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 Pneumatically Applied (Gunned)

Refractory
PROJECT TITLE

SAIC-N-2025
WBS / BI / JO NUMBER

EQUIPMENT ID NUMBER(S)

EQUIPMENT DESCRIPTION

LAYOUT DRAWING NUMBER

REV. NO.

SCHEDULED INSPECTION DATE & TIME

ACTUAL INSPECTION DATE & TIME

PLANT NO.

EC / PMCC / MCC NO.

MH's SPENT

TRAVEL TIME

SAUDI ARAMCO USE ONLY

CONTRACTOR INSPECTION LEVEL

REFERENCE

General Requirements (SAES-N-110 procedure, Section 9)

A1

Checklist SAIC-N-2024 was completed & accepted for Pre-Application

requirements related to Pneumatic (Gunned application) refractory.

As Referenced

A2

Correct Material & Application Method is being used for equipment

with gunned refractory per SAES-N-100, Tables 2 & 3. See Note 1.

As Referenced

B.

Mixing Refractory for Pneumatic Applications (SAES-N-110 Procedure, Section 9)

B1

Mixing of refractory materials is done in a paddle type mixer.

SAES-N-110,
Para. 9.3.1

B2

Only full contents of refractory bags or drums are placed in the mixer.
Fractional parts of the bag or drum are not used.

SAES-N-110,
Para. 9.3.2

B3

Dry gunning application method is being used.

Note: Wet gunning application shall be approved by Saudi Aramco
Engineer.

SAES-N-110,
Para. 9.3.3

B4

When fiber reinforcement is used, the fibers were added to the mixer
through a wire mesh screen with approximately 12 mm openings.

SAES-N-110,
Para. 9.3.4

B5

Refractory is used within 15 minutes of mixing (time of water applied)

SAES-N-110,
Para. 9.3.5

C.

Application of Pneumatically Applied Refractory (SAES-N-110 Procedure, Section 9)

C1

Only qualified personnel who are thoroughly experienced with pneumatic

application of refractory lining are doing the work.

SAES-N-110,
Para. 9.4.1

C2

The proper minimum air pressure to assure adequate refractory

compaction is used (as determined by testing prior to application).

SAES-N-110,
Para. 9.4.2

C3

Gun nozzles are sized properly enabling "nozzleman" to control the

application and maneuver in confined spaces.

SAES-N-110,
Para. 9.4.3

C4

Refractory material is shot at right angles to the surfaces being lined.

SAES-N-110,
Para. 9.4.4

C5

Water supply & air pressure remain constant during application.

SAES-N-110,
Para. 9.4.5

C6

Refractory material rebounded ahead of "Nozzleman", is removed and

not included in the lining.
Note: Under no circumstances is rebound material reused.

SAES-N-110,
Para. 9.4.6
&
Para. 9.4.7

Page 1 of 5

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

In-Process Inspection of Pneumatically Applied (Gunned)
Refractory
PROJECT TITLE

SAIC NUMBER

SAIC-N-2025
WBS / BI / JO NUMBER

ITEM
No.

ACCEPTANCE CRITERIA

REFERENCE

C7

For each specific band all rebound & loose material is removed from the
surface before application of next band is started & no rebound material
is allowed to accumulate at any point where lining is already applied.

SAES-N-110,
Para. 9.4.8

C8

In vertical vessels & piping, lining is applied circumferentially in narrow

bands starting at bottom & proceeding upwards with full final thickness
permitted to develop in each band before the next band is applied.

SAES-N-110,
Para. 9.4.9

C9

In no case is a thickness applied that is less than the thickness that is

specified to allow the applied lining to develop into initial set.
The required thickness is not built up in layers.

SAES-N-110,
Para. 9.4.9

C10

In large vessels & piping, where height of the bands needed to provide
effective bonding is too small to be practical, sectionalizing or multiple
crews are used to meet Paragraph 9.4.9 (Item C10 item above).

SAES-N-110,
Para. 9.4.10

C11

Top of each band is cut back to shell with a steel trowel using a cut with
a right angle to the shell at a location where full refractory thickness is
applied with all refractory above this location removed & discarded.

SAES-N-110,
Para. 9.4.11

C12

The bottom of each successive band is securely bonded to the top of the
preceding band before the latter has developed an initial set.

SAES-N-110,
Para. 9.4.11

C13

Horizontal equipment utilizes the same general procedures unless the

horizontal equipment is rotated for casting or gunning in the flat position.

SAES-N-110,
Para. 9.4.12

C14

The lining is screeded to the final required thickness after placement &
any deficiencies are immediately corrected.
Smoothing, trowelling, and floating are not
permitted.

SAES-N-110,
Para. 9.4.13

C15

When application is interrupted before completion of entire lining, any

refractory applied at thickness less than full thickness is removed by
cutting back to shell with a steel trowel using a beveled cut into adjacent
lining by approximately 10 with all material above the line discarded.

SAES-N-110,
Para. 9.4.14

C16

During a period of interruption in application, the curing of the lining that

has already been applied may be completed.

SAES-N-110,
Para. 9.4.15

C17

Immediately prior to resuming application, the exposed surface of lining

to which a bond must be made is thoroughly wetted with a quality water.

SAES-N-110,
Para. 9.4.16

Page 2 of 5

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

In-Process Inspection of Pneumatically Applied (Gunned)

Refractory
PROJECT TITLE

ITEM
No.

SAIC-N-2025
WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA

30-Jun-08
DATE APPROVED

REFERENCE

D.

In-Process Inspection & Testing (COMPLETE SATR-N-2001)

D1

Inspection & Testing was performed per SAES-N-110 Procedure & SA

Inspection Requirement Form 175-328110.
See Attachment 1.

SAES-N-110,
Para. 11.1.1

D2

Two (2) Production test samples were taken once per shift or each
change of nozzleman/installer (1 sample to lab, 1 sample properly
stored/cured)
Refractory being gunned has samples cut from a gunned panel.

SAES-N-110,
Para. 11.3.1

D2

Samples taken during production are tested for cold crushing strength &
density per ASTM C133, ASTM C134 & ASTM C862 .

SAES-N-110,
Para. 11.3.2

D3

Refractory Installer keeps an accurate log of installation so that location

of refractory that is presented by the production samples can be
determined in case it becomes necessary to remove this refractory.

SAES-N-110,
Para. 11.3.5

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-110 -- Installation Requirements-Castable Refractories (30 Jan 2007)
3. SAES-N-120 -- Installation Requirements-Extreme Erosion Resistant Refractories (30 Jan 2007)
ATTACHMENTS: Attachment 1 -- SA INSP FORM 175-328110 (Refractories)
NOTES: 1. Use Table 2 & 3 Mandatory Refractory Systems of SAES-N-100 (Not Attached) for Pre-installation 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 3 of 5

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 Pneumatically Applied (Gunned)
Refractory

SAIC NUMBER

SAIC-N-2025

30-Jun-08
DATE APPROVED

15-Dec-09

Attachment 1 -- SA INSP FORM 175-328110

Page 4 of 5

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 Pneumatically Applied (Gunned)
Refractory

Page 5 of 5

SAIC NUMBER

SAIC-N-2025

30-Jun-08
DATE APPROVED

15-Dec-09

QR NUMBER

MECH-