SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008)

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

Perform Inspection of Dryout (Furnace, etc)

SAIC-N-2030

PROJECT TITLE

EQUIPMENT DESCRIPTION

LAYOUT DRAWING NUMBER

REV. NO.

SCHEDULED INSPECTION DATE & TIME

ACTUAL INSPECTION DATE & TIME

PLANT NO.

EC / PMCC / MCC NO.

QUANTITY INSP.

MH's SPENT

TRAVEL TIME

SAUDI ARAMCO USE ONLY

SAUDI ARAMCO ACTIVITY NUMBER

SAUDI ARAMCO INSPECTION LEVEL

CONTRACTOR INSPECTION LEVEL

REFERENCE

WORK PERMIT REQUIRED?

PASS

General Requirements (SAES-N-110 & SAES-N-120 Applications, See Note 1)

A1

All new linings are cured & dried out per the Refractory Manufacturer's
recommendations &/or standard procedures of SAES-N-110 Sec. 10 &
SAES-N-120 Sec. 11

SAES-N-110,
Para. 10.1.1
SAES-N- 120
Para 11.1

A2

Checklists SAIC-N-2025, SAIC-N-2026 & SAIC-N-2027, SAIC-N-2028

& SAIC-N-2029 are complete including In-process inspection/sampling.

as referenced

A3

Dryout by Furnace use is initial controlled heating of refractory linings

raised to temperatures near their service temperature after curing to
achieve required physical properties of lining at its service temperature.

SAES-N-110/120
Sec. 4, Definition

B.

Furnace Dryout Specific Requirements (SAES-N-110 & SAES-N-120 Procedure, See Note 1)

B1

During dryout, the equipment is properly supported to prevent damage to

the lining and equipment (at elevated temperatures).

SAES-N-110,
Para. 10.1.2

B2

Adequately calibrated temperature measuring devices are installed to

monitor the temperature.

SAES-N-110,
Para. 10.3.1

B3

When dryout is by auxiliary burners, temperature monitoring is provided

on the gas outlet and burner areas.

SAES-N-110,
Para. 10.3.1

B4

The maximum dryout temperature is controlled* on lined equipment.

See Note 2.

SAES-N-110,
Para. 10.3.2

B5

When dryout is done in a furnace, the temperature measuring devices

are installed on the refractory side & on external surfaces of equipment
(Skin) to indicate differentials between metal & refractory temperatures.

SAES-N-110,
Para. 10.3.3

B6

Unless otherwise specified by the Refractory Manufacturer, minimum

hold times during dryout are 1 hour per 25 mm of refractory thickness.

SAES-N-110,
Para. 10.3.4

B7

Dryout inspection (SAES-N-110, Figure 1 Checklist) are as follows:

A) Firing equipment used is in good condition & meets
procedure
B) Burner
locations spacing relative to refractory is checked
C)
Dryout schedule is available & meets procedure
D) Thermocouple locations are identified & meet the procedure
E) Recording equipment is available & calibrated &
meets procedure

SAES-N-110,
Para. 11.6

C.

Inspection Requirements After Dryout (SAES-N-110 or SAES-N-120 Procedure, Attachment 1)

C1

All inspection is performed per Saudi Aramco Inspection Requirement

Form 175-328110 & SAES-N-110/120 procedure. See Attachment 1.

SAES-N-110,
Para. 11.1.1

C2

Visual examination (Cracking evaluation) & Hammer Test is performed

after the furnace dryout per SA Form 175-328110, Line Item 26.

SAES-N-110,
Para. 11.1.1

Page 1 of 6

MECH-

SYSTEM ID.

PURCHASE ORDER NUMBER

ACCEPTANCE CRITERIA

QR NUMBER

CONTRACTOR / SUBCONTRACTOR

EQPT CODE

SAUDI ARAMCO TIP NUMBER

A.

15-Dec-09

WBS / BI / JO NUMBER

EQUIPMENT ID NUMBER(S)

ITEM
No.

30-Jun-08
DATE APPROVED

FAIL

N/A

RE-INSP DATE

C3

Lining cracks found AFTER DRYOUT are repaired when they are 3 mm
wide and larger and when the depth exceeds 20% refractory thickness.

Page 2 of 6

SAES-N-110,
Para. 11.5.4

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008)

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

Review Procedure & Perform Insp of Furnace Dryout

SAIC-N-2030

PROJECT TITLE

WBS / BI / JO NUMBER

ITEM
No.

ACCEPTANCE CRITERIA

REFERENCE

C4

At completion of furnace dryout, the lining is randomly checked for voids

or damaged areas by lightly striking it with a 1-pound hammer:
A) The refractory is free of voids (no dead, dull sounds)
B) The refractory has sufficient hardness (when
struck).
C) The refractory has not
disbonded from the equipment surface

SAES-N-110,
Para. 11.3.6

C5

The size of dull sounding areas are investigated & samples test results
are compared before a decision is made on removal of the refractory.

SAES-N-110,
Para. 11.3.6

C6

After Dryout, Refractory found to be defective due to presence of voids,

honeycombs, insufficient hardness, disbond & other damage* is marked
by the Inspector for total removal to full thickness of lining layer.

30-Jun-08
DATE APPROVED

QR NUMBER

15-Dec-09

MECH-

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

SAES-N-110,
Para. 11.3.7

*See Note 3.
D.

Inspection of Exterior Surfaces After Dryout

D1

Temporary supports are removed after Dryout, & surfaces have no heat
distortion or mechanical damage from the Dryout operations.

SAES-N-110,
Para. 10.1.2

D2

Inspector checks all heated exterior surfaces closely for evidence of hot
spots, distortion in equipment surfaces, and other related heat damage
after Dryout operations have been completed.

SAES-N-110,
Para. 10.3.2

REMARKS:
REFERENCE DOCUMENTS:
1. SAES-N-100 -- Refractory Systems (30 Jan 2007)
2. SAES-N-110 -- Installation Requirements-Castable Refractories (30 Jan 2007)
3. SAES-N-120 -- Installation Requirements-Extreme Erosion Resistant Refractories (30 Jan 2007)
4. API RP936-Refractory Installation Quality Control Guidelines-Inspection and Testing Monolithic Refractory Linings and Materials (Nov-08)
ATTACHMENTS:
1. Attachment 1 -- SA Form 175-328110 Castable Refractories
NOTES:
1. This checklist applies to Furnace Dryout inspection for castable refractory systems detailed in both procedure SAES-N-110 & SAES-N-120.
2. The dryout plan for newly installed refractory includes key control elements to be monitored by the INSPECTOR (API RP936, Section 6.2 ).
A) Heat up/cool down rates for all control temperature indicators
B) The maximum difference between temperature indicators.
C) Heating rates are monitored by thermocouples closest to the heat source.
D) The hold temperatures and durations are achieved at all thermocouples including those at gas exits of the newly installed refractory.
E) When specified by manufacturer, Table 5 of API RP936 shall be used. See Attachment # 2 (Dryout Schedule)
F) When cool down is included in the dryout work scope, cooling rates shall not exceed 150F (85C) per hour.
3. Final visual inspection after furnace dryout identifies Hot or Explosive Spalling (trapped moisture explodes/dislodges refractory) & bloating/bulges.
The Inspector checks low points (floors) for evidence of spalling. Equipment & Low points are absolutely clean prior to dry-out. After dry-out, any
spalled concrete is easily identified by the presence of refractory chunks & debris on the floor or at low points. On finding evidence of such damage,
the Refractory Inspector can call for scaffolding to reach suspect areas for further investigation & any necessary repairs. A usual cause of explosive
spalling is too rapid a heating rate where entrapped water becomes steam & explodes. Bloating (bulges) occur in plastic subsurface lining systems.

Contractor / Third-Party

Saudi Aramco

Construction Representative*

PMT Representative

Work is Complete and Ready for Inspection:

Name, Initials and Date:

QC Inspector

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

PID Representative
Performed Inspection

Work / Rework May Proceed

Name, Initials and Date:

Name, Initials and Date:

QC Supervisor

Proponent and Others

Quality Record Approved:

Name, Sign and Date:

T&I Witnessed
Name, Initials and Date:

Name, Organization,
Initials and Date:

Page 3 of 6

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008)

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

Review Procedure & Perform Insp of Furnace Dryout

SAIC-N-2030

PROJECT TITLE

ITEM
No.

WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA
Quality Record Approved:

Name, Sign and Date:

REFERENCE

30-Jun-08
DATE APPROVED

15-Dec-09

QR NUMBER

MECH-

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

Y = YES

N = NO F = FAILED

Name, Organization,
Initials and Date:

*Person Responsible for Completion of Quality Work / Test

Page 4 of 6

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008)

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

Review Procedure & Perform Insp of Furnace Dryout

SAIC NUMBER

SAIC-N-2030

30-Jun-08
DATE APPROVED

15-Dec-09

QR NUMBER

MECH-

Attachment 1 -- SA Form 175-328110 Castable Refractories

Page 5 of 6

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008)

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

Review Procedure & Perform Insp of Furnace Dryout

SAIC NUMBER

SAIC-N-2030

30-Jun-08
DATE APPROVED

15-Dec-09

QR NUMBER

MECH-

Attachment 2 -- API RP 936 Table 5, Dryout Schedule

Page 6 of 6