Saudi Aramco Inspection Checklist: Pre-Application Inspection of Castable & Brick Refractory SAIC-N-2024 15-Dec-09 Mech

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008)
Rev 3
SAUDI ARAMCO INSPECTION CHECKLIST
SAIC NUMBER
Pre-Application Inspection of Castable & Brick Refractory

PROJECT TITLE
SAIC-N-2024
WBS / BI / JO NUMBER
EQUIPMENT ID NUMBER(S)
EQUIPMENT DESCRIPTION
LAYOUT DRAWING NUMBER
REV. NO.
SCHEDULED INSPECTION DATE & TIME
ACTUAL INSPECTION DATE & TIME
REFERENCE
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" :
A) Refractory Anchor (Material, Sizes & Types) selection is correct
B) Refractory Material (Type, Weight % of Needles,
Application Method) selection is correct. See Note 3 (Make Field Copy).
SAES-N-100,
Para. 9.1
A2
Checklist SAIC-N-2022 is completed & accepted. Anchorage, supports

& hexsteel installations are welded. All inspection & testing is complete.
as referenced
A3
Checklist SAIC-N-2023 has been completed & accepted & both

applicators & application techniques are fully qualified.
as referenced
A4
Post-weld Heat treatment (PWHT) & hardness testing after welding is

completed & accepted.
See Note 2
SAES-N-110,
Para. 6.2.2
A5
Materials have been stored off the ground & properly covered with tarps
to protect against damage from water or moisture.
See Note 2.
SAES-N-110,
Para. 7.2
B.
Pre-Application Requirements for Castable Refractories (SAES-N-110 Procedure)
B1
All surfaces are clean, dry & free from oil, grease, weld slag & mill scale
prior to installation of refractory.
SAES-N-110,
Para. 8.1
B2
Prior to application of refractory, all metallic surfaces have been grit

blasted in accordance with SSPC SP 6, "Commercial Blast Clean".
SAES-N-110,
Para. 8.2
B3
Surfaces previously coated with a vapor barrier or that are heavily

corroded (such as tie-ins to existing equipment or repairs) are brush
blasted in accordance with SSPC SP 7, "Brush Blasting".
SAES-N-110,
Para. 8.3
B4
Application of hydraulic-setting refractory is by gunning, casting, or

vibration casting (as previously qualified by test sample).
SAES-N-110,
Para. 9.1.1
B5
Testing procedures (test panel & production sample) were performed

per SAES-N-110, Section 11.2 requirements with all testing conducted
by a fully qualified & Company approved independent lab. (Note 4)
SAES-N-110,
Para. 9.1.2
B6
Surfaces to be lined were inspected prior to refractory installation & SA

authorized Refractory Inspector has given approval for lining application.
SAES-N-110,
Para. 9.1.3
B7
Linings backing surface temperatures are monitored & do not exceed

32C for application.
SAES-N-110,
Para. 9.1.4
B8
Protective Steps are taken are maintain a maximum temperature of

32C for a minimum of 24 hours after installation. Linings are protected
from heat-induced accelerated setting by protective measures. Note 5.
SAES-N-110,
Para. 9.1.5
Page 1 of 12
PLANT NO.
EC / PMCC / MCC NO.

MH's SPENT
TRAVEL TIME
SAUDI ARAMCO USE ONLY
CONTRACTOR INSPECTION LEVEL
A1
MECH-
SYSTEM ID.
QUANTITY INSP.
SAUDI ARAMCO INSPECTION LEVEL
ACCEPTANCE CRITERIA
QR NUMBER
CONTRACTOR / SUBCONTRACTOR
PURCHASE ORDER NUMBER
SAUDI ARAMCO ACTIVITY NUMBER
A.
15-Dec-09
EQPT CODE
SAUDI ARAMCO TIP NUMBER
ITEM
No.
30-Jun-08
DATE APPROVED
WORK PERMIT REQUIRED?
PASS
FAIL
N/A
RE-INSP DATE
Rev 3

PROJECT TITLE
ITEM
No.
SAIC NUMBER
SAIC-N-2024
ACCEPTANCE CRITERIA
REFERENCE
B9
Linings & lining materials are kept above 10C during the lining
application and for a period 24 hours after the lining application.
SAES-N-110,
Para. 9.1.7
B10
Linings shall be applied in a manner that will ensure minimal shrinkage.

Manufacturer specific instruction's to minimize shrinkage are followed.
SAES-N-110,
Para. 9.1.8
B11
Water used to mix refractory (certificate) complies with the following:

A) The pH is within a range of 5.8-8.6.
B) Water quality (All Impurities < 1000 ppm, Iron < 500 ppm,
Calcium & Magnesium, both < 300 ppm, Chlorine & Sulfur, both < 200
ppm).
SAES-N-110,
Para. 9.1.9
B12
Admixtures are not used during refractory mixing operations.
SAES-N-110,
Para. 9.1.10
B13
Water ratios specified by Refractory Manufacturer are available & mixing

containers used have accurate level markings to assure mix accuracy.
SAES-N-110,
Para. 9.1.11
B14
Temperature Controls (water & refractory) exist to keep mixed refractory

between 10C and 32C.
SAES-N-110,
Para. 9.1.12
B15
Additives to linings have been approved by Saudi Aramco Engineer

(Supervisor, Piping & Valves Unit, Consulting Services Dept, Dhahran).
SAES-N-110,
Para. 9.1.13
B16
Piping & equipment is supported to prevent distortion during lining.
SAES-N-110,
Para. 9.1.14
B17
Threaded attachments on equipment are protected from lining during

application & Protection does not interfere with the application of lining.
SAES-N-110,
Para. 9.1.15
B18
Equipment nozzle extensions were properly coated with grease to

prevent refractory from bonding to them.
SAES-N-110,
Para. 9.1.16
B19
All openings in equipment are closed & tapered hardwood plugs & sheet
metal sleeves extend beyond the final thickness of the lining.
SAES-N-110,
Para. 9.1.17
B20
These plugs or sleeves are coated with grease, fit snugly into openings,
& shall remain in place until the refractory has set.
SAES-N-110,
Para. 9.1.17
B21
Refractory Manufacturer's recommended time limits (for lining

settlement) are available. The application is well-planned to ensure use
within specified time limits.
SAES-N-110,
Para. 9.1.18
B22
A minimum gap (Cut Back) of 100 mm is provided at the ends of each

section for refractory installed in piping or vessel sections to be
connected by welding.
SAES-N-110,
Para. 9.1.19
B23
The second layer in Double-layer linings is applied after the first layer
has cured for 24 hour minimum and the first layer is thoroughly wetted
just before 2nd layer application.
SAES-N-110,
Para. 9.1.20
B24
Linings of each type of refractory are installed to full thickness in a single

application & are not built up in layers.
SAES-N-110,
Para. 9.1.21
B25
When necessary to apply lining in sections to achieve full thickness in a

single application, edge forms are beveled 10 for keying of adjoining
sections. Construction Joint provisions exist. (Detailed Drawings).
SAES-N-110,
Para. 9.1.21
B26
Anchors were installed per SASD AC-036397.

See Attachment 1.
SAES-N-110,
Para. 9.2.1
Page 2 of 12
30-Jun-08
DATE APPROVED
15-Dec-09
QR NUMBER
MECH-
PASS
FAIL
N/A
RE-INSP DATE
Rev 3

PROJECT TITLE
ITEM
No.
SAIC NUMBER
SAIC-N-2024
ACCEPTANCE CRITERIA
REFERENCE
30-Jun-08
DATE APPROVED
15-Dec-09
PASS
FAIL
Nozzle & manway opening details in refractory lined pressure vessels

& piping were installed per SASD AB-036914.
See Attachment 2.
SAES-N-110,
Para. 9.2.2
B28
Hexsteel was installed per SASD AB-036396.

See Attachment 3.
SAES-N-110,
Para. 9.2.3
B29
Inspector reviews the following procedure before production work:

"Mixing Refractory for Pneumatic Applications" .
See Note 6.
SAES-N-110,
Section 9.3
B30

"Application of Pneumatically Applied Refractory". See Note 6.
SAES-N-110,
Section 9.4
B31

"Mixing Refractory for Casting Applications" .
See Note 6.
SAES-N-110,
Section 9.5
B32

"Application of Cast Refractory".
See Note 6.
SAES-N-110,
Section 9.6
B33

"Application of Vibration Casting".
See Note 6.
SAES-N-110,
Section 9.7
C.
SAES-N-110 Procedure Figure 1 Checklist for Castable Refractory (Section A, Prior to Installation)
C1
MATERIALS are checked as follows:

A) Types of materials supplied are correct
B) Data sheets & mixing instructions are available
C) MSDS sheets are available
SAES-N-110,
Figure 1, Sect. A
C2
DOCUMENTS include approved detail drawings
SAES-N-110,
Figure 1, Sect. A
C3
INSPECTION includes the following:

A) Inspect surface preparation
B) Inspect anchor layout and welding
C4
C5
C6
C7
C) Review
welding procedures
WEATHER PROTECTION exists as follows:
A) Materials are properly stored
B) Equipment to be lined is prepared for inclement
weather
EQUIPMENT - MIXERS is checked as follows:
A) Number and type are adequate
B) Back up mixer is
available
C) Location relative to work
D) Cleanliness
GUNNITE RIGS are checked as follows:
A) Number & Type of Rigs is adequate
B) Operating Condition &
Cleanliness is adequate
C) Hose is sufficient
F) Nozzle type is
correct
VIBRATORS are checked as follows:
A) Number & Type of vibrators is adequate
B) Attachment method
C) Operating condition
D) Backup
Page 3 of 12
SAES-N-110,
Figure 1, Sect. A
SAES-N-110,
Figure 1, Sect. A
SAES-N-110,
Figure 1, Sect. A
SAES-N-110,
Figure 1, Sect. A
MECH-
B27
SAES-N-110,
Figure 1, Sect. A
QR NUMBER
N/A
RE-INSP DATE
Rev 3

PROJECT TITLE
ITEM
No.
C8
SAIC-N-2024
ACCEPTANCE CRITERIA
REFERENCE
CURING COMPOUND APPLICATORS are checked as follows:

A) Type and size
B) Cleanliness
C) Number
D) Working
conditions
AIR COMPRESSORS are checked as follows:
A) Size
C9
C10
SAIC NUMBER
B) Operating Condition
C) Contingencies
SAMPLE MOLDS are checked as follows:
A) Cubes are adequate
B) Gunnited molds are
adequate
30-Jun-08
DATE APPROVED
15-Dec-09
PASS
SAES-N-110,
Figure 1, Sect. A
SAES-N-110,
Figure 1, Sect. A
D.
Pre-Application Requirements for Extreme Erosion-Resistant Refractory (SAES-N-120 Procedure)
D1
Material is unopened & within expiry date (Or material is rejected).
SAES-N-120,
Para. 10.1.1
D2
Water used to mix refractory (certificate) complies with the following:

A) The pH is within a range of 5.8-8.6.
B) Water quality (All Impurities < 1000 ppm, Iron < 500 ppm,
Calcium & Magnesium, both < 300 ppm, Chlorine & Sulfur, both < 200
ppm).
SAES-N-120,
Para. 10.1.3
D3
Admixtures are not used unless approved by Saudi Aramco Engineer.
SAES-N-120,
Para. 10.1.4
D4
Linings will be installed indoors except for in-situ patching & repairs.
SAES-N-120,
Para. 10.1.5
D5
Lining backing surface temperatures will not exceed 32C on application
SAES-N-120,
Para. 10.1.6
D6
Protective Steps are taken are maintain a maximum temperature of

32C for a minimum of 24 hours after installation. Linings are protected
from heat-induced accelerated setting by protective measures. Note 5.
SAES-N-120,
Para. 10.1.7
D7
Linings & lining materials will be kept above 10C during the lining
application and for a period 48 hours after the lining application.
SAES-N-120,
Para. 10.1.9
D8
Surfaces shall be kept dry before, during and after installation.
SAES-N-120,
Para. 10.1.10
D9
Refractory Manufacturer's mixing instructions, installation instructions, &

precautions are available (to be strictly followed during applications).
SAES-N-120,
Para. 10.2.1
D10
A) Hobart, Model #D-33 commercial mixer (or approved equal).

B) Two, 30-quart mixing bowls
C) A beater and a wire whip
SAES-N-120,
Para. 10.2.2
Applicators understand the following mandatory requirements:
D11
A) The Mixed quantity is only what can be applied within 15 mins after
the addition of water.
B) Any mixed refractory not used within 15 minutes is
discarded.
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.
Page 4 of 12
SAES-N-120,
Para. 10.2.3
&
Para. 10.2.4
MECH-
SAES-N-110,
Figure 1, Sect. A
Mandatory mixing equipment (all Stainless Steel) is available as follows:
QR NUMBER
FAIL
N/A
RE-INSP DATE
Rev 3

PROJECT TITLE
ITEM
No.
D12
D13
D14
SAIC NUMBER
SAIC-N-2024
ACCEPTANCE CRITERIA
REFERENCE
SAMPLE TESTING PROCEDURE (9 Steps) has been completed.

(1) Select three packages at random from each batch or lot, then take 5
lbs of dry and damp material from each batch or lot.
(2) Reseal the packages that the samples were taken from and mark
them "Package Opened for Sampling".
(3) Mix the three samples of the dry material together to give a uniform
mixture. Repeat this procedure with the damp material.
(4) Take enough of the sample mix to prepare five 50 mm cubes for the
cold crushing strength tests.
(5) Seal the remainder for possible re-test.
(6) Mix the two materials together & add required amount of water (refer
to mixing instructions in paragraph 10.2.3 above) & cast five cubes.
(7) Air cure and dryout the samples in accordance with Chapter 11.
(8) Perform cold-crushing strength and bulk density tests in accordance
with ASTM C133 and ASTM C134. The cold-crushing strength and bulk
density values are the average result obtained for the five test cubes.
(9) Any sample that does not meet the minimum published strength or
density will be cause for rejection of the complete batch.
Hand packing tools (Plastic or wooden mallets) are available to

hammer refractory into hexsteel to eliminate voids or air pockets &
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)
& securement. No hexsteel protrusions or depressions exist.
30-Jun-08
DATE APPROVED
15-Dec-09
QR NUMBER
MECH-
PASS
FAIL
N/A
RE-INSP DATE
SAES-N-120,
Section 10.3
SAES-N-120,
Para. 10.4.1
SAES-N-120,
Para. 10.4.2
Smooth screeding is flush to the face of the hexsteel & hexsteel

pattern must be visibly distinguishable after screeding of lining.
D15
Air curing & Dryout equipment (Ventilation equipment, furnace,

auxilliary burners, temperature measuring devices, etc) is available.
SAES-N-120,
Section 11.1
Preparations for Sample Testing before Application are as follows:

A) Enough (64-80) sample forms of 50 mm cube size exist on jobsite.
D16
B) A chart is available (Sample number, date & time taken, location).

C) Sketch & log exists to show each batch location &
samples location.
D) Approved test laboratory has been determined for sample testing.
SAES-N-120,
Section 10.5
D17
A 1-pound hammer (head weight as stamped) is available for testing

the lining.
SAES-N-120,
Section 12.2.6
E.
SAES-N-120 Procedure Figure 1 Checklist for Extreme Erosion-Resistant Refractory (Section A, Prior to Installation)
E1

B) Data sheets & mixing instructions
SAES-N-120,
Para 12.5
Check List
Sec. A
Page 5 of 12
Rev 3

PROJECT TITLE
ITEM
No.
SAIC NUMBER
SAIC-N-2024
ACCEPTANCE CRITERIA
REFERENCE
SAES-N-120,
Para 12.5
Check List
Sec. A
E2
DOCUMENTS include approved detail assembly drawings
E3
SURFACE PREPARATION & HEXSTEEL is checked as follows:

A) Surface preparation meets specifications
B) Welding procedures
E4
WEATHER PROTECTION exists as follows:

A) Materials are properly stored
B) Equipment to be lined is prepared for inclement weather conditions
E5
EQUIPMENT - MIXERS are checked as follows:

A) Number and types are adequate
B) Back up mixer is available
C) Location relative to work & Cleanliness
SAES-N-120,
Para 12.5
Check List
Sec. A
SAMPLE MOLDS are checked as follows:

A) Cubes
SAES-N-120,
Para 12.5
Check List
Sec. A
SAES-N-120,
Para 12.5
Check List
Sec. A
E6
B) Plate for erosion testing
SAES-N-120,
Para 12.5
Check List
Sec. A
SAES-N-120,
Para 12.5
Check List
Sec. A
E7
PNEUMATIC RAMMERS are checked as follows:

A) Number of rammers is adequate
B) Operating condition
F.
Pre-Application Requirements for Fireclay Brick Refractory . (SAES-N-130 Procedures)
F1
The Refractory installation procedure incorporates the requirements of

the Refractory Manufacturer, the Equipment Manufacturer, and this
standard and is approved by the Saudi Aramco Engineer prior to
installation.
SAES-N-130
Para. 5.2
F2
Detailed engineering drawings of the refractory system are available

showing anchorage design including spacing and orientation, refractory
thicknesses, all materials, surface preparation, and welding details.
SAES-N-130
Para. 5.3
F3
Structural steel framing members and tie back are provided for
supporting the brick lining on vertical flat sections.
Note:
A) All tie members shall be austenitic alloy material.
B) A minimum of 15% of the bricks shall be tied back.
C) Tie backs are not required when the radius of the curvature of
cylindrical casing keys the brick
SAES-N-130
Para. 6.3
F4
Metal support shelves welded to the casing and centered a minimum of

8 meters vertically to support the Brick lining Note: Shelves shall be
slotted to provide for differential thermal expansion.
SAES-N-130
Para. 6.3
F5
Fireclay bricks are free from mechanical damage prior to placement.
SAES-N-130
Para. 7.1
G.
SAES-N-130 - Checklist for Fire Clay Brick Refractory Installation. (Prior to Installation)
G1

B) Data sheets & mixing instructions are available
G2
DOCUMENTS include approved detail assembly drawings
Page 6 of 12
SAES-N-130
Para 8.3
Check List
SAES-N-120,
Para 12.5
Check List
Sec. A
30-Jun-08
DATE APPROVED
15-Dec-09
QR NUMBER
MECH-
PASS
FAIL
N/A
RE-INSP DATE
Rev 3

PROJECT TITLE
ITEM
No.
G3
SAIC NUMBER
SAIC-N-2024
ACCEPTANCE CRITERIA
REFERENCE
EQUIPMENT - MIXERS are checked as follows:

A) Number and types are adequate
B) Back up mixer is available
C) Brick saw is available.
D) Location relative to work & Cleanliness
SAES-N-120,
Para 12.5
Check List
Sec. A
Page 7 of 12
30-Jun-08
DATE APPROVED
15-Dec-09
QR NUMBER
MECH-
PASS
FAIL
N/A
RE-INSP DATE
Rev 3
SAIC NUMBER

PROJECT TITLE
SAIC-N-2024
ITEM
No.
ACCEPTANCE CRITERIA
30-Jun-08
DATE APPROVED
REFERENCE
QR NUMBER
15-Dec-09
MECH-
PASS
FAIL
N/A
RE-INSP DATE
REMARKS:
REFERENCE DOCUMENTS:
1.
2.
3.
3.
SAES-N-100 -- Refractory Systems (30 Jan 2007)

SAES-N-110 -- Installation Requirements-Castable Refractories (30 Jan 2007)
SAES-N-120 -- Installation Requirements-Extreme Erosion Resistant Refractories (30 Jan 2007)
SAES-N-130 Installation Requirements Fireclay Bricks. (30 January 2007)
ATTACHMENTS:
Attachment 1 -- SASD AC-036397 (Anchoring Details for Castable Refractories)
Attachment 2 -- SASD AB-036914 (Support Details at Nozzles & Manways for Castable Refractory)
Attachment 3 -- SASD AB-036396 (Hexsteel Details)
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 32C 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), consumables (air, water, materials), & set-up (formwork) checks.
Contractor / Third-Party
Saudi Aramco
Construction Representative*
PMT Representative
Work is Complete and Ready for Inspection:

Name, Initials and Date:
T&I Witnessed
QC Record Reviewed
Work Verified
T&I Witnessed
QC Record Reviewed
Work Verified
T&I Witnessed
QC Record Reviewed
Work Verified
QC Inspector
PID Representative
Performed Inspection
Work / Rework May Proceed
QC Supervisor
Proponent and Others

Quality Record Approved:
Name, Sign and Date:
Name, Organization,
Initials and Date:
*Person Responsible for Completion of Quality Work / Test
Y = YES
Page 8 of 12
N = NO F = FAILED
Rev 3

SAIC NUMBER
SAIC-N-2024
30-Jun-08
DATE APPROVED
QR NUMBER
15-Dec-09
MECH-
Attachment 1 -- SASD AC-036397

(Anchoring Details for Castable Refractories)
Note: Use this Attachment on Layout (Pre-Welding) & Final Inspections
Page 9 of 12
Rev 3

SAIC NUMBER
SAIC-N-2024
30-Jun-08
DATE APPROVED
15-Dec-09
QR NUMBER
MECH-
Attachment 2 -- SASD AB-036914

(Support Details @ Nozzles & Manways for
Castable Refractory)
Page 10 of 12
Rev 3

Page 11 of 12
SAIC NUMBER
SAIC-N-2024
30-Jun-08
DATE APPROVED
15-Dec-09
QR NUMBER
MECH-
Rev 3
SAIC NUMBER

SAIC-N-2024
30-Jun-08
DATE APPROVED
15-Dec-09
QR NUMBER
MECH-
Attachment 3 -- SASD AB-036396 (Hexsteel Details)

Page 12 of 12

Saudi Aramco Inspection Checklist: Pre-Application Inspection of Castable & Brick Refractory SAIC-N-2024 15-Dec-09 Mech

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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008)