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 to Extreme Erosion Resistant
SAIC-N-2034 25-May-05 MECH-
Refractory
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 (SAES-N-120 procedure, See Note 1)

Checklist SAIC-N-2033 was completed for Post-Application inspection

A1 As Referenced
of applied extreme erosion resistant refractory.

Repairs are per the SA Inspection Requirement Form 175-328110 & per SAES-N-110,
A2
Company Approval & SAES-N-120 procedure. See Attachment 1. Para. 11.1.1

B. Repair Extent & Excavation Requirements (SAES-N-120 Procedure)

Defective refractory (voids, honeycombs, insufficient cure, damage, etc)

SAES-N-120,
B1 was marked for repair, totally removed to the full layer thickness.
Para. 12.4.1
The extent of repair was approved by a SA Refractory Inspector.

The removal of defective lining was restricted to the use of hand tools. SAES-N-120,
B2
Power tools (electric, pneumatic) were not used to remove refractory. Para. 12.4.2

All hexagons adjacent to a repair area were found with sound refractory SAES-N-120,
B3
prior to the execution of the repair (Hammer Test, visual). See Note 2. Para. 12.4.3

Refractory lining cracks (Width of 1/8″ and larger, Depth above 20%) SAES-N-120,
B4
thoroughly excavated to their full depth to sound refractory. See Note 3. Para. 12.4.4

C. Relining of Repair Areas (SAES-N-120 Procedure)

Linings backing surface temperatures are monitored & do not exceed SAES-N-120,
C1
32°C during repairs (this includes curing). Para. 10.1.6

Protective Steps are taken are maintain a maximum temperature of 32°C

SAES-N-120,
C2 for a minimum of 24 hours after installation. Linings are protected from
Para. 10.1.7
heat-induced accelerated setting.

Linings & lining materials are kept above 10°C during the lining SAES-N-120,
C3
application and for a period 48 hours after the lining application. Para. 10.1.9

SAES-N-120,
C4 Surfaces are kept dry after installation (during curing). No spraying!
Para. 10.1.10

Sch. Q, Att. IV,

C5 Temperature measuring devices are calibrated & have a valid sticker.
Para. 6.1

E. Curing of Repaired Areas (SAES-N-120 Procedure)

Applied linings are allowed an air set (48 hour minimum) & are protected SAES-N-120,
E1
from injury at all times, particularly during the early stages of hardening. Para. 11.2.1

During a 48-hour air set, no water contacts the lining that is sealed from SAES-N-120,
E2
contact with the atmosphere & moist curing is not permitted. Para. 11.2.2

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 to Extreme Erosion Resistant
SAIC-N-2034 25-May-05 MECH-
Refractory
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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

F. Repair Areas Dryout (SAES-N-120 Procedure)

F1 See SAIC-N-2030 for Furnace Dry Out (as applicable) As Referenced

Adequately calibrated temperature measuring devices are installed to

SAES-N-120,
F2 monitor temperature. When dryout is by auxiliary burners, temperature
Para. 11.3.1
monitoring is provided on the gas outlet and burner areas.

Maximum dryout temperature is controlled & does not reduce chemical SAES-N-120,
F3
composition or mechanical properties of lined equipment materials. Para. 11.3.2

Dryout done in furnace has temperature measuring devices installed on

SAES-N-120,
F4 the refractory side & on external surfaces of equipment to indicate
Para. 11.3.3
differentials between metal and refractory temperatures.

Minimum holding times during dryout are 1 hour per 25 mm refractory SAES-N-120,
F5
thickness, unless otherwise specified by the Refractory Manufacturer. Para. 11.3.4

G. Inspection of Relined/Repaired Areas (SAES-N-120 Procedure)

The repair, testing, and inspection procedure was the same as the SAES-N-120,
G1
procedure used for the original installation. Para. 12.4.3

Independent laboratory & personnel were available on site & present SAES-N-120,
G2
during entire repair process for testing purposes relative to sampling. Para. 12.1.2

At completion of curing & drying of repairs, linings are checked by lightly SAES-N-120,
G3
tapping them with a 1-pound hammer and are acceptable. Para. 12.1.1

Repaired areas are free from lining cracks with a width of 1/8" & larger SAES-N-120,
G4
and a depth of more than 20% of refractory thickness. Para. 12.4.4

REMARKS:

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

2. SAES-N-120 -- Installation Requirements-Extreme Erosion Resistant Refractories (30 November 2004)
ATTACHMENTS: 1. Attachment 1 -- SA INSP FORM 175-328110 (Refractories)
NOTES: 1. This checklist applies to Inspection of repairs for extreme erosion resistant refractory systems per procedure of SAES-N-120 only.
2. Repair attempts often result in loose "biscuits" (defined as a small section of refractory shaped like a biscuit that is loose within the hexsteel).
After hand excavation, a thorough visual inspection reveals sound refractory & no disbond to the base metal of the equipment when hammer tested.
3. No portion of the original crack rejected remains after excavation.

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 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
Inspection of Repairs to Extreme Erosion Resistant
SAIC-N-2034 25-May-05 MECH-
Refractory
Attachment 1 -- SA INSP FORM 175-328110

Page 3 of 3