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

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

Inspection of Repairs to Extreme Erosion Resistant

Refractory

SAIC-N-2034

PROJECT TITLE

WBS / BI / JO NUMBER

EQUIPMENT ID NUMBER(S)

EQUIPMENT DESCRIPTION

LAYOUT DRAWING NUMBER

REV. NO.

SCHEDULED INSPECTION DATE & TIME

ACTUAL INSPECTION DATE & TIME

REFERENCE

General Requirements (SAES-N-120 procedure, See Note 1)

Checklist SAIC-N-2033 was completed for Post-Application inspection
of applied extreme erosion resistant refractory.

B.

Repair Extent & Excavation Requirements (SAES-N-120 Procedure)

B1

Defective refractory (voids, honeycombs, insufficient cure, damage, etc)

was marked for repair, totally removed to the full layer thickness.

As Referenced

SAES-N-120,
Para. 12.4.1

The extent of repair was approved by a SA Refractory Inspector.

B2

The removal of defective lining was restricted to the use of hand tools.
Power tools (electric, pneumatic) were not used to remove refractory.

SAES-N-120,
Para. 12.4.2

B3

All hexagons adjacent to a repair area were found with sound refractory
prior to the execution of the repair (Hammer Test, visual). See Note 2.

SAES-N-120,
Para. 12.4.3

B4

Refractory lining cracks (Width of 1/8 and larger, Depth above 20%)
thoroughly excavated to their full depth to sound refractory. See Note 3.

SAES-N-120,
Para. 12.4.4

B4

Refractory lining areas for which the production samples failed the
Density check and/or Cold crushing test are identified* and marked for
replacement.
*Lining Areas shall be Identified from the sketch and log maintained by
Refractory Installer for applied lining and location of sampling.
(Refer to SAIC-N-2032 item G5 & G6)

SAES-N-120,
Para. 10.5.9

C.

Relining of Repair Areas (SAES-N-120 Procedure)

C1

Linings backing surface temperatures are monitored & do not exceed

32C during repairs (this includes curing).

SAES-N-120,
Para. 10.1.6

C2

Protective Steps are taken to maintain a maximum temperature of 32C

for a minimum of 24 hours after installation. Linings are protected from
heat-induced accelerated setting.

SAES-N-120,
Para. 10.1.7

C3

Linings & lining materials are kept above 10C during the lining
application and for a period 48 hours after the lining application.

SAES-N-120,
Para. 10.1.9

C4

Surfaces are kept dry after installation (during curing). No spraying!

SAES-N-120,
Para. 10.1.10

Page 1 of 4

PLANT NO.

EC / PMCC / MCC NO.

MH's SPENT

TRAVEL TIME

SAUDI ARAMCO USE ONLY

CONTRACTOR INSPECTION LEVEL

A1

MECH-

SYSTEM ID.

QUANTITY INSP.

SAUDI ARAMCO INSPECTION LEVEL

ACCEPTANCE CRITERIA

QR NUMBER

CONTRACTOR / SUBCONTRACTOR

PURCHASE ORDER NUMBER

SAUDI ARAMCO ACTIVITY NUMBER

A.

15-Dec-09

EQPT CODE

SAUDI ARAMCO TIP NUMBER

ITEM
No.

30-Jun-08
DATE APPROVED

WORK PERMIT REQUIRED?

PASS

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

Inspection of Repairs to Extreme Erosion Resistant
Refractory
PROJECT TITLE

ITEM
No.

SAIC NUMBER

SAIC-N-2034
WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA

REFERENCE

D.

Curing of Repaired Areas (SAES-N-120 Procedure)

D1

Applied linings are allowed an air set (48 hour minimum) & are protected
from injury at all times, particularly during the early stages of hardening.

SAES-N-120,
Para. 11.2.1

D2

During a 48-hour air set, applied lining is not sealed from contact with
the atmosphere (Air dried). No water is allowed to contact the lining i.e.
moist curing is not permitted.

SAES-N-120,
Para. 11.2.2

E.

Repair Areas Dryout (SAES-N-120 Procedure)

E1

See SAIC-N-2030 for Furnace Dry Out (as applicable)

E2

Adequately calibrated temperature measuring devices are installed to

monitor temperature. When dryout is by auxiliary burners, temperature
monitoring is provided on the gas outlet and burner areas.

SAES-N-120,
Para. 11.3.1

E3

Maximum dryout temperature is controlled & does not reduce chemical

composition or mechanical properties of lined equipment materials.

SAES-N-120,
Para. 11.3.2

E4

Dryout done in furnace has temperature measuring devices installed on

the refractory side & on external surfaces of equipment to indicate
differentials between metal and refractory temperatures.

SAES-N-120,
Para. 11.3.3

E5

Minimum holding times during dryout are 1 hour per 25 mm refractory

thickness, unless otherwise specified by the Refractory Manufacturer.

SAES-N-120,
Para. 11.3.4

F.

Inspection of Relined/Repaired Areas (SAES-N-120 Procedure)

F1

The repair, testing, and inspection procedure was the same as the
procedure used for the original installation, carried out in accordance
with Saudi Aramco Inspections Requirement Form 175-328110 and the
requirements of SAES-N-120

As Referenced

SAES-N-120,
Para. 12.4.3
& Para 12.1.1

F2

At completion of curing & drying of repairs, linings are checked by lightly

tapping them with a 1-pound hammer and are found acceptable, free of
voids, honeycombing, insufficient curing, or construction damage.

SAES-N-120,
Para. 12.4.1

F3

Repaired areas are free from lining cracks with a width of 1/8" & larger
and a depth of more than 20% of refractory thickness.

SAES-N-120,
Para. 12.4.4

Page 2 of 4

30-Jun-08
DATE APPROVED

15-Dec-09

QR NUMBER

MECH-

CONTRACTOR / SUBCONTRACTOR

PASS

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

SAIC NUMBER

Inspection of Repairs to Extreme Erosion Resistant

Refractory

SAIC-N-2034

PROJECT TITLE

ITEM
No.

WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA

30-Jun-08
DATE APPROVED

REFERENCE

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. This checklist applies to Inspection of repairs for extreme erosion resistant refractory systems per procedure of SAES-N-120 only.
2. Repair attempts often result in loose "biscuits" (defined as a small section of refractory shaped like a biscuit that is loose within the hexsteel). After
hand excavation, a thorough visual inspection reveals sound refractory & no disbond to the base metal of the equipment when hammer tested.
3. No portion of the original crack rejected remains after excavation.

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 3 of 4

N = NO F = FAILED

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

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

Inspection of Repairs to Extreme Erosion Resistant
Refractory

SAIC NUMBER

SAIC-N-2034

30-Jun-08
DATE APPROVED

15-Dec-09

Attachment 1 -- SA INSP FORM 175-328110

Page 4 of 4

QR NUMBER

MECH-