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

SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST
Pre-Qualification Test of Applicators & the Application
SAIC-N-2023 25-May-05 MECH-
Procedure
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 (See Note 1)

Refractory Installer installation procedure is approved by Company &

SAES-N-100
A1 follows requirements of Refractory & Equipment Manufacturers, & SA
Section 10
Standard SAES-N-100 (SAES-N-110 & SAES-N-120 as applicable).
For equipment & refractory systems not listed in SAES-N-100, Saudi
Aramco Engineer (Supervisor of Piping & Valves Unit, Consulting SAES-N-100
A2
Services Department, Dhahran) has made a determination relative to Para. 1.4
which standard requirements apply relative to prequalification & testing.
Checklist SAIC-N-2019 (Review & Verification of the Applicator's Pre-
A3 Qualification Record) was accepted. Qualified & thoroughly experienced As referenced
personnel are employed for the tasks of castable refractory installation.

B. Castable Refractory Qualification & Testing for Applicators & Application Techniques (SAES-N-110)

Crew prequalification tests were set up on a test panel to production

thickness for the Refractory Installer application methods as follows:
SAES-N-110,
B1 A) Gunning (pneumatic application)
Para. 11.2.1
B) Casting
C) Vibration casting
Refractory Applicators met specific Refractory Manufacturer training & SAES-N-110,
B2
experience qualifications for type of refractory installed. See Note 2. Para. 5.1
Documented evidence of application crew's prequalification is available SAES-N-110,
B3
to Refractory Inspector (for his review & approval) prior to production. Para. 11.2.2
On gunned materials, each nozzleman gunnited a test panel (1mx1m)
SAES-N-110,
B4 with a lining thickness equal to the production lining thickness with the
Para. 11.2.3
panel position simulating equipment position during production.
On vibration cast materials, applicators took a mock up test that uses
SAES-N-110,
B5 the same prequalified refractory materials, vibrating equipment & mixing
Para. 11.2.4
procedure that will be used in production work.
Test panels (equal to the production lining thickness) were SAES-N-110,
B6
constructed with a removable back for visual examination of sample. Para. 11.2.5
Cast or gunned test panels have cured for 24 hours. Hammer testing &
SAES-N-110,
B7 visually inspection was performed. Test samples were acceptable & free
Para. 11.2.6
of voids, cracking, deformation, or honeycombing.
Metallic-fiber reinforced refractory test panels were cut into four
SAES-N-110,
B8 pieces. Cut edges were examined for dispersion of metallic fibers,
Para. 11.2.7
laminations, inclusions, & voids and were found visually acceptable.
Qualification Testing followed the specified steps of SAES-N-110
procedure (Installation, Section 9) as follows: See Note 3.
A) Surfaces to be lined were clean & dry when inspected prior to testing SAES-N-110,
B9
B) Backing surface temperature did not exceed 32°C (during entire test) Section 9
C) Water pH & quality certificate was available (met Para. 9.1.9 levels)
D) Refractory Manufacturer specified mixing/water ratios were followed.
SATISFACTORY RESULTS qualified both crew & application SAES-N-110
B10
technique for the production application of castable refractory. Section 11.2.8

Page 1 of 3
SAUDI ARAMCO ID/PID - 2/19/05 - REV 0 (Standards Cutoff - August 2004)
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Pre-Qualification Test of Applicators & the Application
SAIC-N-2023 25-May-05 MECH-
Procedure
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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

C. Extreme Erosion Resistant Refractory Qualification & Testing for Applicators & Application Techniques (SAES-N-120)

Refractory Applicators meet specific Refractory Manufacturer training & SAES-N-120,

C1
experience qualifications for specific refractory installed. See Note 2. Para. 5.1
Procedure & crew prequalification testing was carried out by Refractory SAES-N-120,
C2
Installer prior to any lining (production work). Para. 12.2.1
Documented evidence of the application crew's prequalification was SAES-N-120,
C3
made available to the Refractory Inspector prior to production. Para. 12.2.2
Two 600 mm x 600 mm test panels of hexsteel welded to 6 mm thick SAES-N-120,
C4
plate were lined with refractory and cured for 48 hours minimum. Para. 12.2.3
After 48 hours of curing, test panels passed a visual exam as follows:
A) No cracks 1/8" and larger were found
B) No cracks deeper than 20% of refractory thickness were found SAES-N-120,
C5
C) No holidays (voids, honeycombs) were found. Para. 12.2.8
D) No visual evidence of insufficient curing was found.
E) No visual evidence of physical damage was found
After 48 hours of air curing, test panels also passed a hammer test:
A) Test panel surface was lightly struck with 1-pound ball peen hammer
SAES-N-120,
C6 B) No audibly notable voids were found
Para. 12.2.8
C) No evidence of insufficient hardness of refractory was found.
D) Questionable or defective refractory (dead dull sound) was not found.
When a crew failed to pass a qualification test, crew & procedure were SAES-N-120,
C7
changed to improve mixing & application. Tests are repeated as needed Para. 12.2.4
Installer has clearly identified all qualification test panels & stores them SAES-N-120,
C8
properly (until completion of the refractory application production work). Para. 12.2.3
Qualification Testing followed the specified steps of SAES-N-120
procedure (Installation, Section 10) as follows: See Note 3.
A) Surfaces to be lined were clean & dry & no loose hexsteel was found SAES-N-120,
C9
B) Backing surface temperature did not exceed 32°C (during entire test) Section 10
C) Water pH & quality certificate was available (met Para. 10.1.3 levels)
D) Refractory Manufacturer mixing instructions were strictly followed.
SATISFACTORY RESULTS qualified both crew & application SAES-N-120,
C10
technique for the production application of castable refractory. Para. 12.2.4

REMARKS:

REFERENCE DOCUMENTS:
1. SAES-N-100 -- Refractory Systems (30 November 2004)
2. SAES-N-110 -- Installation Requirements-Castable Refractories (30 November 2004)
3. SAES-N-120 -- Installation Requirements-Extreme Erosion Resistant Refractories (30 November 2004)

NOTES: 1. This checklist applies to castable refractory systems detailed in both SAES-N-110 & SAES-N-120 procedures.
1. This checklist applies to castable refractory systems detailed in both SAES-N-110 & SAES-N-120 procedures.
2. Manufacturer Instructions (Not Attached) relative to experience are followed. Applicators meet manufacturer's minimum requirements listed.
3. Inspector ensures SAES-N-110 & SAES-N-120 Procedure (Not Attached, Field Copies needed) Installation Sections are followed for qualification.

Page 2 of 3
SAUDI ARAMCO ID/PID - 2/19/05 - REV 0 (Standards Cutoff - August 2004)
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Pre-Qualification Test of Applicators & the Application
SAIC-N-2023 25-May-05 MECH-
Procedure
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
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 3