SAUDI ARAMCO ID/PID - 2/19/05 - REV 0 (Standards Cutoff - August 2004)

SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST
Review of Refractory Installation Procedure SAIC-N-2018 25-May-05 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.

LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.

SCHEDULED INSPECTION DATE & TIME ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

A. General Requirements

The procedure is project specific and identifiable by Budget Item (BI) or SAEP-1154,
A1
Job Number, Contract Number & Project title. Para. 5.4.2.2a

An approval section exists to document adequacy prior to use. SAEP-1154,

A2
(ISO 9001:2000, Para. 4.2.3a) Para. 5.4.2.3c

A revision control section exists to document procedure changes. SAEP-1154,

A3
(ISO 9001:2000, Para. 4.2.3a) Para. 5.4.2.3a

An attachment section exists listing applicable QC forms & records. SAEP-1154,

A4
(ISO 9001:2000, Para. 4.2.4a) Para. 5.4.2.4a

Procedure Scope covers applicable pressure vessels, boilers, process SAES-N-100,

A5
heaters, exchangers, flare tips, & sulfur recovery unit equipment/piping. Para. 1.1

Procedure Scope limits refractory system types to castable refractory, SAES-N-100,

A6
systems, refractory ceramic fiber (RCF), & fireclay bricks. Para. 1.2

Procedure References list SAES-N-110, SAES-N-120, SAES-N-130 & SAES-N-100,

A7
SAES-N-140 as applicable based on scope of work. Para. 3.1

Procedure References list SA Standard Drawings (SASDs) AB-036395,

SAES-N-100,
A8 AB-036396, AC-036397, AB-036400, & AB-036914 as applicable. Also,
Para. 3.1
these SASDs can be attached to the procedure.

Procedure References list Industry Standards API STD 560, API RP 936 SAES-N-100,
A9
& ASTM Standards applicable to the refractory scope of work. Para. 3.2

Definitions are listed in procedure and match those of SAES-N-100, SAES-N-100,

A10
Section 4 & API RP 936, Section 3 as applicable. Section 4

Procedure covers Quality Control Key Elements of API RP 936

(Documents, material & applicator qualifications, installation monitoring, SAES-N-100,
A11
as-installed tests, pre-dryout inspection, dryout & post dryout inspection. Para. 3.2
See Attachment 1.

Procedure states that "Refractory Installation" work will not begin until Sch. Q, Att. IV,
A12
Refractory work procedures have been approved by Company. Para. 2.1 & Table

Procedure is a "Marriage" of requirements of Refractory Manufacturer,

SAES-N-110,
A13 the Equipment Manufacturer, & applicable SA standards (SAES-N-110,
Para. 5.2
120, 130, 140). See Note 1.

B. Materials Section (Procedure lists material requirements, storage & handling controls)

SAES-N-100,
B1 Procedure lists refractory material restrictions related to asbestos use.
Para. 7.1.1
Procedure lists/references castable refractories (SAMS Serial numbers)
SAES-N-100,
B1 based on physical properties specified on data sheets & values listed in
Para. 7.1.3
SAES-N-100, Table 2 (Data for Castable Refractory). See Note 2
SAES-N-100,
B3 Anchors for single-layer, castable linings are "V" shaped types .
Para. 8.2.1

Page 1 of 4
SAUDI ARAMCO ID/PID - 2/19/05 - REV 0 (Standards Cutoff - August 2004)
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review of Refractory Installation Procedure SAIC-N-2018 25-May-05 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

Anchors for dual-layer linings for the support of insulating castable SAES-N-100,
B4
refractory shall be "Y" types. Para. 8.2.1

SAES-N-100,
B5 All "V" and "Y" type anchors are specified with rubber or plastic caps.
Para. 8.2.2
SAES-N-100,
B6 Anchor Details for castable refractory linings meet SASD AC-036397.
Para. 8.2.3

Anchors for all types of RCF linings are welded to equipment & meet SAES-N-100,
B7
SASD AB-036395 & AB-036400. Para. 8.2.5

SAES-N-100,
B8 Hexsteel material is the offset-lance, tight-clinched type (welded).
Para. 8.3.1

Riveted type hexsteel is limited for use on external surfaces of piping that SAES-N-100,
B9
is 12 inch NPS and less. Para. 8.3.2

Hexsteel supported by "T" studs (two component linings) is material of SAES-N-100,

B10
19 mm wide, 14 gauge thick bars. Para. 8.3.3

Hexsteel welded directly to equipment or piping for support of 25 mm SAES-N-100,

B11
thick extreme-erosion resistant refractory is 25 mm wide, 14 gauge bar. Para. 8.3.4

All ends of hexsteel are to be welded to edging bars or to adjacent SAES-N-100,

B12
hexsteel. Loose ends of hexsteel materials are prohibited. Para. 8.3.5

SAES-N-100,
B13 Hexsteel installation details meet SASD AB-036396 requirements.
Para. 8.3.6

Nozzle and manway opening details in refractory lined pressure vessels SAES-N-100,
B14
and piping meet SASD AB-036914. Para. 8.4

Metallic fiber reinforcement density is 80 kg/m³ (5 lb./ft³) unless otherwise SAES-N-100,

B15
specified. Para. 8.5.1

Metallic fiber reinforcement is made from melt extracted material, SAES-N-100,

B16
approximately 0.5 mm in thickness and approximately 25 mm long. Para. 8.5.2

Castable refractories are stored & handled as follows:

A) Protected from water and moisture. SAES-N-110,
B17
B) Materials are stored off the ground & covered with tarps. Section 7
C) MSDS Sheet & Refractory Manufacturer's precautions are followed.

Extreme erosion resistant refractories are stored & handled as follows:

A) Stored in dry weather tight structures at temperature range of 5-25°C. SAES-N-120,
B18
B) Sealed packages are not opened until required (not on receipt).. Section 7
C) MSDS Sheet & Refractory Manufacturer's precautions are followed.

Fireclay Bricks are stored & handled as follows:

SAES-N-130,
B19 A) Fireclay bricks are protected from mechanical damage.
Section 7
B) MSDS Sheet & Refractory Manufacturer's precautions are followed.
RCF modules are stored & handled as follows:
A) Protected from water and moisture.
SAES-N-140,
B20 B) Materials are stored off the ground & covered with tarps.
Section 7
C) Containers are protected from mechanical damage (tears, rips, etc).
D) MSDS Sheet & Refractory Manufacturer's precautions are followed.

C. Installation Section Content

Procedure incorporates requirements of SAES-N-110, SAES-N-120,

SAES-N-100,
C1 SAES-N-130, & SAES-N-140 requirements for Welding, Surface Prep &
Section 10
Installation of refractories & firebricks. See Note 1.

Page 2 of 4
SAUDI ARAMCO ID/PID - 2/19/05 - REV 0 (Standards Cutoff - August 2004)
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review of Refractory Installation Procedure SAIC-N-2018 25-May-05 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

Refractory systems for specific equipment meet requirements

specified in SAES-N-100 Table 3 "Mandatory Refractory Systems":
A) Refractory Anchor (Material, Sizes & Types) selection is correct SAES-N-100,
C2
B) Refractory Material (Type, Weight % of Needles, Application Method) Para. 9.1
selection is correct.
See Note 2
Fired Process Heater refractory is installed per API 560 Section 7 with
SAES-N-100,
C3 specific requirements for brick & tile, castable refractory, ceramic fiber,
Para. 3.2
& multicomponent lining construction. See Note 3.

D. Quality Control & Responsibility (Inspection, Testing & Repairs)

SAES-N-110,
D1 Final visual dimensional checks of panels per construction drawings.
Para. 5.3

Quality controls & responsibilities listed in procedure incorporate the

requirements in SAES-N-110, SAES-N-120, SAES-N-130, & SAES-N- SAES-N-100,
D2
140 requirements for sections related to Welding, Surface Prep & Section 10
Installation of refractories & firebricks as applicable. See Note 1.

Procedure incorporates Inspection, Testing & Repair requirements of

SAES-N-100,
D3 SAES-N-110 (Sect. 11), SAES-N-120 (Sect.12), SAES-N-130 (Sect.8), &
Section 10
SAES-N-140 (Sect. 10) as applicable. See Note 1.

REMARKS:

REFERENCE DOCUMENTS:
1. Schedule Q -- Quality Requirements (Pro Forma Contract), November 2003
2. SAES-N-100 -- Refractory Systems (30 November 2004)
3. SAES-N-110 -- Installation Requirements-Castable Refractories (30 November 2004)
4. SAES-N-120 -- Installation Requirements-Extreme Erosion Resistant Refractories (30 November 2004)
5. SAES-N-130 -- Installation Requirements-Fireclay Bricks (30 November 2004)
6. SAES-N-140 -- Installation Requirements-Refractory Ceramic Fiber (30 November 2004)
7. SAES-W-010 -- Welding Requirments for Pressure Vessels (30 June 2002)
8. API RP 936 -- Refractory Installation Quality Control Guidelines - Inspection & Testing Monolithic Refractory Lining & Materials (Feb 2004 Edition)
9. API Standard 560 -- Fired Heaters for General Refinery Service (May 2001)

ATTACHMENTS: 1. API RP 936 (Quality Control: Key Elements)

NOTES: 1. Contractor's refractory installation procedure must follow the SA mandatory specific installation procedures. Contractor is encouraged
& copy & paste much of the SA refractory procedures into his own procedure. However, Refractory & Equipment Manufacturer requirements
must also be incorporated into the procedure (This is a typical requirement of SAES-N-110, N-120, N-130, N-140, Para. 5.2 for procedure sections)
2. Use Table 3 – Mandatory Refractory Systems of SAES-N-100 (Not Attached) for Receipt & Pre-installation inspection checks of materials.
3. Incorporate API 560 general/specific requirements & utilize API 560 Section 7 as a checklist during Heater construction. (This is Not Attached).
Process Heater refractory procedures may be submitted separately from other equipment refractory procedures with a heater installation package.
Ensure SAES-N-100, Table 3 & Notes (Not attached) are incorporated in procedure to check Process Heater Refractory materials on installation.

Contractor / Third-Party Saudi Aramco

Construction Representative* PMT Representative
Work is Complete and Ready for Inspection: T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:

QC Inspector PID Representative

Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:

QC Supervisor Proponent and Others

Quality Record Approved: T&I Witnessed QC Record Reviewed Work Verified
Name, Organization,
Name, Sign and Date:
Initials and Date:
*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FAILED

Page 3 of 4
SAUDI ARAMCO ID/PID - 2/19/05 - REV 0 (Standards Cutoff - August 2004)
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review of Refractory Installation Procedure SAIC-N-2018 25-May-05 MECH-

Attachment 1 -- API RP 936 Table 1

Page 4 of 4