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

SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Repairs of Castable Refractories SAIC-N-2029 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. Refractory Rejection Criteria & Extent of Repairs (SAES-N-110 Procedure, See Note 1)

The need for repairs was determined at the completion of curing and
SAES-N-110
A1 drying when the lining was randomly checked for voids or damaged
Section 11.3.6
areas with light tapping with a 1-pound ball peen hammer.

The refractory identified for repair (questionable or defective) produced a SAES-N-110

A2
dead dull sound when struck with the 1-pound ball peen hammer. Section 11.3.6

The size of dull sounding areas were investigated & sample test results SAES-N-110
A3
were compared prior to the decision to removal the refractory. Section 11.3.6

Refractory sample testing has been performed in addition to hammer SAES-N-110

A4
testing. Section 11.3.6

Refractory found to be defective due to presence of voids, honeycombs,

SAES-N-110
A5 insufficient curing, or construction damage was rejected & identified for
Section 11.3.7
total removal to the full thickness of the layer installed (prior to relining).

Cracking Criteria to require the repair was met as follows:

SAES-N-110
A6 A) Crack width was 3 mm or larger.
Section 11.5.4
B) Crack depth (any width) exceeded 20% refractory thickness.

B. Excavation/Removal of Refractory Prior to Repairs (SAES-N-110 Procedure)

Any part of a single layer lining, except hexmesh or S-bar linings, which
SAES-N-110
B1 is defective, is removed for the full thickness of the refractory material.
Section 11.5.1
See Note 2.

Surfaces are completely cleaned of refuse & checked by SA Inspector

SAES-N-110
B2 who determines the full extent of repair (before pre-wetting & relining).
Section 11.5.1
See Note 2.

SAES-N-110
B3 The minimum area removed is approximately one square foot.
Section 11.5.1

C. Performance of Refractory Repairs (SAES-N-110 Procedure)

The method of repair, curing & retesting is per the original installation SAES-N-110
C1
procedure & SAES-N-110 procedure requirements. Section 11.3.7

SAES-N-110
C2 Extent of repairs was agreed upon by SA Refractory Inspector.
Section 11.5.1

Where needed, replacement or additional refractory anchors are installed SAES-N-110

C3
in accordance with SASD AD-036916. See Note 2. Section 11.5.2

Refractory that is under repair has exposed surfaces of the joint SAES-N-110
C4
thoroughly wetted with a quality water prior to placement of refractory. Section 11.5.3

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
Inspection of Repairs of Castable Refractories SAIC-N-2029 25-May-05 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
Water used to wet refractory (certificate available) for repairs as follows:
A) The pH is within a range of 5.8-8.6. SAES-N-110
C5
B) Water quality (All Impurities < 1000 ppm, Iron < 500 ppm, Calcium & Section 11.5.3
Magnesium, both < 300 ppm, Chlorine & Sulfur, both < 200 ppm).

Repaired linings are cured & dried out per the Refractory Manufacturer's SAES-N-110,
C6
recommendations &/or standard procedures of SAES-N-110 Section 10 Para. 10.1.1

All inspection is performed per Saudi Aramco Inspection Requirement SAES-N-110,

C7
Form 175-328110 & SAES-N-110 procedure. See Attachment 1. Para. 11.1.1

D. Final Inspection After Both Curing & Drying of Repaired Areas (SAES-N-110 Procedure)

No Lining cracks are found 3 mm wide and larger and when the depth SAES-N-110,
D1
exceeds 20% refractory thickness. Para. 11.5.4

At completion of curing and drying, the repaired lining is randomly

checked by lightly striking it with a 1-pound hammer: SAES-N-110,
D2
A) The refractory is free of voids (no dead, dull sounds) Para. 11.3.6
B) The refractory has sufficient hardness

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)

ATTACHMENTS: None
NOTES: 1. This checklist applies to Post-Application inspection for castable refractory systems detailed only in procedure of SAES-N-110.
2. Refractory removal is performed mechanically and often damages anchors & base metal when removal is accomplished by pneumatic chisel.
The damage caused by excavation/removal of refractory must be reassessed by the qualified Refractory Inspector. Often, disbonding to equipment
substrate (base metal) results in adjacent areas of marked repairs after the excavation/removal of refractory. As a result, the repair area can grow
in size until the complete section or panel will require removal & repair. Extreme care should be exercised in methods for performing small repairs.
Anchors exposed after refractory is removed are reinspected & repaired as necessary in accordance with the procedure. Equipment surfaces after
refractory removal are checked for damage. Areas adjacent to identified repairs display good bonding after refractory layers are removed. Hammer
test these areas again after removal & visually check for disbonding at equipment surfaces as applicable.

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

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SAUDI ARAMCO ID/PID - 2/19/05 - REV 0 (Standards Cutoff - August 2004)
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Repairs of Castable Refractories SAIC-N-2029 25-May-05 MECH-

Attachment 1 --

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