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

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

Review Installation Procedure for Fireclay Bricks

SAIC-N-2035

PROJECT TITLE

WBS / BI / JO NUMBER

EQUIPMENT ID NUMBER(S)

EQUIPMENT DESCRIPTION

LAYOUT DRAWING NUMBER

REV. NO.

SCHEDULED INSPECTION DATE & TIME

ACTUAL INSPECTION DATE & TIME

SYSTEM ID.

MH's SPENT

TRAVEL TIME

SAUDI ARAMCO USE ONLY

SAUDI ARAMCO INSPECTION LEVEL

CONTRACTOR INSPECTION LEVEL

REFERENCE

WORK PERMIT REQUIRED?

PASS

FAIL

General Requirements (Note: This Checklist applies to Fireclay Brick Refractories Only per SAES-N-130)

A1

The procedure is project specific and identifiable by Budget Item (BI) or

Job Number, Contract Number & Project title.

Sch Q,
Section 3.1

A2

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

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

Sch Q,
Section 3.1

A3

An attachment section exists listing applicable QC forms & records.

(ISO 9001:2000, Para. 4.2.4a)

Sch Q,
Section 3.1

A4

Procedure Scope covers fireclay bricks used for bridges and dividing
walls in boilers, sulfur recovery unit equipment and process heaters.

SAES-N-130,
Para. 1.1

A5

Procedure list under References:

A) SAES-N-100, SAES-N-130.
B) SA Std Drawings AD-036393, sheet 1 through 28 as applicable for
Boiler Installations
C) SA Form 175-328110
C) Applicable International Standards i.e. API STD 560, API RP 936 &
ASTM Standards applicable to the refractory scope of work.

SAES-N-100,
Sec. 3

A6

Definitions are listed & match SAES-N-100/130, Section 4, and API RP

936, Section 3 & Appendix A (Glossary of Terms).

SAES-N-100,
Section 3 & 4

A7

Procedure covers Quality Control Key Elements of API RP 936

(Documents, material & applicator qualifications, installation monitoring,
as-installed tests, pre-dryout inspection, dryout & post dryout inspection.
See Attachment 1.

SAES-N-100,
Para. 3.2

A8

Procedure is a "Marriage" of requirements of Refractory Manufacturer,

the Equipment Manufacturer, & applicable SA standards (SAES-N-130).
See Note 1.

SAES-N-130,
Para. 5.2

A9

Procedure Responsibility section states:

A) Refractory Installer is responsible for installing
refractory systems per SA STDs (SAES-N-100/130) & specific
requirements of Refractory Manufacturer and the Equipment
Manufacturer.
B) Equipment Manufacturer is
responsible for preparing fully detailed engineering drawings of
refractory system (also referenced in procedure).

SAES-N-130,
Section 5

A10

Procedure states that "Refractory Installation" work will not begin until
Refractory work procedures have been approved by Company.

Page 1 of 9

PLANT NO.

EC / PMCC / MCC NO.

QUANTITY INSP.

SAUDI ARAMCO ACTIVITY NUMBER

A.

MECH-

CONTRACTOR / SUBCONTRACTOR

PURCHASE ORDER NUMBER

ACCEPTANCE CRITERIA

QR NUMBER

15-Dec-09

EQPT CODE

SAUDI ARAMCO TIP NUMBER

ITEM
No.

30-Jun-08
DATE APPROVED

Sch. Q, Att. IV,

Para 2.1 & Table

N/A

RE-INSP DATE

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

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

Review Installation Procedure for Fireclay Bricks

PROJECT TITLE

SAIC-N-2035
WBS / BI / JO NUMBER

ITEM
No.

ACCEPTANCE CRITERIA

REFERENCE

B.

Materials Section (Procedure lists material requirements, storage & handling controls)

B1

Material Handling & Storage section details fireclay brick protection

(Handling & Stacking) measures to prevent mechanical damage.

SAES-N-130,
Para. 7.1

B2

The Refractory Manufacturer's precautions for material handling &

storage, as specified on the MSDS sheets, are strictly followed (stated).

SAES-N-130,
Para. 7.2

B3

Target walls with flame impingement on both sides are constructed of

high-duty firebrick, at least 1538C (2800F) rating. (API 560, Par.
11.1.7)

SAES-N-130,
Para. 1.1

B4

Material of metallic shelves used for support of firebricks in process

heaters (selected on surface temperature) shall be specified in
procedure
Note: The support material shall be rated for surface temperature (as
calculated and shown in equipment data sheet) plus 10C.
(API 560, Par. 11.2.8)

SAES-N-130,
Para. 6.4

B5

Fibrous refractory material (Ceramic fiber to pack expansion joint gaps)

comes in strip form (Continuous roll), not in a loose bulk form.

SAES-N-130,
Para. 6.2

C.

Preparations & Pre-Installation Inspection Requirements (Procedure)

C1

Types of materials supplied are checked upon receipt including the data
sheets & specific mixing instructions for materials (mortars, bricks).

C2

Refractory Manufacturer's safety precautions & MSDS sheet are

available & are "to be strictly followed".

C3

Documents (IFC detailed drawings & specifications) have been

approved and are checked by the Inspector prior to installation of brick.

C4

Equipment for Mixing is checked & available as follows (as stated):

A) Number and type of mixers are adequate.
B) A back up mixer is available.
C) A Brick saw is available.
D) Set-up location is acceptable relative to work location
E) Equipment cleanliness is acceptable.

D.

Installation Section Content Requirements

D1

Firebricks for specific equipment meet requirements specified in

SAES-N-100 Table 3 "Mandatory Refractory Systems":

SAES-N-130,
Para. 8.3
SAES-N-130,
Para. 8.3
SAES-N-130,
Para. 8.3

SAES-N-130,
Para. 8.3

SAES-N-100,
Para. 9.1

See Note 2.
D2

Fired Process Heater refractory is installed per the API 560, Section 11
specific requirements, unless otherwise specified.
See Note 3.

Page 2 of 9

SAES-N-100,
Para. 3.2

30-Jun-08
DATE APPROVED

15-Dec-09

QR NUMBER

MECH-

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

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

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

Review Installation Procedure for Fireclay Bricks
PROJECT TITLE

ITEM
No.

SAIC NUMBER

SAIC-N-2035
WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA

REFERENCE

During installation, Inspection is performed for the following (as stated):

D3

A) Verify all dimensions are per detail drawings.

B) Verify construction joints installed as required per drawings & codes
C) Verify plumbness and straightness is per detail drawings.
D) Verify the integrity of bricks (complete or sections) used.

SAES-N-130,
Para. 8.3
(SA
Checklist)

E.

Expansion Joint Requirements

E1

Expansion joints exist in both vertical and horizontal directions of walls,

at wall edges, around burner tiles & doors. See Note 4.

SAES-N-130,
Para. 6.1

E2

Walls, arches & floors allow for proper expansion of parts & multilayer
bricks have staggered joints that are not continuous through the lining.
(API 560, Para. 11.1.3)

SAES-N-130,
Para. 1.1

E3

Target walls with flame impingement on both sides (Bricks are laid dry or
mortared joints) have expansion joint gaps packed with ceramic fiber
strips having a service temp rating equal to brick. (API 560, Para. 11.1.7)

SAES-N-130,
Para. 1.1

E4

Floor bricks are not mortared & have a 13 mm expansion gap on a 1.8
meter interval (gaps are packed with fibrous strip refractory material).

SAES-N-130,
Para. 6.2

F.

Support Requirements (Tie-backs & Lintels)

F1

Brick lining on vertical flat casing is tied back (minimum 15% of bricks) &
supported by structural steel framing members with tie members
constructed of austenitic alloy material.

SAES-N-130,
Para. 6.3

F2

Tie backs are not required when the radius of the curvature of cylindrical
casing keys the bricks.

SAES-N-130,
Para. 6.3

F3

Brick lining is supported by metal support lintels (shelves) welded to

casing & centered a maximum of 1.8 meters (6 ft.) vertically with shelves
slotted to allow for thermal expansion.

SAES-N-130,
Para. 6.4

G.

Installation of Firebricks & Tiles (API 560 Fired Process Heaters Specific Requirements)

G1

Radiant chamber walls of gravity construction shall not exceed 7.3

meters in height & are made of high-duty fireclay brick.
The walls shall have a base width a minimum of 8% of the wall height &
a maximum height to width ratio of 5 to 1.
The walls of firebrick shall be self-supporting and the wall base rests
directly on the steel floor, not on other refractory.
(API 560, Par. 11.2.2).

SAES-N-130,
Para. 1.1

G2

Gravity walls are of mortared construction. Mortar used is non-slagging,

air-setting & chemically compatible with adjacent refractory, including the
rated temperature of the brick.
(API 560, Para.11.2.3)

SAES-N-130,
Para. 1.1

Page 3 of 9

30-Jun-08
DATE APPROVED

15-Dec-09

QR NUMBER

MECH-

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

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

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

Review Installation Procedure for Fireclay Bricks

SAIC-N-2035

PROJECT TITLE

WBS / BI / JO NUMBER

ITEM
No.

ACCEPTANCE CRITERIA

30-Jun-08
DATE APPROVED

REFERENCE

G3

Vertical expansion joints are provided at gravity wall ends and required
intermediate locations. All expansion joints are kept open & free to
move.
If the expansion joint is formed with lapped brick, no mortar is used. it
shall be, a dry joints.
(API 560, Para.11.2.4)

SAES-N-130,
Para. 1.1

G4

Expansion joint gaps are packed with ceramic fiber strips with a service
temperature rating equal to or greater than brick. (API 560, Para. 7.1.7)

SAES-N-130,
Para. 1.1

H.

Quality Control & Responsibility (Inspection, Testing & Repairs)

H1

Inspection & Testing is performed per SA Inspection Form 175-328110 &

SAES-N-130 procedure. use SATR-N-2001.

SAES-N-130,
Para. 8.1

H2

ASTM C134 production testing (Size and Bulk Density, Squareness and
Warpage of Firebricks) was performed per SA Insp. Form 175-328110
Line 23 with certificates available.

SAES-N-100
Sec. 3.2

H3

Repair methods are in accordance with original installation procedure &

where needed, additional supports are installed (as stated).

SAES-N-130,
Para. 8.2

QR NUMBER

15-Dec-09

MECH-

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

REMARKS:
REFERENCE DOCUMENTS:
1.
2.
3.
4.

Schedule Q -- Quality Requirements (Project Specific)

SAES-N-100 -- Refractory Systems (30 Jan 2007)
SAES-N-130 -- Installation Requirements-Fireclay Bricks (30 Jan 2007)
API Standard 560 -- Fired Heaters for General Refinery Service (Aug 2007)

5. API RP 936 -- Refractory Installation Quality Control Guidelines - Inspection & Testing Monolithic Refractory Lining & Materials (Nov 2008 Edition)
ATTACHMENTS:
1. Attachment 1, API RP 936 Table 1
2. Attachment 2, SA Inspection Requirement Form 175-328110 (Refractories)
NOTES: 1. Contractor's refractory installation procedure must follow the SA mandatory specific installation procedure SAES-N-130. Contractor can
copy & paste much of the SA refractory procedure into his own procedure. However, Refractory & Equipment Manufacturer requirements must also
be incorporated into the procedure (per SAES-N-130, Para. 5.2 for procedure section)
2. Use Table 3 Mandatory Refractory Systems of SAES-N-100 (Not Attached) for Receipt & Pre-installation inspection checks of firebricks.
3. Incorporate API 560 general/specific requirements & utilize API 560 Section 7 as a checklist during Heater construction. (This is Not Attached).
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 (Not attached) are incorporated in procedure to check Process Heater Refractory materials on installation.

Contractor / Third-Party

Saudi Aramco

Construction Representative*

PMT Representative

Work is Complete and Ready for Inspection:

Name, Initials and Date:

QC Inspector

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

PID Representative
Performed Inspection

Work / Rework May Proceed

Name, Initials and Date:

Name, Initials and Date:

QC Supervisor

Proponent and Others

Quality Record Approved:

Name, Sign and Date:

T&I Witnessed
Name, Initials and Date:

Name, Organization,
Initials and Date:

Page 4 of 9

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

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

Review Installation Procedure for Fireclay Bricks

SAIC-N-2035

PROJECT TITLE

ITEM
No.

WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA
Quality Record Approved:

Name, Sign and Date:

REFERENCE

30-Jun-08
DATE APPROVED

15-Dec-09

QR NUMBER

MECH-

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

Y = YES

N = NO F = FAILED

Name, Organization,
Initials and Date:

*Person Responsible for Completion of Quality Work / Test

Page 5 of 9

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

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

Review Installation Procedure for Fireclay Bricks

SAIC NUMBER

SAIC-N-2035

30-Jun-08
DATE APPROVED

15-Dec-09

Attachment 1 -- API RP 936 Table 1

Page 6 of 9

QR NUMBER

MECH-

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

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SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

Review Installation Procedure for Fireclay Bricks

SAIC-N2035

30-Jun-08

DATE APPROVED

15-Dec-09

Attachment 2 -- SA Form 175-328110 (Refractories)

Page 7 of 9

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

Rev 3

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SAIC NUMBER

Review Installation Procedure for Fireclay Bricks

Page 8 of 9

SAIC-N2035

30-Jun-08

DATE APPROVED

15-Dec-09

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

Rev 3

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SAIC NUMBER

Review Installation Procedure for Fireclay Bricks

Page 9 of 9

SAIC-N2035

30-Jun-08

DATE APPROVED

15-Dec-09