Saudi Aramco Inspection Checklist

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008)
Rev 3
SAUDI ARAMCO INSPECTION CHECKLIST
SAIC NUMBER
Review Qualifications & Performance - Authorize Applicator

& Inspector for (ALL) Refractory Installations
PROJECT TITLE
SAIC-N-2019
WBS / BI / JO NUMBER
EQUIPMENT ID NUMBER(S)
EQUIPMENT DESCRIPTION
LAYOUT DRAWING NUMBER
REV. NO.
SCHEDULED INSPECTION DATE & TIME
ACTUAL INSPECTION DATE & TIME
A1
REFERENCE
SAES-N-110,
Para. 5.1
Only qualified personnel who are thoroughly experienced with pneumatic

application (gunning) of refractory lining are employed for this work.
SAES-N-110,
Para. 9.4.1
See Note 3.
A3
Only qualified personnel who are thoroughly experienced with cast

application of refractory lining are employed for this work.
See Note 3.
SAES-N-110,
Para. 9.6.1
Crew prequalification tests were completed on a test panel to the

production thickness for Refractory Installer application methods:
A4
EC / PMCC / MCC NO.
A) Gunning (pneumatic application)

B) Casting
SAES-N-110,
Para. 11.2.1
C) Vibration casting
A5
Documented evidence of application crew's prequalification is available

to Refractory Inspector (for his review & approval) prior to production.
SAES-N-110,
Para. 11.2.2
A6
On gunned materials, each nozzleman has gunnited a test panel

1mX1m size with a lining thickness equal to the production lining
thickness with the panel position simulating equipment position during
production.
SAES-N-110,
Para. 11.2.3
A7
On vibration cast materials, applicators have taken a mock up test

employing the same prequalified refractory materials, vibrating
equipment & mixing procedure that will be used in production work.
Note: A test panel shall be constructed and the back side of sample shall
be visually examined.
SAES-N-110,
Para. 11.2.4
A8
Cast or gunned test panels were cured for 24 hours, hammer tested &
visually inspected for correct curing. Test samples were acceptable &
free of voids, cracking, deformation, or honeycombing.
SAES-N-110,
Para. 11.2.6
A9
Metallic-fiber reinforced refractory test panels are to be cut into four

pieces. Cut edges are examined for dispersion of metallic fibers,
laminations, inclusions, & voids.
SAES-N-110,
Para. 11.2.7
Page 1 of 4
MH's SPENT
TRAVEL TIME
WORK PERMIT REQUIRED?
PASS
Castable Refractory Qualification & Testing for Applicators (SAES-N-110 Procedure, See Notes)
See Note 2.
A2
PLANT NO.
SAUDI ARAMCO USE ONLY
CONTRACTOR INSPECTION LEVEL
Refractory Applicators meet any specific Refractory Manufacturer

training & experience qualifications for specific type refractory installed.
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
FAIL
N/A
RE-INSP DATE
Rev 3

& Inspector for Refractory Installations
PROJECT TITLE
ITEM
No.
B.
B1
SAIC NUMBER
SAIC-N-2019
ACCEPTANCE CRITERIA
REFERENCE
30-Jun-08
DATE APPROVED
15-Dec-09
QR NUMBER
MECH-
PASS
FAIL
N/A
Extreme Erosion Resistant Refractory Qualification & Testing for Applicators (SAES-N-120 Procedure, See Notes)
Refractory Applicators meet any specific Refractory Manufacturer
training & experience qualifications for specific type refractory installed.
SAES-N-120,
Para. 5.1
See Note 2.
B2
Procedure & crew prequalification testing was carried out by Refractory

Installer prior to any lining (production work).
SAES-N-120,
Para. 12.2.1
B3
Documented evidence of the application crew's prequalification was

made available to the Refractory Inspector prior to production.
SAES-N-120,
Para. 12.2.2
B4
Two 600 mm x 600 mm test panels of hexsteel welded to 6 mm thick

plate were lined with refractory and cured for 48 hours minimum.
SAES-N-120,
Para. 12.2.3
B5
After 48 hours of air curing, test panels also passed a hammer test:
A) Test panel surface was lightly struck with 1-pound
ball peen hammer
B) No audibly notable voids were found
C) No evidence of insufficient hardness of
refractory was found.
D)
Questionable or defective refractory (dead dull sound) was not found.
SAES-N-120,
Para. 12.2.8
After 48 hours of curing, test panels passed a visual exam as follows:
B6
B7
A) No cracks 1/8" and larger were found

B) No cracks deeper than 20% of refractory
thickness were found
C) No
holidays (voids, honeycombs) were found.
D) No visual evidence of insufficient curing was found.
E) No visual evidence of physical damage was
found
When a crew fails to pass a qualification test, crew & procedure are
changed to improve mixing & application. Tests are repeated with final
test result acceptable to the Refractory Inspector.
SAES-N-120,
Para. 12.2.8
SAES-N-120,
Para. 12.2.4
B8
Installer has clearly identified all qualification test panels & stores them
properly (until completion of the refractory application production work).
SAES-N-120,
Para. 12.2.3
C.
API RP 936 (When Testing of Cut Sections is Specified by Manufacturer)
C1
Applicators are experienced & capable of meeting specified quality

standards for monolithic refractory (Castable or plastic refractories
applied by casting, gunning, or hand/ram packing to form monolithic
lining structures) by qualification testing (API RP936, Definition 3.2, 3,11)
SAES-N-100,
Section 3.2
Satisfactory examination & test results serve to qualify the mixing and
installation procedures & the nozzleman/gun operator teams as follows:
C2
D.
D1
A) Test panel (with removable back for visual castable inspection) is

sectioned (18 hours after completion) with cut surfaces inspected for
voids, laminations, non-uniformities & rebound entrapment.
B) Tested specimens cut from each panel comply to the physical
property standards for density, permanent linear change, and
cold crushing strength or abrasion resistance. (API RP936, 8.3)
SAES-N-100,
Section 3.2
FIRECLAY BRICK REFRACTORY QUALIFICATION FOR APPLICATORS for SAES-N-130 Procedure (See Notes Below)
Fireclay Brick Refractory Installers are responsible (qualified) to install
refractory systems per the requirements of SAES-N-130 & the specific
requirements of Refractory Manufacturers & Equipment Manufacturers.
Note: ONLY qualified personnel who are thoroughly experienced with the
refractory application shall be employed for & perform work.
Page 2 of 4
SAES-N-130,
Section 5
RE-INSP DATE
Rev 3
SAIC NUMBER

PROJECT TITLE
E1
SAIC-N-2019
ITEM
No.
ACCEPTANCE CRITERIA
30-Jun-08
DATE APPROVED
REFERENCE
QR NUMBER
15-Dec-09
MECH-
PASS
FAIL
N/A
RE-INSP DATE
Refractory Ceramic Fiber REFRACTORY QUALIFICATION FOR APPLICATORS for SAES-N-140 Procedure (See Notes Below)
RCF Refractory Installers are responsible (qualified) to install refractory
systems per the requirements of SAES-N-140 & specific requirements of
Refractory Manufacturers & Equipment Manufacturers.
Note:
ONLY qualified personnel who are thoroughly experienced with the
refractory application shall be employed for & perform work.
SAES-N-140,
Section 5
AUTHORIZE INSPECTORS FOR REFRACTORY INSTALLATIONS (PER SA STDs & API RP 936, Section 1.4)
Refractory Inspector has been authorized by SA Inspection Dept to

inspect specific refractory installations per SA standard requirements
Note 1: CV has been presented to Company & approved prior to work.
F1
Note 2: Inspector has satisfactory verifiable experience in application.
SAES-N-Series,
Section 4,
Definition
Note 3: Inspector meets Schedule Q, Sect 3.3 minimum experience

requirements for Sr. Inspector (8 yrs overall, 5 years in refractory, 3
years Oil & Gas)
Alternatively, an API 936 certified Inspector is used (Best Practice)
F2
Inspector shall have no commercial affiliations with contractor or

manufacturer(s), unless otherwise agreed to by Saudi Aramco.
(API RP 936, 6.1)
SAES-N-100,
Section 3.2
F3
Inspector demonstrates a working knowledge of API 936 requirements,

owner specs (SAES-100 thru 140), job specific requirements (SATIPs,
etc) & Refractory system manufacturer specific requirements. (detailed
instructions).
(API RP 936, 6.3)
SAES-N-100,
Section 3.2
REMARKS:
REFERENCE DOCUMENTS:
1. SAES-N-100 -- Refractory Systems (30 Jan 2007)
2. SAES-N-110 -- Installation Requirements-Castable Refractories (30 Jan 2007)
3. SAES-N-120 -- Installation Requirements-Extreme Erosion Resistant Refractories (30 Jan 2007)
4. SAES-N-130 -- Installation Requirements-Fireclay Bricks (30 Jan 2007)
5. SAES-N-140 -- Installation Requirements-Refractory Ceramic Fiber (30 Jan 2007)
6. API RP 936-Refractory Installation Quality Control Guidelines-Inspection & Testing Monolithic Refractory Lining & Materials (Nov-2008)
ATTACHMENTS: None
NOTES:
1. This checklist applies to installers following the specific procedures in SAES-N-110, 120 , 130 & 140 as applicable to their workscope.
ONLY qualified personnel who are thoroughly experienced with the refractory application shall be employed for work & listed on roster
2. Manufacturer Instructions (Not Attached) relative to experience are also followed. Applicators meet manufacturer's minimum requirements listed.
3. Contractor provides a work history of the applicators on his roster to show their experience in a particular application along with any special
manufacturer specified training. A roster shall list the names and positions of all personnel and be counted toward Schedule Q required Insp ratios.
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
QC Supervisor
Proponent and Others

Quality Record Approved:
Name, Sign and Date:
T&I Witnessed
Name, Organization,
Initials and Date:
Page 3 of 4
Rev 3
SAIC NUMBER

PROJECT TITLE
ITEM
No.
SAIC-N-2019
ACCEPTANCE CRITERIA
Quality Record Approved:
Name, Sign and Date:
REFERENCE
30-Jun-08
DATE APPROVED
15-Dec-09
QR NUMBER
MECH-
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 4 of 4

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