SAIC N 2024 Pre ApplicationInspCastableRefractInstall EL Rev2

SAUDI ARAMCO ID/PID - 2/19/05 - REV 0 (Standards Cutoff - August 2004)
SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST
Pre-Application Inspection of Castable Refractory SAIC-N-2024 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 (Both SAES-N-110 & SAES-N-120 Applications, See Note 1)
Refractory systems for specific equipment meet requirements

specified in SAES-N-100 Table 3 "Mandatory Refractory Systems" :
SAES-N-100,
A1 A) Refractory Anchor (Material, Sizes & Types) selection is correct
Para. 9.1
B) Refractory Material (Type, Weight % of Needles, Application Method)
selection is correct. See Note 3 (Make Field Copy).
Checklist SAIC-N-2022 is completed & accepted. Anchorage, supports
A2 as referenced
& hexsteel installations are welded. All inspection & testing is complete.
Checklist SAIC-N-2023 has been completed & accepted & both
A3 as referenced
applicators & application techniques are fully qualified.
Post-weld Heat treatment (PWHT) & hardness testing after welding is SAES-N-110,
A4
completed & accepted. See Note 2 Para. 6.2.2
Materials have been stored off the ground & properly covered with tarps SAES-N-110,
A5
to protect against damage from water or moisture. See Note 2. Para. 7.2
Surfaces to be lined are inspected prior to refractory installation & Lining
SAES-N-110,
A6 is not applied shall not be applied without prior approval of Saudi
Para. 9.1.3
Aramco's authorized Refractory Inspector. See Note 2.
B. Pre-Application Requirements for Castable Refractories (SAES-N-110 Procedure)
All surfaces are clean, dry & free from oil, grease, weld slag & mill scale SAES-N-110,
B1
prior to installation of refractory. Para. 8.1
Prior to application of refractory, all metallic surfaces have been grit SAES-N-110,
B2
blasted in accordance with SSPC SP 6, "Commercial Blast Clean". Para. 8.2
Surfaces previously coated with a vapor barrier or that are heavily
SAES-N-110,
B3 corroded (such as tie-ins to existing equipment or repairs) are brush
Para. 8.3
blasted in accordance with SSPC SP 7, "Brush Blasting".
Application of hydraulic-setting refractory is by gunning, casting, or SAES-N-110,
B4
vibration casting (as previously qualified by test sample). Para. 9.1.1
Testing procedures (test panel & production sample) were performed

SAES-N-110,
B5 per SAES-N-110, Section 11 requirements with all testing conducted by
Para. 9.1.2
a fully qualified & Company approved independent lab. Note 4.
Surfaces to be lined were inspected prior to refractory installation & SA SAES-N-110,

B6
authorized Refractory Inspector has given approval for lining application. Para. 9.1.3
Linings backing surface temperatures are monitored & do not exceed SAES-N-110,
B7
32°C for application. Para. 9.1.4
Protective Steps are taken are maintain a maximum temperature of 32°C
SAES-N-110,
B8 for a minimum of 24 hours after installation. Linings are protected from
Para. 9.1.5
heat-induced accelerated setting by protective measures. Note 5.
Linings & lining materials are kept above 10°C during the lining SAES-N-110,
B9
application and for a period 24 hours after the lining application. Para. 9.1.7
Linings shall be applied in a manner that will ensure minimal shrinkage. SAES-N-110,
B10
Manufacturer specific instruction's to minimize shrinkage are followed. Para. 9.1.8
Page 1 of 8
ITEM
No.
Water used to mix refractory (certificate) complies with the following:
A) The pH is within a range of 5.8-8.6. SAES-N-110,
B11
B) Water quality (All Impurities < 1000 ppm, Iron < 500 ppm, Calcium & Para. 9.1.9
Magnesium, both < 300 ppm, Chlorine & Sulfur, both < 200 ppm).
SAES-N-110,
B12 Admixtures are not used during refractory mixing operations.
Para. 9.1.10
Water ratios specified by Refractory Manufacturer are available & mixing SAES-N-110,
B13
containers used have accurate level markings to assure mix accuracy. Para. 9.1.11
Temperature Controls (water & refractory) exist to keep mixed refractory SAES-N-110,
B14
between 10°C and 32°C. Para. 9.1.12
Additives to linings have been approved by Saudi Aramco Engineer SAES-N-110,
B15
(Supervisor, Piping & Valves Unit, Consulting Services Dept, Dhahran). Para. 9.1.13
SAES-N-110,
B16 Piping & equipment is supported to prevent distortion during lining.
Para. 9.1.14
Threaded attachments on equipment are protected from lining during SAES-N-110,
B17
application & Protection does not interfere with the application of lining. Para. 9.1.15
Equipment nozzle extensions were properly coated with grease to SAES-N-110,
B18
prevent refractory from bonding to them. Para. 9.1.16
All openings in equipment are closed & tapered hardwood plugs & sheet SAES-N-110,
B19
metal sleeves extend beyond the final thickness of the lining. Para. 9.1.17
These plugs or sleeves are coated with grease, fit snugly into openings, SAES-N-110,
B20
& shall remain in place until the refractory has set. Para. 9.1.17
Refractory Manufacturer's recommended time limits are available. The SAES-N-110,
B21
application is well-planned to ensure use within specified time limits. Para. 9.1.18
Refractory installed in piping or vessel sections prior to connection by SAES-N-110,
B22
welding allows a minimum gap of 100 mm at the ends of each section. Para. 9.1.19
Double-layer linings allow a first layer 24 hour minimum cure & first layer SAES-N-110,
B23
thorough wetting (quality water is used) just before 2nd layer application. Para. 9.1.20
Linings of each type of refractory are installed to full thickness in a single SAES-N-110,
B24
application & are not built up in layers. Para. 9.1.21
When necessary to apply lining in sections to achieve full thickness in a
SAES-N-110,
B25 single application, edge forms are beveled 10° for keying of adjoining
Para. 9.1.21
sections. Construction Joint provisions exist. (Detailed Drawings).
SAES-N-110,
B26 Anchors were installed per SASD AC-036397. See Attachment 1.
Para. 9.2.1
Nozzle & manway opening details in refractory lined pressure vessels SAES-N-110,
B27
& piping were installed per SASD AB-036914. See Attachment 2. Para. 9.2.2
SAES-N-110,
B28 Hexsteel was installed per SASD AB-036396. See Attachment 3.
Para. 9.2.3
Inspector reviews the following procedure before production work: SAES-N-110,
B29
"Mixing Refractory for Pneumatic Applications" . See Note 6. Section 9.3

B30
"Application of Pneumatically Applied Refractory". See Note 6. Section 9.4

B31
"Mixing Refractory for Casting Applications" . See Note 6. Section 9.5

B32
"Application of Cast Refractory". See Note 6. Section 9.6

B33
"Application of Vibration Casting". See Note 6. Section 9.7
Page 2 of 8
ITEM
No.
C. SAES-N-110 Procedure Figure 1 – Checklist for Castable Refractory (Section A, Prior to Installation)
MATERIALS are checked as follows:

A) Types of materials supplied are correct SAES-N-110,
C1
B) Data sheets & mixing instructions are available Figure 1, Sect. A
C) MSDS sheets are available
SAES-N-110,
C2 DOCUMENTS include approved detail drawings
Figure 1, Sect. A
INSPECTION includes the following:
A) Inspect surface preparation SAES-N-110,
C3
B) Inspect anchor layout and welding Figure 1, Sect. A
C) Review welding procedures
WEATHER PROTECTION exists as follows:
SAES-N-110,
C4 A) Materials are properly stored
Figure 1, Sect. A
B) Equipment to be lined is prepared for inclement weather
EQUIPMENT - MIXERS is checked as follows:
A) Number and type are adequate
SAES-N-110,
C5 B) Back up mixer is available
Figure 1, Sect. A
C) Location relative to work
D) Cleanliness
GUNNITE RIGS are checked as follows:
A) Number & Type of Rigs is adequate
SAES-N-110,
C6 B) Operating Condition & Cleanliness is adequate
Figure 1, Sect. A
C) Hose is sufficient
F) Nozzle type is correct
VIBRATORS are checked as follows:
A) Number & Type of vibrators is adequate
SAES-N-110,
C7 B) Attachment method
Figure 1, Sect. A
C) Operating condition
D) Backup
CURING COMPOUND APPLICATORS are checked as follows:
A) Type and size
SAES-N-110,
C8 B) Cleanliness
Figure 1, Sect. A
C) Number
D) Working conditions
AIR COMPRESSORS are checked as follows:
A) Size SAES-N-110,
C9
B) Operating Condition Figure 1, Sect. A
C) Contingencies
SAMPLE MOLDS are checked as follows:
SAES-N-110,
C10 A) Cubes are adequate
Figure 1, Sect. A
B) Gunnited molds are adequate
D. Pre-Application Requirements for Castable Refractories (SAES-N-120 Procedure)
SAES-N-120,
D1 Material is unopened & within expiry date (Or material is rejected).
Para. 10.1.1
Water used to mix refractory (certificate) complies with the following:
A) The pH is within a range of 5.8-8.6. SAES-N-120,
D2
B) Water quality (All Impurities < 1000 ppm, Iron < 500 ppm, Calcium & Para. 10.1.3
Magnesium, both < 300 ppm, Chlorine & Sulfur, both < 200 ppm).
SAES-N-120,
D3 Admixtures are not used unless approved by Saudi Aramco Engineer.
Para. 10.1.4
SAES-N-120,
D4 Linings will be installed indoors except for in-situ patching & repairs.
Para. 10.1.5
SAES-N-120,
D5 Lining backing surface temperatures will not exceed 32°C on application
Para. 10.1.6
Page 3 of 8
ITEM
No.
Protective Steps are taken are maintain a maximum temperature of 32°C
SAES-N-120,
D6 for a minimum of 24 hours after installation. Linings are protected from
Para. 10.1.7
heat-induced accelerated setting by protective measures. Note 5.
Linings & lining materials will be kept above 10°C during the lining SAES-N-120,
D7
application and for a period 48 hours after the lining application. Para. 10.1.9
SAES-N-120,
D8 Surfaces shall be kept dry before, during and after installation.
Para. 10.1.10
Refractory Manufacturer's mixing instructions, installation instructions, & SAES-N-120,
D9
precautions are available (to be strictly followed during applications). Para. 10.2.1
Mandatory mixing equipment (all Stainless Steel) is available as follows:
A) Hobart, Model #D-33 commercial mixer (or approved equal). SAES-N-120,
D10
B) Two, 30-quart mixing bowls Para. 10.2.2
C) A beater and a wire whip
Applicators understand the following mandatory requirements:
A) The Mixed quantity is only what can be applied within 15 mins after
the addition of water.
SAES-N-120,
D11 B) Any mixed refractory not used within 15 minutes is discarded.
Para. 10.2.3
C) Mixing does not continue after the plastic stage occurs.
D) All equipment, mixing bowls & tools must be kept clean & free of
foreign material & must be cleaned thoroughly after each mix.
SAES-N-120,
D12 SAMPLE TESTING PROCEDURE (9 Steps) has been completed.
Section 10.3
(1) Select three packages at random from each batch or lot, then take 5 SAES-N-120,
D13
lbs of dry and damp material from each batch or lot. Para. 10.3.1 (1)
(2) Reseal the packages that the samples were taken from and mark SAES-N-120,
D14
them "Package Opened for Sampling". Para. 10.3.1 (2)
(3) Mix the three samples of the dry material together to give a uniform SAES-N-120,
D15
mixture. Repeat this procedure with the damp material. Para. 10.3.1 (3)
(4) Take enough of the sample mix to prepare five 50 mm cubes for the SAES-N-120,
D16
cold crushing strength tests. Para. 10.3.1 (4)
SAES-N-120,
D17 (5) Seal the remainder for possible re-test.
Para. 10.3.1 (5)
(6) Mix the two materials together & add required amount of water (refer SAES-N-120,
D18
to mixing instructions in paragraph 10.2.3 above) & cast five cubes. Para. 10.3.1 (6)
SAES-N-120,
D19 (7) Air cure and dryout the samples in accordance with Chapter 11.
Para. 10.3.1 (7)
(8) Perform cold-crushing strength and bulk density tests in accordance
SAES-N-120,
D20 with ASTM C133 and ASTM C134. The cold-crushing strength and bulk
Para. 10.3.1 (8)
density values are the average result obtained for the five test cubes.
(9) Any sample that does not meet the minimum published strength or SAES-N-120,
D21
density will be cause for rejection of the complete batch. Para. 10.3.1 (9)
Hand packing tools (Plastic or wooden mallets) are available to
SAES-N-120,
D22 hammer refractory into hexsteel to eliminate voids or air pockets &
Para. 10.4.1
increase the installed density of the material.
Extreme care prevents overlaying of lining material over hexsteel. Form
for screeding is checked for levelness (screed board, line, straightedge)
SAES-N-120,
D23 & securement. No hexsteel protrusions or depressions exist.
Para. 10.4.2
Smooth screeding is flush to the face of the hexsteel & hexsteel
pattern must be visibly distinguishable after screeding of lining.
Air curing & Dryout equipment (Ventilation equipment, furnace, SAES-N-120,
D24
auxilliary burners, temperature measuring devices, etc) is available. Section 11.1
SAES-N-120,
D25 A 1-pound hammer (head weight as stamped) is available for testing.
Section 12.2.6
Page 4 of 8
ITEM
No.
Preparations for Sample Testing before Application are as follows:
A) Enough (64-80) sample forms of 50 mm cube size exist on jobsite.
SAES-N-120,
D26 B) A chart is available (Sample number, date & time taken, location).
Section 10.5
C) Sketch & log exists to show each batch location & samples location.
D) Approved test laboratory has been determined for sample testing.
E. SAES-N-120 Procedure Figure 1 – Checklist for Extreme Erosion-Resistant Refractory (Section A, Prior to Installation)
MATERIALS are checked as follows:

A) Types of materials supplied are correct SAES-N-120,
E1
B) Data sheets & mixing instructions Figure 1, Sect. A
C) MSDS sheets are available
SAES-N-110,
E2 DOCUMENTS include approved detail assembly drawings
Figure 1, Sect. A
SURFACE PREPARATION & HEXSTEEL is checked as follows:
SAES-N-110,
E3 A) Surface preparation meets specifications
Figure 1, Sect. A
B) Welding procedures
WEATHER PROTECTION exists as follows:
SAES-N-110,
E4 A) Materials are properly stored
Figure 1, Sect. A
B) Equipment to be lined is prepared for inclement weather conditions
EQUIPMENT - MIXERS are checked as follows:
A) Number and types are adequate SAES-N-110,
E5
B) Back up mixer is available Figure 1, Sect. A
C) Location relative to work & Cleanliness
SAMPLE MOLDS are checked as follows:
SAES-N-110,
E6 A) Cubes
Figure 1, Sect. A
B) Plate for erosion testing
PNEUMATIC RAMMERS are checked as follows:
SAES-N-110,
E7 A) Number of rammers is adequate
Figure 1, Sect. A
B) Operating condition
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 Pre-Application inspection for castable refractory systems detailed in procedures SAES-N-110 & SAES-N-120.
2. This is a requirement for both SAES-N-110 & SAES-N-120.
3. Use Table 3 – Mandatory Refractory Systems of SAES-N-100 (Not Attached) for Pre-installation inspection checks of materials.
4. The standard refers to Paragraph 11. This is an error. Testing requirements are in Section 11. This will be revised upon the next standard review.
5. To achieve temperature limitations specified (Maximum 32°C for 24 hours minimum), the backing surface may be shaded from direct sunlight,
the refractory lining may be applied indoors, or apply refractory lining at night with proper illumination. Cooling by water spraying is prohibited.
6. Inspector reviews a Field Copy of SAES-N-110, Section 9, Installation. (This is not attached to this checklist & a field copy will be needed). The
Inspector uses the procedure as a checklist for equipment (mixing, application), consummables (air, water, materials), & set-up (formwork) checks.
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 5 of 8
Pre-Application Inspection of Castable Refractory SAIC-N-2024 TESTING MECH-
Attachment 1 -- SASD AC-036397

(Anchoring Details for Castable Refractories)
Note: Use this Attachment on Layout (Pre-Welding) & Final Inspections
Page 6 of 8
Attachment 2 -- SASD AB-036914

(Support Details @ Nozzles & Manways for Castable Refractory)
Page 7 of 8
Attachment 3 -- SASD AB-036396 (Hexsteel Details)

Page 8 of 8

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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 LEVEL CONTRACTOR INSPECTION LEVEL

A. General Requirements (Both SAES-N-110 & SAES-N-120 Applications, See Note 1)

Refractory systems for specific equipment meet requirements

B. Pre-Application Requirements for Castable Refractories (SAES-N-110 Procedure)

Testing procedures (test panel & production sample) were performed

Surfaces to be lined were inspected prior to refractory installation & SA SAES-N-110,

Inspector reviews the following procedure before production work: SAES-N-110,

Inspector reviews the following procedure before production work: SAES-N-110,

Inspector reviews the following procedure before production work: SAES-N-110,

Inspector reviews the following procedure before production work: SAES-N-110,

MATERIALS are checked as follows:

D. Pre-Application Requirements for Castable Refractories (SAES-N-120 Procedure)

MATERIALS are checked as follows:

REFERENCE DOCUMENTS: 1. SAES-N-100 -- Refractory Systems (30 November 2004)

Contractor / Third-Party Saudi Aramco

QC Inspector PID Representative

QC Supervisor Proponent and Others

Attachment 1 -- SASD AC-036397

Attachment 2 -- SASD AB-036914

Attachment 3 -- SASD AB-036396 (Hexsteel Details)

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