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Rev 2 SAIC NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Proprietary Fireproofing System & Procedure (Intumescent Epoxy Mastics & Lightweight Concretes)
31-Dec-05 DATE APPROVED QR NUMBER
WBS / BI / JO NUMBER
CONTRACTOR / SUBCONTRACTOR
EQUIPMENT ID NUMBER(S) LAYOUT DRAWING NUMBER SCHEDULED INSPECTION DATE & TIME SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO INSPECTION LEVEL
EQUIPMENT DESCRIPTION REV. NO. PURCHASE ORDER NUMBER
EC / PMCC / MCC NO. QUANTITY INSP. MH's SPENT TRAVEL TIME
ACTUAL INSPECTION DATE & TIME SAUDI ARAMCO ACTIVITY NUMBER CONTRACTOR INSPECTION LEVEL
SAUDI ARAMCO USE ONLY
WORK PERMIT REQUIRED?
ITEM No. A
ACCEPTANCE CRITERIA General Requirements Proprietary Fireproofing Material System was approved by the Chief Fire Prevention Engineer as follows: A) Qualifying documentation of fireproofing material was submitted to the Chief Fire Prevention Engineer for approval. (Approval) B) Refer to Attachment 1 for proprietary fireproofing mat'l list for various applications in SA facilities. *Latest revision of SAES-B-006 is to be used with checklist. Application procedure approved by fireproofing manufacturer is submitted to Inspection Department (manager) for approval. Procedure indicates the requirement for application personnel to be trained & certified by mat'l manufacturer. See Also SAIC-B-2002 Application section details: Application is in strict accordance with manufacturer's guidelines for temperatures, storage, materials, proportioning, mixing & other considerations (safety, cleaning, etc.) Application procedure details QC steps & inspection points for inspection of surface preparation and reinforcement. Application procedure details the required surface preparation of steel surface to be covered with intumescent or other proprietary fireproofing materials. (SAES-H-101, APCS-1B). Surface prep & coating system specified shall be referenced on all drawings. Procedure application for intumescent material specifies a minimum wet thickness that will yield the required dry thickness (DFT). (API PUBL 2218, Para. 18.104.22.168) Note: Procedure details extent & location of checks to ensure adequate DFT (evaporation loss). Procedure details top coating requirements & manner of application: A) See Attachment 1 (Cementitious per Para. 8.5) B) See Attachment 1 (Intumescent Epoxy per Para. 8.6) Procedure details the manner of applying the required top-coating approved by the fireproofing manufacturer. Procedure Definition Section lists applicable SAES-B-006 & API Publication 2218 applicable definitions: A) Intumescent mastic: B) Fire-hazardous equipment: C) Fire-hazardous zone: D) Other applicable definitions (SAES-B-006, API 2218). Procedure Mat'l Section lists applicable materials selected and states or infers (data sheet inference) their limits for application: A) Intumescent epoxy mastics (equipment or supports) such as Chartek 4, 7 (Int'l Coatings, Ltd.), Thermo-Lag 440 (Thermal Sci, Inc), Pitt-Char XP (PPG Industries, Inc.), or other approved material. B) Proprietary Intumescent epoxy coatings (Valve Actuators) like KMass® (Thermal Designs, Inc) or FR Coating™ (MOV Limited) C) Other proprietary coatings that meets Company requirements See also Sections B & C for specific application reqmts
SAES-B-006, Para. 8.2.1 See Note*
SAES-B-006, Para. 8.2.1 SAES-B-006, Para. 8.2.2 SAES-B-006, Para. 8.2.3 SAES-B-006, Para. 8.2.4 SAES-B-006, Para. 8.4
SAES-B-006, Para. 5.2 & 8.2.3
SAES-B-006, Sect. 8.6 SAES-B-006, Para. 8.6.4
SAES-B-006, Section 4, Definitions
SAES-B-006, Appendix 1
Page 1 of 5
SAUDI ARAMCO ID/PID . D) Fireproofing materials are applied directly from original sealed containers to avoid contamination and changes in their formulation. application thickness and finishing. density.2 B2 C C1 SAES-B-006 Para.2 SAES-B-006. not wet thickness. 7. 6. E) Materials requiring controlled curing periods are identified F) Appliers & inspectors understand specified thickness is dry thickness. Data Sheet lists specific applications & limits for materials C) Certified Report (fireproofing & environmental exposure tests) D) Material Safety Data Sheet (MSDS) listing hazards & precautions Procedure details API Publication 2218 material application considerations (ensure checks by those responsible) as follows: A) Shelf life is determined and maintained. Small variations are significant to the fire-resistance of the finished coating when using thin mastics. Data Sheet lists material's physical properties B) Mfg.1 A15 SAES-B-006. 8.3. Para. Para. Specific Requirements (Equipment & Supports) Intumescent materials have been subjected to a test furnace environment per UL 1709 or equivalent fire exposure test procedure accepted by the SA Chief Fire Prevention Engineer.2 A16 SAES-B-006. Procedure details or infers API Publication 2218 material application Quality Control responsibilities/considerations: A) Qualified personnel familiar with job specs monitor mixing. C) Inspection is aware of user & applier agreements regarding the extent of random sampling necessary to verify coat thickness.4 Page 2 of 5 .December 2005) Rev 2 SAIC NUMBER SAUDI ARAMCO INSPECTION CHECKLIST Review Proprietary Fireproofing System & Procedure (Intumescent Epoxy Mastics & Lightweight Concretes) PROJECT TITLE 31-Dec-05 DATE APPROVED QR NUMBER SAIC-B-2001 WBS / BI / JO NUMBER 1-Dec-06 MECH- CONTRACTOR / SUBCONTRACTOR ITEM No. B) Materials are applied per manufacturer’s recommendations for dry thickness. proper bond. These are identified in procedure & Material Data sheet (two options): A) FP must be clean. C) Other applicable tests performed to qualify materials Procedure Material Section covers Top coating considerations (as required by Manufacturer). dry & free of contaminants prior to top-coat. ACCEPTANCE CRITERIA Procedure Material Section lists material testing requirements for material qualification: A) Intumescent materials have been subjected to a test furnace environment per UL 1709 or equivalent fire exposure test procedure B) Fireproofing manufacturer has demonstrated no peel-back at edges or terminations in a fire situation for intended application. 7.6 A14 SAES-B-006. Section 3.18-MAY-05 . 7.2 A13 SAES-B-006. Fireproofing manufacturer has demonstrated no peel-back at edges or fireproofing terminations in fire situation for intended application. and are most often found in parts of a structure that are congested or difficult to reach.2 B B1 SAES-B-006. C) Temperature-sensitive material storage and shipping. recommendations prior to top-coat C) Top-coat with SA Stock No 1000194797 or 1000194960 applied to a dry-film thickness of 75 to 125 microns. Para. Section 8. Specific Requirements (Actuators) Fireproofing protects valve actuators for a minimum of 20 minutes when subjected to test furnace environment per the full-scale test method of UL 1709 or an equivalent "rapid-rise" fire test procedure REFERENCE PASS FAIL N/A RE-INSP DATE A12 SAES-B-006. B) FP must be cured per mfg. (Option 1) D) Top-coat for proprietary fireproofing other than intumescent epoxy mastic as approved by fireproofing manufacturer & Company Material APPLICATION section is specific and breaks down the elements of the documentation package from manufacturer: A) Mfg.REV 0 (Standards Cutoff . B) Material storage is per manufacturer’s recommendations. substrate preparation.2. lack of voids & specific evaluation procedures used. Cured mastics shrink up to 30% . Section 3. Para.
discharge. Section 4 Page 3 of 5 . etc) for operations. confined spaces. D) Pressure relief valves. equipment ground (AWG-4). equipment pressure component condition. hearing protection C) Vessel use (air receivers. operation speeds.2 C4 Actuator outer surface of fireproofing is a distinctive color or colors 21-SAMSS-014. safety guards. surge tanks. QC Records section lists requirements & responsibility as follows: A) Equipment Check Sheet (Attachment B) B) In-process Inspection Sheet (Attachment C) C) Paints/Coatings & Equipment Log (Att D) D) Daily Job Log Final Acceptance Report is listed. leather glove use. pump pressure relief valves. washing facilities.18-MAY-05 . personnel protection equipment & MSDS Safety Requirements (Equipment) are detailed in procedure: A) Airless spray gun basic safety. Section 9 SAES-H-100. & work permits B) Ventilation (forced.3. purple is one acceptable color used. Report includes four (4) QC documents (Attachments B. welding/heating coil use. D. tip guards. gusts to 44 m/sec (160km/h) • Ambient temperatures range from 0°C (minimum for EIV actuators) to 50°C (for sheltered actuators). added fans. air-fed hoods. Issued whenever any defect from coating material deficiency or/ and application malfunctioning. to max 80°C (exposed actuators) The fireproofing fully covers the actuator body. B) Power Tool Equipment Hazards covers grounding. 5000 psi line limit. chemical burns. 6. excluding: A) Indicator lights B) Stem protector on top of the actuator C) Handwheel or declutch lever. Section 4) Safety Requirements are detailed in procedure as follows: A) Fire and Explosion Prevention covers Smoking.4 C3 21-SAMSS-014. electrical items (lighting equipment & connections). skin contact. ACCEPTANCE CRITERIA Newly constructed Emergency Isolation Valves (EIVs) that require actuator fireproofing have a vendor shop-applied intumescent fireproofing per 21-SAMSS-014 requirements as follows: A) Material is rated to withstand environmental conditions below: • UV irradiation by direct sunlight. Section 4 E2 SAES-H-102. Section 9 D D1 D2 SAES-H-100. etc) are code vessels stamped per ASME SEC VIII D1.4 coating as fireproofing. hose ground (anti-static type). solvent/paint application. hydrotested at 250 psig annually with vessel test certificates submitted to SA Inspector for review. Section 9 D3 SAES-H-100. • Wind velocity to 36 m/sec (130 km/h). etc). Non Conformance Report is listed.REV 0 (Standards Cutoff . solvent flushing safety. pump shut down & fluid pressure bleed before servicing/cleaning parts (clogged spray tips. The color is not a Safety color (per SAES-B-067). Shaft extenders (where specified) are Type 316 SS Controls & Indicators shall be accessible for maintenance REFERENCE PASS FAIL N/A RE-INSP DATE C2 SAES-B-006 Para. C) Health Hazards cover Alkaline catalysts. Safety during Applications (SAES-H-102. pumps. Daily Logs) above. designated areas. • Relative humidity of 0 to 100% (condensing). Section 7. (agreeable to Chief Fire Prevention Engineer) to identify this special Section 7. Section 9 D4 E E1 SAES-H-102. & emergency care for high pressure fluid injuries. Remedial action & method of repair are defined & agreed upon. C. gauges & devices are tested/tagged E) Blasting/coating equipment grounding (electrostatic disch. Quality Control (QC) Requirements (Procedure) QC Equipment listed in SAES-H-100 Attachment A is listed for inspection of surface preparation & coatings application.) SAES-H-100.December 2005) Rev 2 SAIC NUMBER SAUDI ARAMCO INSPECTION CHECKLIST Review Proprietary Fireproofing System & Procedure (Intumescent Epoxy Mastics & Lightweight Concretes) PROJECT TITLE 31-Dec-05 DATE APPROVED QR NUMBER SAIC-B-2001 WBS / BI / JO NUMBER 1-Dec-06 MECH- CONTRACTOR / SUBCONTRACTOR ITEM No. hot work.SAUDI ARAMCO ID/PID . trigger safety catches. For example. natural) & equipment used covers fresh air inlets. pressure ratings (Hoses.
SAES-B-006 Appendix 1 . Coating Materials & Application Requirements for Industrial Facilities (31 July 2004) 3. REFERENCE DOCUMENTS: 1.18-MAY-05 . 2003) ATTACHMENTS: 1. Initials and Date: QC Record Reviewed Work Verified QC Supervisor Quality Record Approved: Name. Initials and Date: Name. Initials and Date: Saudi Aramco PMT Representative T&I Witnessed QC Record Reviewed Work Verified QC Inspector Performed Inspection Name. ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE REMARKS: *Always use latest approved revision of B-Std. Initials and Date: T&I Witnessed QC Record Reviewed Work Verified Y = YES N = NO F = FAILED Page 4 of 5 . (*18 July. Safety Requirements for Coating Applications (31 July 2004) 4. API Publication 2218 . Fireproofing for Plants. Sign and Date: *Person Responsible for Completion of Quality Work / Test Proponent and Others Name. not the Cut-off stds.REV 0 (Standards Cutoff . Initials and Date: Work / Rework May Proceed PID Representative T&I Witnessed Name.Intumescent Fireproofing for Valve Actuators (30 June.December 2005) Rev 2 SAIC NUMBER SAUDI ARAMCO INSPECTION CHECKLIST Review Proprietary Fireproofing System & Procedure (Intumescent Epoxy Mastics & Lightweight Concretes) PROJECT TITLE 31-Dec-05 DATE APPROVED QR NUMBER SAIC-B-2001 WBS / BI / JO NUMBER 1-Dec-06 MECH- CONTRACTOR / SUBCONTRACTOR ITEM No.Approved Proprietary Fireproofing Materials Contractor / Third-Party Construction Representative* Work is Complete and Ready for Inspection: Name.SAUDI ARAMCO ID/PID . 21-SAMSS-014 . SAES-H-102.Fireproofing Practices in Petroleum & Petrochemical Processing Plants (2nd EDITION. Organization. 2006) See Remarks 2. AUG 1999) 5. SAES-H-100. SAES-B-006.
5..SAUDI ARAMCO ID/PID . nor are requisition originators restricted to the products of manufacturers or vendors on this list. and effectiveness in hydrocarbon fires. This listing is intended to provide useful information on the available proprietary fireproofing materials to requisition originators and others responsible for the development and evaluation of bids. 7. as a composite system.Approved Proprietary FP Materials Appendix 1 (Use SAES-B-006. Refer to latest revision of SAES-A-006 available & utilize Appendix 1: A) Approved Material .. SA Stock # 1000194629 thinned 10% to 15% & applied to a dry-film thickness of 50 to 90 microns.. and effectiveness in hydrocarbon fires. • When fireproofing is installed on equipment that is protected by a fixed firewater spray or deluge system. However.1 Dense concrete meeting the material requirements of Section 8 and applied with a minimum thickness of 50 mm is accepted as complying with the performance requirements for fireproofing without further testing. Fireproofing may be purchased from any qualified source that can comply with the mandatory requirements.6. 7. The coating shall be applied in a manner approved by the fireproofing manufacturer and by the Manger. shall be installed with a thickness to provide a minimum fire-resistance rating of two (2) hours when subjected to a test furnace environment in accordance with UL 1709 or an equivalent fire exposure test procedure accepted by the Chief Fire Prevention Engineer. and free of contaminants prior to top-coating. Page 5 of 5 . 8.2 When cementitious fireproofing is to be provided with a top coat.5 Top-Coating of Cementitious Fireproofing 8.1 Fireproofing must be clean. exchangers. • Second top coat. other than qualifying dense concrete. 8. Certified test reports shall be submitted to the Chief Fire Prevention Engineer for his approval.6.2 Fireproofing must be cured in accordance with the manufacturer's recommendations prior to top-coating..REV 0 (Standards Cutoff . July 2006 or latest revision) Ordinary dense concrete is the preferred fireproofing of structures and supports because of its proven economy. & equipment externally insulated for process reasons shall be considered to be fireproofed if process insulation per SAES-N-001. Approval shall be received from Chief Fire Prevention Engineer for each product unless it is already listed.3 Top-coating of Saudi Aramco Stock Number 1000194797 or 1000194960 shall be applied to a dry-film thickness of 75 to 125 microns.6 Top-Coating of Intumescent Epoxy Mastic Proprietary Fireproofing Intumescent epoxy mastic and other noncementitious proprietary fireproofing shall be top-coated when it is required by the fireproofing manufacturer.5. for some applications. See Section 8 reqmts. This is not intended to list all acceptable materials. Refer to Appendix 1 for more info. • When fireproofing is installed within 3 m vertically from grade.2 Minimum thickness of fireproofing mat'ls for structural members & vessel supports. Dhahran. Dense concrete is the preferred fireproofing for onshore facility structures & supports because of its proven economy.December 2005) Rev 2 SAIC NUMBER SAUDI ARAMCO INSPECTION CHECKLIST Review Proprietary Fireproofing System & Procedure (Intumescent Epoxy Mastics & Lightweight Concretes) 31-Dec-05 DATE APPROVED QR NUMBER SAIC-B-2001 1-Dec-06 MECH- Attachment 1 -. SA Stock Number 1000194797 shall be applied to dry-film thickness of 75 to 125 microns. alternative proprietary fireproofing mat'ls may be justified. 8. dry. 8. durability. APPLICATION NOTE (DESIGN): 8. Are they on the list? Note: Any item "not on list" shall be appv'd by Chief Fire Prevention Engineer 8. • When fireproofing is installed below atmospheric drains or vents that are used during normal operations.. prior to top-coat application.6.1 All cementitious fireproofing (whether dense or lightweight concrete) shall be provided with a top coat under any of the following conditions: • When top-coating is required by the manufacturer. Is it on the list? C) Approved Material Supplier & Installer .18-MAY-05 . the following shall apply: • Surface shall be dry & loose contaminants shall have been removed by brushing (stiff bristle brush) & vacuuming.3 Process Insulation Vessels. durability. satisfies FP performance Stds in Section 7 below. Verification of compliance shall be the responsibility of the requisition originator.. Is it on the list? B) Approved Manufacturer . • Fireproofing must be fully cured in accordance with manufacturer's technical reqmts. Inspection Department.All materials and methods of fireproofing shall also be listed to meet the ASTM E119 Hose Test. 8. 8. Fireproofing manufacturer shall also demonstrate that there is no peel-back at the edges or terminations of the fireproofing in a fire situation for the intended application. • First top coat.4 Top-coating for proprietary fireproofing other than an intumescent epoxy mastic shall be approved by the fireproofing manufacturer and the Chief Fire Prevention Engineer.6.
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