 1 ~ SA Form 175328110 Castable Refractories NOTES: This checkist applies to Fumace Dryout inspection for castable refractory systems detaled in both procedure SAES-N-110 & SAES-N-120 2. The aryout pan for newy installed refractory includes key conto elements to be monitored by the INSPECTOR (API RP936, Secton 62 ). |a) Heat upiecol dou rates for al contol temperature indcators lb) The maximum aference between temperature indicators. [c) Heating rates re montored by thermocouples closest othe heat source, ) The hols temperatures and durations are achieved a ll thermocouples including those at gas exis ofthe newly installed refractory |e) When specified by manufacturer, Table 5 of APL RP936 shall be used. See Attachment #2 (Dryout Schedule) IF When coo! downs included inthe yout work scope, cooling rates shallot excoed 150°F (85°C) por hour. 3, Final visual ingpection after furnace cryoutdentfies Het or Explosive Spaing (trapped moisture explodesidisodgesreracton) & bloatinghbulges. Ihe Ingpector checks low points (oors) for evidence of spaling. Equipment & Low poins ae absolutely clean pir to dy-out. Alter éy-out, any epated concrete is easly identified by the presence of refractory chunks & debris onthe floor or at low points. On finding evidence af such damage, ine Retactory Inspector can cal for scaling to reach suspect areas for urherInvestigaton & any necessary repairs. A usual couse of explosve spaling i too rapid a heating rate where entrapped valer becomes steam & explodes. Bloating (bulges) occur in plastic subsurface iming systems. Contractor / Third-Party Saudi Aramco [Construction Representatve™ rt Rant orp JOC inspector (Coreen iescion” [Jan Rev ay Pass lac supervisor [PMT Reprocortaive. None trcwegong Litters [aera ravine [on vet Pe Reet ma Loner CR Prevonent and OE es Cocnent tem [Joa ets STITT TST TT ATT Page TW TRS toft‘al INSPECTION CHER EET aS oT Review Procedure & Perform iep of Furnace Dryout ~~ _sxcnzoan 1504008 ech Attachment 1 -- SA Form 175-328110 Castable Refractories WWSPECTION & TESTING REQUIREMENTS ESSE WER PAGE ‘Ship seao eos fs2etz0 frat t ‘SED ERRETOUEE Wp ag Cn Ss ToD ae P| PURCHASE ORDER MBE ‘ee Bota rete hr Hes Pg TERT an RSPECTON PER uaa aan TE Trew ROBERT | [a WSORT SFE TON WITESSING BY DIVER REPRESENTATIVES ERTIES T RECORDS TOBE CHECKED BY BUYER REPRESENTATIVE £ YS) CERTREATES TORTA To BE PROVED BY VENDOR SUPPLIER MANUFACTURER hy wacecon rs Terr) Sournraa) Pe 7) Joy cxneg ana yout Proceasrat ee eT = = a Se Ta RSE REE ORE frsacomsoncnconcon DEE a see Aor oe “Briprnthnee Eire ee mlx 1 Ry aca Tae zie Te aa RS — all 1 Cog ro SOR red a Se ATE x faveemohe Byer aaa ae Tae 4084SAI AMED DPD. BAYES: REO Gur don ses sososs SAUDI ARAMCO INSPECTION CHECKLIST "=" SYEIPmver CRnSER Review Procedure & Perform Insp of Furnace Dryout SAIC-N-2030 15-Dec-09 MECH. Attachment 2 -- API RP 936 Table 5, Dryout Schedule Tabe 5 Devout Sidelines for Conventional Castable Reftactories f es Tein Dena | Lonertac Ba? om Sse kg Theta oe ina OP —200°F 21s. old HEL | ‘tumor eesiue [peer nape apertg verse (Dar ieaar pias bo feoaean Page 1 of 1[SAUDI ARAMCO INSPECTION CHECKLIST a ONEAFRGVESGRNOWEEE Final Inspection & Punchlisting of Castable Refractories SAIC-N-2031__15-Dec-09 MECH — __ "SAUDI ARAMGO USE ONLY Tew No. ‘A, General Requirements (GAESIN-110 & SAESN-120 Applications, See Note 1) ‘ACCEPTANCE CRITERIA REFERENCE PASS FAIL NIA REANSP DATE Applied lining is verified and accepted using following Checklists: ‘A) Post Apploation inspection of castabe RotactoriosSAIC-N.2028 B) Inspection of repair of Casable Refactores SAIC-N-2020 ©) Inspection of Furace Dry out SAIC-N-2030, at 9 referenced SAES.N-110, ledforcold crushing erength Para, 113.2 ‘Samples takon during production were na Sense Aoi Ole ASTHCISSLASTW CHEE rene foman | SACGAZO imopenertiss ume abe fo 838 Pots Testels fom la compared acon Wanutacue’s peat SRESNO aa TentesoulheTestakoctené cutie cumhacwat PAR T133 g_ Testes oma compare RefecoyWanuace’ publhed—_SAES-N0, Thuestordomy ween! ign Gbalt}o putes vee Pa 1134 “Test results om lab for density cheeks made In accordance wth ASTM SAES-N-120 as ESC shot bees an 20 poten On Fin npecto, ter alepisSiempoysippoterenored, Pare 18 Tge wre hme acoso 88 Rafocay hepeoer|——SAESAED tee aes On Fainspecte, ier emooay suppor vere renevedaferdnot SAESATO, Ar fnhowucawinetash fom liebansarerandaaepnermee Pee 1S4 trash chctaouy Dies densi hetaedings SAESA20 (Q¢ Documentation listed in Form # 175-328110 (Material Certs, Water SAES-N-110, ‘ag Analysis, Procedures, Sample Location logs, QC records for welding. ft Para. 11.1.4 up, preheat weld repairs, bend tests) was completed & accepted byQC SAES.N-120, signed off by the SA Refrctory Inspector Para. 121.1 ‘ag_ Final eaningis done & ll protective coverings are removed & all SAESN-110 rebound & loose males removed tom equipment. Para. 94.8 Page 1 of 2[SAUDI ARAMCO INSPECTION CHECKLIST ee BATE APPROVED GR MOWBER. Final Inspection & Punchlisting of Castable Refractorios_SAIC-N-203115-Dec-09 MECH. (ema 1 REFERENCE DOCUMENTS: f. SAES-N-110 ~ nstalaton Requirements Casiabe Refractories (30 Jan 2007) l2_ SAES.N-120 ~ installation Requiremonts-Exreme Erosion Resistant Refractories (90 Jen 2007) [SITAGHONENTS ( Ataonmen 1- SA Form 1755261 0Gadabe Retecores [NOTES:7_ This checlst appiesto Fina inspection of Gaatabie refractory ayer duiiad ribo procedure SAES ATION SAESNVIZD ‘Contractor / Third-Party ‘Saudi Aramco [Construction Representaivey PT Renreeri vires” [Joe Ror Raves [0 Ves is Col ey ter veasion [aC inspector — a — ~|PID Representative —— — — seri YW nein | Leen LJactearannimes []Worvates lac supervisor [Proponent and Others Neeeewmme * ty Ros ono an, Jarvaresd [Joc Res evienes [oo vests SST CST OR ET TST Page 2 of 2“SAUDI ARANCO INSPECTION CHECKLIST a = al Fina inspection & Punching of CastaieRatiatovies sain 2091 150004 ecu ‘Attachment 1 -- SA Form 175-328110 Castable Refractories INSPECTION & TESTING REQUIREMENTS Eas or ae Pe ‘SGP REIT ORE. nae ig CNS TORS TETSS WR PURCHASE ORDER NIMBER, ‘en ary ps ae pn ne a TEST ar NSPECTION PER BSF fechas Dr [FET WOMBERGF =, TON WHNESSING BY BUYER REPRESENTATIVED AS) [EY CERTCRTEST RECORDS TOBE CHECKED BY BUYER REPRESENTATIVE zi ‘GERTIFECRTESTBRTA TO BE PROVIDED BY VENDORT SUPPLIER ARUFAGTORER TaD a] asst eens Sects Ea) Peas atten — fopeon ana tn Fe OMEN, Wa PN eR Ric eocnandane oom ance aren ran oe DEL | seen ore Cony SE OTE SESE vo [x] [x [eirtanc orca iverson este er he Fear as ST nil shswaba sacs SLE] | ee ra TST SPORE ACT FETE et te | Yara REET x a] Marg oes Prsaesurioe ru ca ee aT = a Rese Sones aIe [heen cme ae Ta efx) x]? oneomoven SOUP ps sas Ss Fo TTT | | ae ————— ES 4084‘SAUDLARANCO IOP FORM REY 1010100 ov cos sac008 [SAUDI ARAMCO TYPICAL INSPECTION PLAN peers: [OPOrEP ORT TARCTERE Fired Heaters - Field Installat SATIP-F-001-01 | 01-Jun-09 MECHANICAL be INSPECTION RESPONSIBILITY TEM | PROJECT PHASE & quaury | quaumry ‘ASSIGNMENTS. no. | activiry cope a PROCEDURE | RECORD Nsereral exe [> REMARKS. 10 DOCUMENT REVIEW evow procedure - “Speci Process Procedure Pr Sch 1 Fev Proceirn snc#2001 | sncr2001 RH OR Unete cheese in te SAT poco wed Hee (eld Insta (SAIC-F-2002 through SAIC-F-2008) Lasonic teks recon othe : 12 ops eens snce2u02 | sxe-2002 RHR 13 Data Sheet & Soey ns wuclonShest_ | SAC-F.2009 | SAKC-F-20n9 RH RH 1“ Eipment nspeconSchecle Seo Remarks _SeeRemarks RHR Tee submits 60 dys porto MCC per SAEP Furnace Dy-Out Paced (pt Procadire pr Meafecur’sroommerdaton hed ‘Manufacturer's Recommendation) Se ene cee onion RH R (Refer to G.1.-2.710-6, Item 5,5c) 20 MATERIAL RECEIVING | Equipment Verification, Traceabiity and | Visual Inspection of Hester's ‘Components: 13) Tubes ) Piping As sembly ©) Gaskets 18) Tube supports 2a 2) Retractor, SAIC-F-2008 | SAIC-F-2008 wi w 1) Insulation 9) Structure (Heater box) & Access 1) Casing (Convection and Rackant) | 1) Stack |), Forced draft fan & Duc vereeching 1) Burners im) Valves | 22 ‘Storage, Handing & Pres ervation SAIC-F-2005SAIC-F-2005, wos Page 1 of 4[SAUDI ARAMCO TYPICAL INSPECTION PLAN SATIP-F-001-01 MECHANICAL Page 2 of 4 TRSPECTION REGPORSTENTY PROJECT PHASE & auary | quany ASSIGNMENTS ACTIVITY CODE eee PROCEDURE | RECORD [ewracrn| SAO REMARKS ‘Material Verific ation, Vis ual inspection | Refer to the res poctive SATIPs for Electrical & a3 tnd StrogePrecenatovafticics | SooRemats | SeeRamaks Incas (Sarin ovi99} rte, be etmrtatencomponerts [october 20-01 10209) 30" INSTALLATION aa concrete Pacem lero sari-co01.02 32 ‘Verify Structural Support / Foundation ‘SAIC-M-2008 | SAIC-M-2006 H w Eavomert Amen Eeaton Chock 33 '9) Heater box SAIC-M-2007 | SAIC-M-2007 H w Use SATR-M-2002 : ©) Forced ba Fan 8 ver 6) Smoke Stack uu croung seers | Seo Remars eer saTI-.1001 [x ee eee [natant Se til compares and 35 : Sco Remarks | See Remarks [Retr t saria-co.o1 36 Isa. of Fred Hester Com pons | SAC2008 | SAI-#2008 w Feta W ting Ee or 2) Hetero oniboue | SeeRemats Seeremarks | 010M ites & heros Ht or. ta 1) sane art ero eral NDE rote nts Use SATRW-2007 trot flowing 2) unt on foot cover hares ofa 2 SanPnDe-rrat os Welds in Austenitic alloy materials | SAIC--2006 SAIC-F-2006 | Hi /HURt |b. SAIC-F-2006, tem B2, 83 & B4 (heater c oils) Stok td wetdg) 2: Sale 2008, tom Hi (Steck elt) 2 NDE PERFORMANCE SeeRemaks | See Renata [Retort appcaleNDE ATP ; seRomate | seeRemas | ~ lect SATIP-A.00L2. Pos enon shal bo 10 Pressure testing & Layap SeeRemaks | Soe Rena i BATE 2 Ps Installation of Bumer ¢ ontrol & mg [Refer to SATIPs # J-100-01, J-200-01, J-300-01, J-| eae Instrumentation oe ae eee |902-03, P-515-01 asa Ltn etaten seoremons | See Remake etero sarr-r123.02 a1 acto taaton SeoRemarks | See Rematis Reerto SAnP.N+10.0%,Nt20-06rN-4091SAUOLARAMCO IDPIO FORIAREV 1010100 aed cos won [SAUDI ARAMCO TYPICAL INSPECTION PLAN Tr Fired Heaters - Field Installation SATIP-F-001-01 | 01-Jun-09 MECHANICAL INSPECTION RESPONSIBILITY PROJECT PHASE & quaury | quaury ASSIGNMENTS, Mo riny Cope ‘TASK ACTIVITY PROCEDURE | RECORD Ar REMARKS. Fire Bricks instalation See Remarks See Remarks Rafer to SATIP-N-130-01 [ter to SATIP- H.002.07 an ote ppc able Paining!Coeting See Remarks See Remarks [Samia eevee tear Insulation See Remarks See Remarks | Refer to SATIP-N.001-02, Page 3 of 4[SAUDI ARAMCO TYPICAL INSPECTION PLAN een Ppmomore ee Fired Heaters - Field Installation SATIP-F-001-01 | 01-Jun-09 MECHANICAL INSPECTION RESPONSIGLITY trem | PROJECT PHASE & auaury | quaury ASSIGNMENTS, No. | ACTIVITY CODE ea eaeana PROcEDURE | RECORD REMARKS. ur Piping Reliving Devices Reset Vahe ‘See Remarks | See Remarks [Refer to SATIP-J-600.01 Inspection 348 Heater Boxee Closure Inspection ‘SAIC-F-2007 | SAlC-F-2007 HoH 40. PRE-COMMISSIONING | 4a Resintatement Final ns pecton SMC-F2008 | SAIC-F-2008 Hoos {Use SATR-A2011 a2 Punch isting Clearance / Fina ine p SAGISS | SAGISS ry (Check Contactors SAIC-F-2008 & SATR-A-2011 ‘wou for MCC (FE) (EL) | (em 41) for incomplete punc ist tems (GENERAL NOTES {The it thvee incidents of each Inspacion or testing acinvy listed require 100 % paricipation by Saudi Aramco Site Inspection Personnel. Afler this period, Saudi Aramco Inepecion may _agjust the loves of Saudi Aram co participation bas ed upon the Contractor's perform ance, 2 Sunellance: QAIGC organization tom ontor work in progress without notice from Construction Organization ‘3 Winess: QNOC organization shal be notified ofthe tim ing of inspection or testin advance. Homer, the inspection or test shall be performed as scheduled ithe QAVOC organization representative ls not present 44 Hold: QA/QC organization s hal be noted ofthe tim ing of inspection or tastn advance. Inspection or test shall not be carried out without the QVC organization repres entatve in sitendance, 5 Ifthe Main Contractor delegates the assigned responsibilty tothe Sub ontractor, then the Main Contractor wil have the same degree of responsibilty as assigned to Saud Aram co, LEGEND. H_] Hold Pont for OC ins peston’ Test [Review of Documenta W_| Witness inspectovTest RH_[Review ana Approval of Doc uments s_| Surveitance [100% Contactor inspection Page 4 of 4[SAUDI ARAMCO INSPECTION CHECKLIST SAENONSER ‘DATE APPROVES GR NGIEER |Heater Box Closure Inspection ____ SAIC-F-2007_15-Dec-09 __ MECH- REreEE TSE SE aaa RTE "SAUDI ARANICO USE ONLY |SHALL BE COMBINED. PROPONENT CONCURS". a ‘ACCEPTANCE GRITERIA REFERENCE PASS FAL NA _ REINSPOATE wo rs Da TaN ewes omand STE oa wnat git amas an ra nb apa Qa Sours parti ioral Feros lbs sony bend Tbs ow dean G2 pe ae Clee wens conn feet Ga een er ores en. nena company ; 1s See neta aes scone tomesysoncrmaeaay SAP (AG Hester tubes are installed in their respective locations. Design Dwoe ee Aghia ay DN Believe wey sete wows odin ttm SES, a serene em ee eK CONCLUSION: ISA ENGINEER & PROPONENT CHECKLIST/TEMS — |+Heater Box is accepted for Final Closure. [REFERENCE DOCUMENTS: 1. G.-2.7106 - Meenaniea! Completion and Performance Accepianes of Facies, (7/132002) Jz. SAES-F-001, Design Crtaria of Fired Heater, (28 January, 2004) Is. S2-SANssS-029, manciocture of Fos Heatar, (28 January 2004) la. SATIP-001-01, S.A Inspecton & Test Pan for Fred Healor Field instalation, Rev. 2 5. SAEP-251, Bed Flange soins Ascombly, (7 Novembsr 2008) Contractor / Third-Party Saudi Aramco [Construction Representatives Pi Representative ronson er ons era Raby hasan Me mepenerie ewes CJocrnea tos [woh votes lac inspector - PIO Representative — aoe poe Liman: Cea Taam ras | MPUOCNNIN (ames [Jocreesteines [Wore lac Supervisor as Proponent and Othe ~ - aaaeees ‘iy Re Se ane OPE a viesies [Jac Reod Rewed [Wek vet ET ECT ss eT Page 1 of 17 sess. saison a pater [SAUDI ARAMCO INSPECTION CHECKLIST eanaaad pean canes! Final Insp of Fired Heater & Components (Re-Instatement) _SAIC-F-2008 15-Dec-09 MECH- 5s - eee SAUDIARAMCO USE ONLY [netructions on use ofthis checklist 1 Any lem marked as “Fall” requis tobe Kentfed wth the specie description and iocaton of the descivancyvolationand shall be sted in te Contractors Re-instatement Punchist Form, 2. Column "YIN" is uted to pre-determine each respective tem as required for star-up V), or not require for startup (N). Final {designation of "YIN" items willbe atthe Mecharical Completion Punchisting by Saudi Aramco Inspection, a, This Cheeklst along nth the Re-instatement Punchlst, th or whh out cleared tems, shal be submited to Saudi Aramco on or before the requested tie fr Mechanical Completion Punching, Trew ae ‘ACCEPTANCE CRITERIA REFERENCE PASS FAIL NIA YIN REAINSPDATE ‘A Equipment Documentation ‘aa Safety instruction Sheet (Form SA 2737-ENG & 2731-MENG) {or Fred SAES-AODS, Para, 5.16 ‘The EiS (Equipment Inspection Schedules complete and incuded in ‘ag_ the Inspection Recore Book as prt ofthe Project Record Book SAEP.20, (NOTE: Tho EIS shal be submited for approval 60 days pir to Para, 5.14 ‘mechanical completion ) Documents required as listed In project's Non-matrial Requirements a2-SANSS-029 [AS form# NNUR-7900 ar avaiable onsite for veieations eed ‘aa Allconstrction and pre-commissioring aces forthe project shal G.270 have bean completed. Para 41.42 ‘Allnon-conformance repors and worksheels have been resohed tothe G.l-2.710 satisfaction of inspection Deparment Para 41.4.4 ‘Alllog book entries have been resolved tothe eatisfaction of Irspection _G.I-2.710 Superior Retowroe Sit Nononomane Repos) peat ‘Atexipmersbeniondonments ard wapeton nour Booka a ar tata forveten Retence pcier, Enzo, Eamon epecen Scheu) PID check Wathvouph 5) Alfie et compares a aed nok apie batons at PID ‘Alnabe expert neounerin wn Headed Ba eapecbe az bustonsecabownntteP8iO (eigen vanes towne, PAID Src ing, Pros nat Tanger erperte dears Sonvle probe.) aad Ree! Ves wre vee andi conetpoding Fom 88861-27048, tone. (Ret SAEs 800 See) ‘ante su Pa ont ig al et aes, casa vaes rd sally oi271008, aspen er beaes Sanaa. ‘ame BS Pressure gages installed are ofthe same range as shown In the PBID. sama Page 1 of 1[SAUDI ARAMCO INSPECTION CHECKLIST ‘SAENONBES DATE APPROVED GR NOME Final Insp of Fired Hester & Components (Re-Instatement) SAIC-F-2008 15-Dec-09 MECH TEM ‘ACCEPTANCE CRITERIA REFERENCE PASE FAL WA YN REINS DATE go Pisnu goges si ang wi Duck ard Ded abs (he bind —_SAES.I20, Vai sal be pgged} Pon bi aes a7 Tenpertue Gapesinaldarofhe same ange estoymintte ‘PAID Pao : Themalh a povd i daked sigan RGTHREMEWEO® yas, — - 5 b8 lonprsure aa are oven (6. Omg sass.s400 mobeore ; Giarieae Bo Fumnsce you comput 2.7100 era 71000, B10 Coupe fansio dives tar uae unin of ve, 127100 rem derives and vsti clnre es been pers Nols: .SAMSS.029 Inpoton Chai treaer bor eee SACPOO0E ogres. Par 94130 rz. N oewteprooctonequonest ste andes ae oia71eae, commision tomb © Heotrcas C1 Potorm hrs et por SAES A004 srareee Towel wir fom cal are conpoly moved by ERO BPE a yapgp, — ca_ by Sut Nano SASMTDPeponr su-2ri008 Soren nis alr inearanane co Fiji wt poied vt) covoson nh wan eae’ g.2 7 2 fatduhabe four ennaie mbes porsacsivonrans S4:27008 SAIC-A-2018) a Ge Min bemocoueson he een/coltaw popeiyineaiedand G2 71D frcaoel iomase > Stuctra tame: tess areas rug atom, oy, dG ae ’ 1 fewstdebin tot ad orvaneout ater wich oa 77000, trail inped Sperone av tel conn, ‘ili esperar stad a winened by nacon goo. ~ ee ner nopecton sir fu nuced et Gp. Azelf, dor tat, wave anda are congo. (G2 71608 Inetceng Sains) tomze ezine gs vimana a ys. tachouppor tna mii oases pr pe reason, (Now: Novconplane salon erie os-YES" fem ine Facity Pam 81.38 Eecepton tm it forthe Me) Alster oft reo siucue sal alow fas Ganingcfan S2.SaNiSS-29 vate No Pandg) bam ba oe Al oted connector or uct enum endhendorboresare———SBSANSS-020, proved win suite pests evra he gu eeoge om.82 13 7 Heder ors consign ings ae proved in ivended—~S2SANSS-CV, cousin tr tare and motets wea comactans. tam 8318 sasauss-28, DB Access dor ae bled ad avait zeanss.a Titer ae pondod altho Towra ecto pp (Aectee tov teeaton annul cometons se-sausscas, (atau anpingcomecions rom (Chatanehan an recone - eo” Stet daners, it goes and tac Pamocoun caonedions ay S7SANSS.R8, tecasble ton snk scan oo peo, am, b43 | Gi-a7eae DIT Mechanical operon co oer and damp wa verted 12700 Page 1 of 3sauce 84s [SAUDI ARAMCO INSPECTION CHECKLIST SAENTTE SATE APPREVED GR NUMBER Final Insp of Fired Heater & Compononts (Re-Instatement) SAIC-F-2008 15:D00.09 MECH. rem {ACCEPTANCE CRITERIA REFERENCE PASS FAIL WA YN REANS® DATE pra Tea clvert daha comp, FetuneTk and shez deanng SB SAVESOZD Suman ar occennb fo heat pao ue, po ba 17 arson recud fr ce atenton an esheprotng rar auc” 32-SANS6-29 om 0121 E Associa Pinon Pie bledo nazis aren toy np supports Shins ae £1 hiakcandectivetediopesupeorstnananconacense SAESLSE0 eee 2 Pe damper ightered andi lois wt ie oe SAEs L380, “oak ew bein ntages wt peace pes £3 OTE Winconcurenc fomine propor jar ec bots neyo SAESL3SD a tfarg seroadrsoalobe} sq. Shipboard navel mannan ae comecieecyn ” SAESIS00, vewren on ote nor oe pr eat gq. Spots olconaced ote boo vee erpecy wre SAES.JS00, seamen often arp ban at AZ‘, tok va isin ot tp on toiom connection ote £6. Sanipbeloine vessel (GA Lon Droung DCOSO0eE) Type bock SAES./SED ‘tire nated mcoromaroe wh poe eag o PaID Gy Verve wh ligand on op Bid fange& arin valve on boton ” SAES.J300 Dru tng of tandpve (68 by Demos e8088) parts ange rp eupponedon the vne. Diagonal cng h seu. ta formant dr voc pane ay Soreguree ava virmon, SAES/300 {Snut Wome Lian Dron D6-850069) Pare Co Te £0 Aprenie nsiumest nttaone ar supped venta vabes, SAESS2IN ae - - 7 SAES-L-108, 7 a 10 Atmospheric drain and vent valves shall be provided with a plug or blind Para. 7.7 tt Press sot ald aed png euelgsine)ar compe. U2 TTR 12 Arts ard bot of ang connelon ae iy wgeae ear ~~ Flange joints for piping Class ANS! 6008 and above were verified to be ae ao = cig, tohoned sm he ayeaie Tous pocatue onde apie” GI2.7106, guatel maetalteedih tone Dre & OTe boom tenth NOTE Reere SACL 2014 8 SATRL-200) awit ofcoseton (sa our ase are fexble gap er 55 says E14 cononingehccoton mrimum min ber &no eae, opp SASSO, [eacbtenordes menu, ahS00 pm wa shores, Spa ound guts vseetibing a deson ps sabe £18 AupindgeG Type T0SSiretalming wn oS oaertngs, — *ASAMSS.020 BabowesBee “Type S885 cur and oer oe 7 PattingWorte 1 Wenticaton of eqn are proved ada gio on SO feet 61271008, tony tr ocean equ emf Patan are cole enough tat an excessive amount sstdg gy 2 Crolthsilsunarinieawne mere oveson mis wanto C2 77040, Statup he at 3. Coungonsinctunl tars scampi andcotme wih et pe ook contngearaent Sate) ylowanieck spe pans on obec ha ast 4, bump ant fononstuppoms sie oesefeoivaye races, SAES-BO87 pesagemy shchpors upuaradedgen vppngranis) sipes Par, 429.8 thane 08 me Z Cig eeumen an davies all pnd why elowand daly garg, F5 marked wth the rated capacty of the equipment in Arabie and English in SAES-8-067, roti ton. a Page 2 of 3saucuaeancs o = [SAUDI ARAMCO INSPECTION CHECKLIST Ls SRERFROVED GNSS Final Insp of Fired Heater & Components (Re-intatement) SAIC-F-2008 16-Dec-09 _-MECH- TEM ACCEPTANCE CRTERIA REFERENCE PASS FAL NA YN REANSPOATE ce Rep ondvap aged nna Gano GT) we oar consis pana 6 _ Insulation worksiFire Proofing 61 Ate pot are conpee H2ri00 Tokton urd noe abound toca ri ack : G2 fronmhocnerensale atenrauieanteseomnaaugecr %SANSEEO?, Spo wa ce thine nies raaiaie TENOR ONTENTS gy Welding wos sy Avis om euch ovens wd acai pte ——~SAEGADON Sito Ans 011 Fyre SAIC E wes accepted toes sacs woot M2 Teco fash comatng fete ar snp waves, SAESIODH, "REMARKS: [REFERENCE DOCUMENTS: 1, GI2710, Mechanical Completion and Porformance Acceplance of Facies, (18 August 2008) ‘SAES-A-005, ‘Safety Ineruction Sheet, (28Feb 2005) & 3. SAEP.20, Equipment Inspection Schedule, (28 September 2005) ‘SAES-L350, Construction of Pian Piping, (30 Sept, 2003) & 5. SAES-M-001, Stuctual Design Criteria, (28 February 2008) ‘SRES-.200, Pressure (18 may 2008) & 7. SAESW-400, Temperature, (81 May, 2004) & ‘SAESY600, Pressure Rebe Devices (18 february 2008) ‘SAES-8-054, Access, Egress, & Mat's Handing for Plant Facies (18 March, 2006) 0. SAES-B.067, Saely Idenification and Safety Color, (30 November, 2003) Contractor / Third-Party ‘Saudi Aramco (Construction Representative lac inspector [eC Supervisor — PMT Representative a iis ate ne tan one, Liaemes Ceemoenvnr [] sevens apes enna [Jairo | MPM aaa orm [He Piseoint and Os Lemeemow E] ‘nat Reese ae organ ae STIS CASS TOT TEA TT =F WSS FRIES Page 3 of 30 be commissioned & readyREFRACTORY DRY OUT STEP 4 (2/7)REFRACTORY DRY OUT [ 1. Gs TERE REATEDTO RAMEN TED STEP 4 (3/7)STEP 1 (4/7) REFRACTORY DRY OUT “ pres er eSATA RE FNP OW Mien [> by fi neREFRACTORY DRY OUT [Fully open)} wyREFRACTORY DRY OUTMEME penne BEAST = Dp amenesase i | (SUCRE REAEE i; [REFRACTORY DRY OUT Y ISTEP 4 (7/7) i HI ie gl | me SFR TTT ROGAN CHWof nismsmnto ene mamnamamcnso emacs | | i i REFRACTORY DRY OUT = ISTEP 2 (1/1)=e REFRACTORY DRY OUT STEP 3 (1/3) JAN OIL COMPANY THERUAL OBIS (SRU TRANS SULFUR ESOVERY PNTeT eee Tea! Hela REFRACTORY DRY OUT STEP 3 (2/3) pene | ee RD [Open]le REFRACTORY DRY OUT STEP 3 (3/3)le REFRACTORY DRY-OUT STEP 4 (1/8) g gs: 5REFRACTORY DRY-OUTREFRACTORY DRYOUToa L crmyyree ne wmesvannet a wesc masenaneom ee snunsh nsnonoan or ont Kets mH stm eneectcKmnst ere by WE i | REFRACTORY DRYOUTREFRACTORY DRYOUT (518)REFRACTORY DRYOUT ry—| IT EFRACTORY DRYOU REZERR qt twoX oR K =e ase ISTEP 4 (7/8)REFRACTORY DRYOUT | | APOnoEEo! q i I | |[REFRACTORY DRYOUT STEP 5 (4/5) Y Teoh Rako Fomrech x HAZESe REFRACTORY DRYOUTREFRACTORY DRYOUT STEP 5 (3/5)REFRACTORY DRYOUT ISTEP 5 (4/5)sp evmnouiomeen imine 2 nen or numerous wu meu He He 1 i REFRACTORY DRYOUTTARABIAN OIL COI EWG & WSTRUMENTATON AGRA REFRACTORY DRY-OUT RAZEH RatqaiteoR Re Rakes FdTEMPORARY PREHEAT GUN P&ID FOR PEFRACTORY DR’ ACID GAS — REFRACTORY DRY-OUT as ox STEP 6.(3/4) ag" X az" foe PRESSURE INSTRUMENT AIR . ee REGULATOR > see eal a Xue NaTROSeN ve ean PROCES AR E _ ~----: PERMANENT CONNECTION FOR NORMAL OPERATION. < GS ——: TEMPORARY CONNECTION FOR REFRACTORY DRY-OUT. MGF Project Pre-commissioning Team Date 13 July, 2011“EEL ——4 ~ G_envenoe. ogeepnaergec | ee Gj saemsie] pete is a oR EST ARTA MAO EARS NOMRTTENOL OR TRT-> (Eames eeD J] Y [rofl Rofo For h RR 7i bh BRZERReoqeetwo RoXeHoHes TA ‘SAUDI ARABANOILwv BEST SQ) aanrenenee| ieicamanislanareen ee REFRACTORY DRYOUT STEP 8-2 (1/2) 5 a e & a a “aREFRACTORY DRYOUT STEP 8-2 (2/2)REFRACTORY DRYOUT = a & & & & a a 1 TORTS RT ORREFRACTORY DRYOUT STEP 8-3 (2/2)REFRACTORY DRYOUT STEP 9 (1/3) * Sa aren fio Ce) REFRACTORY DRYOUT STEP 9 (2/3) Y Leeks koko Fomr eho k RE7RRISTEP 9 (3/3) ARAB RATA aR