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

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

In-Process Inspection of Extreme Erosion Resistant

Refractory
PROJECT TITLE

SAIC-N-2032
WBS / BI / JO NUMBER

EQUIPMENT ID NUMBER(S)

EQUIPMENT DESCRIPTION

LAYOUT DRAWING NUMBER

REV. NO.

SCHEDULED INSPECTION DATE & TIME

ACTUAL INSPECTION DATE & TIME

SYSTEM ID.

MH's SPENT

CONTRACTOR INSPECTION LEVEL

REFERENCE

WORK PERMIT REQUIRED?

PASS

FAIL

N/A

General Requirements (SAES-N-120 procedure)

A1

Checklist SAIC-N-2022 was completed & accepted relative to welding

of anchors, supports & hexsteel prior to application of extreme erosion
resistant refractory.

As Referenced

A2

Checklist SAIC-N-2023 was completed & application method &

applicator qualifications were accepted prior to application of extreme
erosion resistant refractory.

As Referenced

A3

Checklist SAIC-N-2024 Pre application Inspection of Castable

Refractory was completed & accepted prior to any application of extreme
erosion resistant refractory.

As Referenced

A4

Refractory Application Method for specific equipment using extreme

erosion resistant refractory meets SAES-N-100, Table 2 & 3.
Refer to Note 1.

SAES-N-100,
Para. 9.1

Material Type used for equipment with extreme erosion resistant

refractory meets SAES-N-100, Table 2 & 3 as listed below:
SAES-N-100,
Para. 9.2, 9.3

A5

A) Type H, Chemical Setting Castable (SAMS S/N 32163570) or

B) Type I,
Chemical Setting Plastic (SAMS S/N 32163580)
Refer to Note 1

B.

Specific SA Inspection Requirements Form 175-328110 (SAES-N-120 Procedure)

Inspection & Testing is performed per SAES-N-120 Procedure and the
SA Inspection Requirement Form 175-328110, Lines 13 thru 25.

SAES-N-120,
Para. 12.1.1

See Attachment 1.
B2

Independent laboratory & personnel are available on site & present

during entire installation process for testing purposes.

C.

Specific Procedure Requirements Related to Materials & Environment for Application (SAES-N-120 Procedure)

C1

Refractory material used is within a valid expiry date.

SAES-N-120,
Para. 10.1.1

C2

Packages were undamaged, dry & were not be opened until mixing.

SAES-N-120,
Para. 10.1.2

C3

The water quality for mixing complies (certs available) as follows:

A) The pH shall be within a range of 5.8-8.6.
B) Water quality limits are Total Impurity Level <1000 ppm, Magnesium &
Calcium < 300 ppm, Chlorine & Sulfur < 200 ppm, & Iron < 500 ppm.

SAES-N-120,
Para. 10.1.3

C4

Admixtures (normally not allowed) have been approved by the Saudi

Aramco Engineer (CSD Supervisor, Piping & Valves Unit).

SAES-N-120,
Para. 10.1.4

C5

Lining is installed indoors area, except for in-situ patching (tie-ins) and
repairs on site.

SAES-N-120,
Para. 10.1.5

C6

Lining is not be applied when the temperature of the backing surface

exceeds 32C.

SAES-N-120,
Para. 10.1.6

Page 1 of 6

TRAVEL TIME

SAUDI ARAMCO USE ONLY

SAUDI ARAMCO INSPECTION LEVEL

B1

PLANT NO.

EC / PMCC / MCC NO.

QUANTITY INSP.

SAUDI ARAMCO ACTIVITY NUMBER

A.

MECH-

CONTRACTOR / SUBCONTRACTOR

PURCHASE ORDER NUMBER

ACCEPTANCE CRITERIA

QR NUMBER

15-Dec-09

EQPT CODE

SAUDI ARAMCO TIP NUMBER

ITEM
No.

30-Jun-08
DATE APPROVED

SAES-N-120,
Para. 12.1.3

RE-INSP DATE

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

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

In-Process Inspection of Extreme Erosion Resistant
Refractory
PROJECT TITLE

ITEM
No.

C7

SAIC NUMBER

30-Jun-08
DATE APPROVED

SAIC-N-2032

15-Dec-09

WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA

REFERENCE

Lining is protected against heat induced accelerated setting by keeping

the temperature of the area being lined at 32C or less during application
and for a minimum of 24 hours after application

SAES-N-120,
Para. 10.1.7

MECH-

CONTRACTOR / SUBCONTRACTOR

PASS

C8

In order to achieve temperature limitations, backing surface are shaded

from direct sunlight, refractory is applied indoors or at night with proper
illumination. Cooling by use of water spraying is prohibited.

SAES-N-120,
Para. 10.1.8

C9

The lining material temperature, the backing surface temperature and

the atmospheric temperature around the lining during and 48 hours after
refractory application are not below 10C.

SAES-N-120,
Para. 10.1.9

C10

Lining surfaces are kept dry before, during, and after installation.

SAES-N-120,
Para. 10.1.10

D.

Specific Procedure Requirements Related to Mixing of Materials (SAES-N-120 Procedure)

D1

Refractory manufacturer mixing instructions, installation instructions &

precautions are available on site and strictly followed.

SAES-N-120,
Para. 10.2.1

D2

For mixing, Hobart Model # D-33 commercial mixer (or approved equal)
& (2) 30-quart mixing bowls, beater & wire whip (all Stainless) are used.

SAES-N-120,
Para. 10.2.2

D3

The quantity to be mixed is only as much as can be applied within 15

minutes after addition of water.

SAES-N-120,
Para. 10.2.3

D4

Any mixed refractory that is not used within 15 minutes is discarded &
mixing does not continue after plastic stage occurs.

SAES-N-120,
Para. 10.2.3

D5

All equipment, mixing bowls & tools are kept clean and free of foreign
material & are cleaned thoroughly after each mix.

SAES-N-120,
Para. 10.2.4

E.

Sample Testing Prior to Application or "First Mix Sampling" (SAES-N-120, 9-Step Procedure)

E1

Select three packages at random from each batch or lot, then take 5 lbs
of dry and damp material from each batch or lot.

SAES-N-120,
Para. 10.3.1 (1)

E2

Reseal the packages that the samples were taken from and mark them
"Package Opened for Sampling".

SAES-N-120,
Para. 10.3.1 (2)

E3

Mix the three samples of the dry material together to give a uniform
mixture. Repeat this procedure with the damp material.

SAES-N-120,
Para. 10.3.1 (3)

E4

Take enough of the sample mix to prepare five 50 mm cubes for the cold
crushing strength tests.

SAES-N-120,
Para. 10.3.1 (4)

E5

Seal the remainder for possible re-test.

SAES-N-120,
Para. 10.3.1 (5)

E6

Mix the two materials together, and add the required amount of water
(refer to mixing instructions in paragraph above) and cast five cubes.

SAES-N-120,
Para. 10.3.1 (6)

E7

Air cure & dryout the samples per procedure in SAES-N-120, Section 11

SAES-N-120,
Para. 10.3.1 (7)

Page 2 of 6

QR NUMBER

FAIL

N/A

RE-INSP DATE

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

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

In-Process Inspection of Extreme Erosion Resistant
Refractory
PROJECT TITLE

SAIC NUMBER

SAIC-N-2032
WBS / BI / JO NUMBER

ITEM
No.

ACCEPTANCE CRITERIA

REFERENCE

E8

Perform cold-crushing strength and bulk density tests in accordance with

ASTM C133 and ASTM C134. The cold-crushing strength and bulk
density values are the average result obtained for the five test cubes.

SAES-N-120,
Para. 10.3.1 (8)

E9

Any sample that does not meet the minimum published strength or
density will be cause for rejection of the complete batch.

SAES-N-120,
Para. 10.3.1 (9)

F.

Application Procedure (SAES-N-120 Procedure)

F1

Mixed refractory is hand packed thoroughly into hexsteel, worked to fill

anchorage holes & eliminate air bubbles & pockets. After material is
uniformly distributed, a plastic or wooden mallet is used to hammer the
refractory into the hexsteel to eliminate any voids or air pockets &
achieve proper installed density of the material.

SAES-N-120,
Para. 10.4.1

F2

Extreme care is taken to prevent any overlaying of lining material over

hexsteel with refractory screeded smooth & flush with the face of the
hexsteel. The hexsteel pattern is visibly distinguishable after screeding.

SAES-N-120,
Para. 10.4.2

G.

Production Sample Testing During Application (SAES-N-120 Procedure) ---

G1

Samples are taken during each shift that refractory is being applied.

G2

SAES-N-120,
Para. 10.5.1

SAES-N-120,
Para. 10.5.1

G3

All samples are in the form of a 50 mm cube.

SAES-N-120,
Para. 10.5.2

G4

Samples are hand packed into molds & a number is scratched carefully
onto the top of each sample using a small diameter rod.

SAES-N-120,
Para. 10.5.3

G5

A chart is kept showing the following information: sample number, date

and time sample was taken, and location where sample was taken.

SAES-N-120,
Para. 10.5.3

G6

Refractory Installer keeps a sketch & log showing clearly where each
batch of refractory was applied & locations where samples were taken.

SAES-N-120,
Para. 10.5.4

Page 3 of 6

QR NUMBER

15-Dec-09

MECH-

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

COMPLETE SATR-N-2002.

About 8 to 10 samples are taken at each following time during shifts:

A) First batch each shift
B) Last batch each prelunch break
C) First batch after each prelunch break
D) Last batch before lunch
E) First
batch after lunch
F) Last batch before post lunch break
G) First batch after post lunch break
H) Last batch of the shift.

30-Jun-08
DATE APPROVED

N/A

RE-INSP DATE

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

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

In-Process Inspection of Extreme Erosion Resistant

Refractory

SAIC-N-2032

PROJECT TITLE

ITEM
No.

WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA

30-Jun-08
DATE APPROVED

REFERENCE

G7

After the 24 hour air set, samples are dried using muffle furnace dryingout temperatures and cycles for samples as follows:
A) Heat to 82C - 93C and hold for one hour.
B) Heat to 150C and hold for three hours.
C) Heat to 370C and hold for four hours.
D) Cool to ambient temperature.

SAES-N-120,
Para. 10.5.5

G8

After air curing & drying out, two density checks (results= not less than
2,400 kg/m) are obtained from each shift's samples per ASTM C134.

SAES-N-120,
Para. 10.5.6

G9

After air curing and drying out, all samples are subjected to cold-crush
strength tests in accordance with ASTM C133.

SAES-N-120,
Para. 10.5.7

G10

All testing is to be carried out by an approved & experienced laboratory.

SAES-N-120,
Para. 10.5.8

G11

Physical properties are not less than 90% of published values & the
refractory below required values for properties after dryout is rejected.

SAES-N-120,
Para. 10.5.9

QR NUMBER

15-Dec-09

MECH-

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

REMARKS:
REFERENCE DOCUMENTS:
1. SAES-N-100 -- Refractory Systems (30 Jan 2007)
2. SAES-N-120 -- Installation Requirements-Extreme Erosion Resistant Refractories (30 Jan 2007)
ATTACHMENTS: 1. Attachment 1 -- SA INSP FORM 175-328110 (Refractories)
NOTES: 1. Use Table 2 & 3 Mandatory Refractory Systems of SAES-N-100 (Not Attached) for In-Process inspection checks of materials.

Contractor / Third-Party

Saudi Aramco

Construction Representative*

PMT Representative

Work is Complete and Ready for Inspection:

Name, Initials and Date:

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

Name, Initials and Date:

QC Inspector

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:

Name, Organization,
Initials and Date:

*Person Responsible for Completion of Quality Work / Test

Y = YES

Page 4 of 6

N = NO F = FAILED

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

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

In-Process Inspection of Extreme Erosion Resistant
Refractory

SAIC NUMBER

SAIC-N-2032

30-Jun-08
DATE APPROVED

15-Dec-09

Attachment 1 -- SA INSP FORM 175-328110

Page 5 of 6

QR NUMBER

MECH-

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

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

In-Process Inspection of Extreme Erosion Resistant
Refractory

Page 6 of 6

SAIC NUMBER

SAIC-N-2032

30-Jun-08
DATE APPROVED

15-Dec-09

QR NUMBER

MECH-