SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008) Rev 3 30-Jun-08

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Castable & Extreme Erosion Resistant

SAIC-N-2018 15-Dec-09 MECH-
Refractory Installation
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 (Note: This Checklist applies to Castable Refractories Only per SAES-N-110 & SAES-N-120)

The procedure is project specific and identifiable by Budget Item (BI) or Sch Q,
A1
Job Number, Contract Number & Project title. Section 3.1

A) An approval section exists to document adequacy prior to use.

B) A revision control section exists to Sch Q,
A2
document procedure changes. Section 3.1
(ISO 9001:2000, Para. 4.2.3a)

An attachment section exists listing applicable QC forms & records. Sch Q,

A3
(ISO 9001:2000, Para. 4.2.4a) Section 3.1

Procedure Scope covers applicable pressure vessels, boilers, process SAES-N-100,

A4
heaters, exchangers, flare tips, & sulfur recovery unit equipment/piping. Para. 1.1

Procedure list under References:

A) SAES-N-100, SAES-N-110 & SAES-N-120.
B) SA Std Drawings AB-036395, AB-036396, AC-036397, AB-036914 &
SAES-N-100,
A5 AB-036916.
Section 3
C) SA Form 175-328110
D) Applicable International Standards i.e. API STD 560, API RP 936 &
ASTM Standards applicable to the refractory scope of work.

Definitions are listed & match SAES-N-100/110/120, Section 4, and API SAES-N-100,
A6
RP 936, Section 3 & Appendix A (Glossary of Terms). Section 4

Procedure covers Quality Control Key Elements of API RP 936

(Documents, material & applicator qualifications, installation monitoring, SAES-N-100,
A7
as-installed tests, pre-dryout inspection, dryout & post dryout inspection. Para. 3.2
See Attachment 1.

Procedure Responsibility section states:

A) Refractory Installer is responsible for installing
refractory systems per SA STDs (SAES-N-100/110/120) & specific
SAES-N-
requirements of Refractory Manufacturer and the Equipment
A8 110/120, Section
Manufacturer.
5
B) Equipment Manufacturer is responsible for preparing fully detailed
engineering drawings of refractory system (also referenced in
procedure).

Procedure is a "Marriage" of requirememts of Refractory Manufacturer, SAES-N-

A9 the Equipment Manufacturer, & applicable SA STDs (SAES-N-110, 120). 110/120, Para.
See Note 1. 5.2

Procedure states that "Refractory Installation" work will not begin until Sch. Q, Att. IV,
A10
Refractory work procedures have been approved by Company. Para 2.1 & Table

Page 1 of 9
 SAES-N-110,
Furnace Dryout Procedure is included for Castable Refractory. Par. 10.3
A11
SAES-
N-120, Par. 11.3

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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008) Rev 3 30-Jun-08

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Castable & Extreme Erosion Resistant

SAIC-N-2018 15-Dec-09 MECH-
Refractory Installation
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
B. Materials Section (Procedure lists material requirements, storage, handling & preservation controls)
SAES-N-100,
B1 Procedure lists refractory material restrictions related to asbestos use.
Para. 7.1.1

Procedure lists/references castable refractories (SAMS Serial numbers)

based on physical properties specified on data sheets & values listed in SAES-N-100,
B2
SAES-N-100 Table 2 (Data for Castable Refractory). Para. 7.1.3

Procedure specifies the requirements of Anchors:

A) Single-layer, castable linings anchors are "V" shaped types.
SAES-N-100,
B3 B) Anchors for dual-layer linings for the support of insulating castable
Para. 8.2.1
refractory shall be "Y" types.

All "V" and "Y" type anchors are specified with rubber or plastic caps.

Note: Color of plastic/rubber caps can clearly identify differing SAES-N-100,

B4
anchor metallurgy. See Attachment 3 (API 936 Anchor Color Code) Para. 8.2.2

Note: PMI extent & color code shall be detailed in procedure.

Anchor Details meet the SASD AC-036397 SAES-N-100,

B5
Para. 8.2.3

Procedure Specifies Hexsteel installation details:

A) Material is the offset-lance, tight-clinched type (welded).
B) Riveted type hexsteel is limited for use on external surfaces of piping
that is 12 inch NPS and less.
C) Hexsteel supported by "T" studs (two component linings) is material of
19 mm wide, 14 gauge thick bars.
D) Hexsteel welded directly to equipment or piping for support of 25 mm SAES-N-100,
B6
thick extreme-erosion resistant refractory is 25 mm wide, 14 gauge bar. Sec.8.3
E) All ends of hexsteel are to be welded to edging bars or to adjacent
hexsteel. Loose ends of hexsteel materials are prohibited.
F) Hexsteel installation details meet SASD AB-036396 requirements.
Note: Hexsteel ID can be accomplished by
Stamping. See Att. 3

Nozzle and manway opening details in refractory lined pressure vessels SAES-N-100,
B7
and piping meet SASD AB-036914. Para. 8.4

Metallic fiber reinforcement density is 80 kg/m³ (5 lb./ft³) unless otherwise SAES-N-100,

B8
specified. Para. 8.5.1

Metallic fiber reinforcement is made from melt extracted material, SAES-N-100,

B9
approximately 0.5 mm in thickness and approximately 25 mm long. Para. 8.5.2

Castable refractories are stored & handled as follows:

A) Protected from water and moisture.
SAES-N-110,
B10 B) Materials are stored off the ground & covered with tarps.
Section 7
C) MSDS Sheet & Refractory Manufacturer's precautions are strictly
followed.

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SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Castable & Extreme Erosion Resistant

SAIC-N-2018 15-Dec-09 MECH-
Refractory Installation
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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

Extreme erosion resistant refractories are stored & handled as follows:

A) Stored in dry weather tight structures at temperature range of 5-25°C. SAES-N-120,

B11
B) Sealed packages are not opened until required (not on receipt).. Section 7
C) MSDS Sheet & Refractory Manufacturer's precautions are strictly
followed.

C. Installation Section Content (Use Attachment 6 & the Following)

Procedure incorporates detailed requirements of SAES-N-110/120

regarding the following elements:
A) Welding*
B) Surface Prep
C) SAES-N-100,
C1
Installation of refractories & firebricks Section 10
*Procedure details anchor & support welding for pressure vessels, boilers,
fired heaters, heat exchangers, flare tips, SRU equipment & piping per the
applicable workscope. Prior to production welding, WPS are submitted to and
approved by CSD Welding Specialist, or CSD designated Representative.

Fired Process Heater refractory is installed per API 560 Section 7 with
SAES-N-100,
C2 specific requirements for brick & tile, castable refractory, ceramic fiber, &
Para. 3.2
multicomponent lining construction. See Note 2

Refractory systems for specific equipment meet requirements

specified in SAES-N-100 Table 3 "Mandatory Refractory Systems":
SAES-N-100,
C3
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 & Attachment 8!

D. Quality Control & Responsibility (Inspection, Testing & Repairs)

SAES-N-110,
D1 Final visual dimensional checks of panels per construction drawings.
Para. 5.3

Quality controls & responsibilities listed in procedure incorporate the

requirements in SAES-N-110 & SAES-N-120 for sections related to
SAES-N-100,
D2 Welding, Surface Prep & installation of refractories & firebrick as
Section 10
applicable.
See Note 1. Also, reference & use SATR-N-2001 & SATR-N-2002.

Procedure incorporates Inspection, Testing & Repair requirements of

SAES-N-110 (Sect. 11) & SAES-N-120 (Sect.12) as applicable. SAES-N-100,
D3
Section 10
See Note 1.

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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008) Rev 3 30-Jun-08

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Castable & Extreme Erosion Resistant

SAIC-N-2018 15-Dec-09 MECH-
Refractory Installation
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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

REFERENCE DOCUMENTS:
1. Schedule Q -- Quality Requirements (Project Specific)
2. SAES-N-100 -- Refractory Systems (30 January 2007)
3. SAES-N-110 -- Installation Requirements-Castable Refractories (30 January 2007)
4. SAES-N-120 -- Installation Requirements-Extreme Erosion Resistant Refractories (30 January 2007)
5. SAES-W-010 -- Welding Requirments for Pressure Vessels (14 November 2005)

6. API RP 936 -- Refractory Installation Quality Control Guidelines - Inspection & Testing Monolithic Refractory Lining & Materials (Nov 2008 Edition)

7. API Standard 560 -- Fired Heaters for General Refinery Service (Aug 2007)

ATTACHMENTS:
1. API RP 936 Table 1 (Quality Control: Key Elements)
2. API RP 936 Appendix B (Color Coding for Metallic Anchors)
5. SA Form 175-328110 (Refractories: Hydraulic-Setting Castable Systems)

NOTES: 1. Contractor's refractory installation procedure must follow the SA mandatory specific installation procedures. Contractor is encouraged
& copy & paste much of the SA refractory procedures into his own procedure. However, Refractory & Equipment Manufacturer requirements
must also be incorporated into the procedure (This is a typical requirement of SAES-N-110 & N-120, Para. 5.2 for procedure sections)
2. Incorporate API 560 general/specific reqmts & utilize API 560 Section 7 as a review tool for Fired Heater Refractory Procedures & Inspection.
Process Heater refractory procedures may be submitted separately from other equipment refractory procedures with a heater installation package.
Ensure SAES-N-100 Table 3 & Notes are incorporated with procedure to verify Process Heater refractory materials on installation.

3. Use Table 3 of SAES-N-100 – Mandatory Refractory Systems for Receipt & Pre-installation inspection checks of materials.

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 - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008) Rev 3 30-Jun-08

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Castable Refractory Installation SAIC-N-2018 15-Dec-09 MECH-

Attachment 1 -- API RP 936 Table 1

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SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Castable Refractory Installation SAIC-N-2018 15-Dec-09 MECH-

Attachment 3 -- API RP 936 Appendix B
Note:This is an acceptable method to SA. Procedure shall detail a method for SA approval. PMI extent, Material segregation practice,
material traceability & id procedures for anchors are critical since a variety of metallurgies exist. Table 7 utilizes a PFI-ES-22 scheme.
Plastic or rubber straws or caps and/or color coding can easily accomplish this task (also prevents fouling from Vapor barrier mastics)

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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008) Rev 3 30-Jun-08

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Castable Refractory Installation SAIC-N-2018 15-Dec-09 MECH-

Page 8 of 9
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008) Rev 3 30-Jun-08

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review Procedure - Castable Refractory Installation SAIC-N-2018 15-Dec-09 MECH-

Attachment 5 -- SA Form 175-328110 (Refractories)

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