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

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

In-Process Inspection of Refractory Applied by Vibration

Casting
PROJECT TITLE

SAIC-N-2027
WBS / BI / JO NUMBER

EQUIPMENT ID NUMBER(S)

EQUIPMENT DESCRIPTION

LAYOUT DRAWING NUMBER

REV. NO.

SCHEDULED INSPECTION DATE & TIME

ACTUAL INSPECTION DATE & TIME

PLANT NO.

EC / PMCC / MCC NO.

MH's SPENT

TRAVEL TIME

SAUDI ARAMCO USE ONLY

CONTRACTOR INSPECTION LEVEL

REFERENCE

General Requirements (SAES-N-110 procedure, Section 9)

A1

Checklist SAIC-N-2024 was completed & accepted for Pre-Application

requirements related to casting of refractory.

As Referenced

A2

Correct Material & Application Method is being used for equipment

with casting of refractory per SAES-N-100, Tables 2 & 3. See Note 1.

As Referenced

B.

Mixing Refractory for Casting Applications (SAES-N-110 Procedure, Section 9)

B1

Mixing of refractory materials is done in a paddle type mixer.

SAES-N-110,
Para. 9.5.1

B2

Only full contents of refractory bags or drums are placed in the mixer.
Fractional parts of the bag or drum are not used.

SAES-N-110,
Para. 9.5.2

B3

When fiber reinforcement is used, the fibers are added to the mixer
through a wire mesh screen with approximately 12 mm openings.

SAES-N-110,
Para. 9.5.3

B4

The quantity of refractory material that is mixed in one mixing does not
exceed the quantity that can be placed prior to initial set or 15 minutes
after addition of water, whichever is shorter.
Note: Mixed Materials not used within this time (15 minutes) shall be
discarded.

SAES-N-110,
Para. 9.5.4

B5

Precautions exist to prevent the separation of aggregates and cement

prior to placement.

SAES-N-110,
Para. 9.5.4

B6

Water used is a minimum amount to give achieve proper consistency for

placement & does not exceed the Manufacturer's specified amount.

SAES-N-110,
Para. 9.5.5

B7

The "Ball in Hand" Test (Per ASTM C860) is used to determine the
correct consistency. See Attachments 1 (Procedure) & Attachment 2
(Photos).

SAES-N-110,
Para. 9.5.6

C.

Application of Refractory by (Vibration) Casting

C1

Only qualified personnel who are thoroughly experienced with cast

application of refractory lining are employed for this work.

SAES-N-110,
Para. 9.6.1

C2

Refractory materials are manufactured specifically for vibration casting

and are fine grain with even distribution.

SAES-N-110,
Para. 9.7.1

C3

Additives used to promote flow are used in strict accordance with the
Refractory Manufacturer's instructions.

SAES-N-110,
Para. 9.7.2

C4

Forms used shall be made of steel sheet and shall be rigidly

constructed.

SAES-N-110,
Para. 9.7.3

C5

Surfaces in contact with the lining are uniform, reasonably smooth, and
were suitably coated to prevent bonding of refractory to the forms.

SAES-N-110,
Para. 9.6.2

Page 1 of 5

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

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

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

In-Process Inspection of Refractory Applied by Vibration

Casting
PROJECT TITLE

SAIC-N-2027
WBS / BI / JO NUMBER

ITEM
No.

ACCEPTANCE CRITERIA

REFERENCE

C6

Forms allow easy removal without damage to the refractory.

SAES-N-110,
Para. 9.6.2

C7

Refractory is applied in a manner that will minimize section segregation.

SAES-N-110,
Para. 9.6.3

C8

Refractory is compacted with care by vibrating to avoid material

segregation & damage to previously applied portions of the lining, or
damage to the equipment.

SAES-N-110,
Para. 9.6.4

C9

Work does not stop until a panel or section is complete & when work is
resumed, the contact surface of the lining in place is thoroughly cleaned,
roughened & wetted with quality water (with excess water removed).

SAES-N-110,
Para. 9.6.5

C10

Curing is carried out whenever the application is interrupted.

SAES-N-110,
Para. 9.6.6

E.
E1

30-Jun-08
DATE APPROVED

QR NUMBER

15-Dec-09

MECH-

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

In-Process Inspection & Testing (COMPLETE SATR-N-2001)

Inspection & Testing was performed per SAES-N-110 Procedure & SA
Inspection Requirement Form 175-328110. See Attachment 3.

SAES-N-110,
Para. 11.1.1

E2

Two (2) Production test samples were taken once per shift or each
change of nozzleman/installer (1 sample to lab, 1 sample site stored &
cured)
The samples from materials being cast are taken from mixer & cast into
molds.

SAES-N-110,
Para. 11.3.1
&
Para. 11.3.2

E3

Samples taken during production are tested for cold crushing strength &
density per ASTM C133, ASTM C134 & ASTM C862 .

SAES-N-110,
Para. 11.3.2

E4

Refractory Installer keeps an accurate log of installation so that location

of refractory that is presented by the production samples can be
determined in case it becomes necessary to remove this refractory.

SAES-N-110,
Para. 11.3.5

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)
ATTACHMENTS:
1. Attachment 1 -- ASTM C-860 (Ball in Hand Test) Procedure
2. Attachment 2 -- ASTM C-860 (Ball in Hand Test) Figures 2, 3 & 4 (Photographs)
3. Attachment 3 -- SA INSP FORM 175-328110 (Refractories)
NOTES: 1. Use Table 2 & 3 Mandatory Refractory Systems of SAES-N-100 (Not Attached) for Pre-installation inspection checks of materials.

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

Name, Initials and Date:

QC Inspector

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:

Name, Organization,
Initials and Date:

*Person Responsible for Completion of Quality Work / Test

Y = YES

Page 2 of 5

N = NO F = FAILED

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

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

In-Process Inspection of Refractory Applied by Vibration
Casting

SAIC NUMBER

SAIC-N-2027

30-Jun-08
DATE APPROVED

15-Dec-09

QR NUMBER

MECH-

Attachment 1 -- ASTM C-860 (Ball in Hand Test) Procedure

5. Sampling
5.1 A representative handful of freshly mixed castable should be drawn from the center of the mixer while the mixer is not running.

6. Procedure
6.1 Preparation of Castable:
6.1.1 Load the mixer with dry castable to an appropriate level so as to allow proper mixing action by the mixer but not so much as to
cause dry or wet castable to splash out of the mixer.
6.1.1.1 The amount of water required to reach the consistency specified in 6.2 increases as the dry volume loading of a mixer
drops below 40 % of its capacity. This occurs because the percentage of the total water required to wet the mixer surfaces
increases with decreased volume loading.
6.1.2 Dry mix the castable for the manufacturers recommended dry mixing time or until the castable appears to be fully mixed.
6.1.3 Start the mixer and note the time. Add 90 % of the estimated water requirement over a period of 30 s. If a water content
specified by the manufacturer is available, it should be used to calculate this amount. Then add additional water in small amounts
and continue mixing until the batch appears to have the desired ball-in-hand consistency specified in 6.2.
6.1.3.1 The moisture content of lightweight, porous aggregates can affect the water demand of a castable. Dry aggregates can
change the consistency of a castable after mixing is completed by absorbing the mixing water into its pores. This can cause
premature stiffening and poor consolidation of the castable.
6.1.4 Total actual wet mixing time, including water additions, should be 3 min +/- 10 seconds for dense castables, 5 min +/- 10
seconds for insulating castables, 4 to 6 min for mixes needing heavy vibration, and at least 5 min for castables containing
deflocculating admixtures (to allow for wet-out) such as low cement castables (LCC) or ultra-low cement castables (ULCC). These
recommendations do not override any specified by the manufacturer.

6.2 Ball-in-Hand Test: (Figure 2 = Too much water, Figure 3 = Too little water, Figure 4 = Proper Consistency)
6.2.1 Prepare the castable in accordance with 6.1.
6.2.2 While the mixer is off, remove a handful of castable from the center of the mixer.
6.2.3 Form a fist-sized compact ball of the mix with the hands (see Fig. 2, Fig. 3, and Fig. 4). Toss it upward about 1 ft (300 mm),
and catch it in one hand with the fingers spread slightly apart. The proper consistency and variations are illustrated in Figs. 2-4.

6.2.3.1 Precaution: If the castable contains metal fibers, the operator must wear a heavy rubber glove to
prevent the needles from cutting or otherwise injuring his hand.

Attachment 2 -- ASTM C-860 (Ball in Hand Test) Figures 2, 3 & 4

In Figure # 2, it slips through the fingers. In Figure # 3, the dry ball is solid on the impact. In Figure # 4, proper consistency exists

Page 3 of 5

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

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

In-Process Inspection of Refractory Applied by Vibration

SAIC-N-2027
Casting
Fig. 2 (TOO MUCH WATER)
Fig. 3 (TOO LITTLE WATER)

Page 4 of 5

30-Jun-08
DATE APPROVED

15-Dec-09

QR NUMBER

MECH-

Fig. 4 (GOOD)

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

Rev 3

SAUDI ARAMCO INSPECTION CHECKLIST

In-Process Inspection of Refractory Applied by Vibration
Casting

SAIC NUMBER

SAIC-N-2027

30-Jun-08
DATE APPROVED

15-Dec-09

Attachment 3 -- SA INSP FORM 175-328110

Page 5 of 5

QR NUMBER

MECH-