Inspection and Test Plan

SPECIFICATION: SAES-N-110
REFRACTORY INSTALLATION TO 8 HEATERS AT 2220 JIZAN
SAES-N-130, SAES-N-140
REFINERY
W.P. / Description : REFRACTORY INSTALLATION

Doc. No: 16-JRTP-02-ITP

Rev : 01

Date: 21/3/2016
Responsibility

Inspection / Test Stage

Reference Document

Acceptance Criteria

Verifying Documents
CAPE RB H

TR

SAUDI ARAMCO

1.0 PRE-PRODUCTION REQUIREMENTS

1.1 PROCEDURE SUBMITTALS
1.1.1 Inspection and Test Plan (ITP)

16-JRTP-02-ITP

S. ARAMCO

Approved ITP

1.1.2 Method Statement

16-JRTP-01-MS

S. ARAMCO

Approved M.S

SAES-N-110

Section 7

AFI / FORM NO: 008

SAES-N-110

Section 9.1.7 &

Product Data Sheet

AFI / FORM NO: 008

SAES-N-110

Section 9.1.6

AFI/FORM NO: 009

SAES-N-110

Section 8.1

AFI/FORM NO: 009

2.1.3 Anchor Layout as per drawing (if provided)

Anchor layout drawing

Approved drawing

AFI/FORM NO: 009

2.1.4 Application of surface coating to internal surface

Anchor layout drawing

Approved drawing

AFI/FORM NO: 009

1.2 MATERIAL HANDLING AND STORAGE

1.2.1 Material Storage
1.2.2 Condition of refractory materials

2.0 IN - PROCESS INSPECTION & TESTING

2.1 SURFACE PREPARATION
2.1.1 Weather Protection of work area
2.1.2

Surface free from oil, excessive rust, loose

mill scale.

2.2 FORM WORK / SHUTTERING APPLICATION

2.2.1

Correct type and size of Form work installed

SAES-N-110

Section 11.2.3

AFI/FORM NO: 012

2.2.2

Correct method used for the formwork installation

SAES-N-110

Section 9.6.2 & 11.2.3

AFI/FORM NO: 012

---

2.3 GUNNITING APPLICATION

2.3.1

Verify water ratio and temperature of water

SAES-N-110

Section 9.1.11;
Section 9.1.12

AFI/FORM NO: 011

2.3.2

Verify lining surface temperature and ambient temperature

SAES-N-110

Section 9.1

AFI/FORM NO: 011

2.3.3

Correct method used for gunning

SAES-N-110

Section 9.4

AFI/FORM NO: 011

2.3.4

Verify thickness of refractory to be installed

Approved drawing

approved drawing

AFI/FORM NO: 011

2.3.5

Production sample casting and marking

SAES-N-110

Section 11.3

AFI/FORM NO: 015

2.3.6

Curing

SAES-N-110

Section 10.2

AFI/FORM NO: 011

Page 1 of 13

Inspection and Test Plan

SPECIFICATION: SAES-N-110
REFRACTORY INSTALLATION TO 8 HEATERS AT 2220 JIZAN
SAES-N-130, SAES-N-140
REFINERY
W.P. / Description : REFRACTORY INSTALLATION

Doc. No: 16-JRTP-02-ITP

Rev : 01

Date: 21/3/2016
Responsibility

Inspection / Test Stage

Reference Document

Acceptance Criteria

Verifying Documents
CAPE RB H

TR

SAUDI ARAMCO

2.4 CASTABLE REFRACTORY APPLICATION

2.4.1 Verify water ratio and temperature of water

SAES-N-110

Section 9.1.11;
Section 9.1.12

AFI/FORM NO: 010

2.4.2 Verify lining surface temperature and ambient tempure.

SAES-N-110

Section 9.1.4 & 9.1.5

AFI/FORM NO: 010

2.4.3 Mixing of refractory castable

SAES-N-110

section 9.5

AFI/FORM NO: 010

Approved drawing

Approved drawing

AFI/FORM NO: 010

2.4.5 Production sample casting and marking

SAES-N-110

Section 11.3

AFI/FORM NO: 015

2.4.6 Curing

SAES-N-110

Section 10.2

AFI/FORM NO: 010

Approved drawing

------

AFI/FORM NO:013

2.5.2 Brick lining method

SAES-N-130

Section 6

AFI/FORM NO:013

2.5.3 Verify the staggering of bricks

SAES-N-130

Section 6

AFI/FORM NO:013

Approved drawing

2.4.4 Verify thickness of refractory to be installed

2.5 BRICK LINING APPLICATION

2.5.1 Type of material as per drawing / agreed for the contract

2.5.4 Verify the thickness of installed bricklining

-----

AFI/FORM NO:013

------

-----

AFI/FORM NO:013

2.6.1 Orientation of studs

As per approved drawing specification

Approved drawing

AFI/FORM NO:014

2.6.2 Type of ceramic fiber blanket

As per approved drawing specification

Approved drawing

AFI/FORM NO:014

2.5.5 Excess mortar removed

2.6 RCF APPLICATION

2.6.3 Joints (Lap / butt joint)

2.6.4 Verify thickness of installed blanket
2.6.5 Verify Orientation / Securement of blanket lining

SAES-N-140

Section 9.1.2

AFI/FORM NO:014

As per approved drawing specification

Approved drawing

AFI/FORM NO:014

----

Approved drawing

AFI/FORM NO:014

---

AFI/FORM NO: 010 & 011

Section 11.3.6

AFI/FORM NO: 010 & 011

3.0 FINAL INSPECTION AND TESTING

3.1 Visual inspection after curing of casting and gunniting
3.2 Hammer Test

---SAES-N-110

Page 2 of 13

Inspection and Test Plan

SPECIFICATION: SAES-N-110
REFRACTORY INSTALLATION TO 8 HEATERS AT 2220 JIZAN
SAES-N-130, SAES-N-140
REFINERY
W.P. / Description : REFRACTORY INSTALLATION

Doc. No: 16-JRTP-02-ITP

Rev : 01

Date: 21/3/2016
Responsibility

Inspection / Test Stage

Reference Document

Acceptance Criteria

Verifying Documents
CAPE RB H

TR

SAUDI ARAMCO

4.0 FINAL DOCUMENTATION AND PACKAGE REVIEW

4.1 All Documents in file

----

All inspection documents signed

by client inspector

ITP & Inspection forms

H&R

4.2 Final Acceptance & release

----

Final Acceptance Certificate

----

H&R

Legend :
H = Hold Point
Surveillance

W = Witness (if no show, work may proceed)

R = Record and/or review
Cape RBH

SAUDI ARAMCO

TR

S=

SAUDI ARAMCO

Comments

Name

Approved

Sign

Approved with
comments

Date

To be resubmitted

Page 3 of 13

APPLICATION FOR INSPECTION

INSP. DATE:
INSP. TIME:
RECEIVING INSP:

IN-PROCESS INSP:

FINAL INSPECTION:

OTHER: (specify)

PROJECT:

EQPT. TO BE INSPECTED:

CONTRACT NO:
SITE LOCATION:
ATTENTION OF:
REQUESTED BY:

AREA LOCATION:
REF. DWG. / SPECS.:
DISCIPLINE:

TYPE OF INSPECTION
VISUAL

DIMENSIONAL

WITNESS

TEST

ITEM DESCRIPTION:

SUMMARY OF RESULTS:

DISPOSITION:
PROCEED TO NEXT STAGE

REWORK / REPAIR

PUNCH LIST ITEMS

REMARK:

CAPE RB HILTON SA LTD

TR

SAUDI ARAMCO

PRINT NAME
SIGNATURE
DATE

Form: AFI

Page 4 of 13

Project Name

Contract Number

Project Location

J. O. No.

MATERIAL INSPECTION AND ACCEPTANCE RECORD

EQUIPMENT / TAG NO. :

AREA :

REPORT NO. :

DATE :

SERVICE DESCRIPTION :

SYSTEM

REF. DRWG NO. :

TYPE OF MATERIAL & MANUFACTURER

ITP NO. :
ITP STEP NO. :
COMPLIANCE
YES

1. INSPECTION REQUIREMENTS
1.1

Material conformity to specification.

1.2

Material conformity certificates (pre-shipment test certificates)

1.3

Material Data sheets

1.4

Visual condition of material acceptable upon receipt

1.5

Material stored properly

For items marked "NO" raise punchlist and categories "A" for completion
as prior to next stage or "B" - those items which can be rectified after
completion of testing.

NO

Punchlist Attached
YES
NO

N/A

P/list No.

REMARKS:

APPROVED BY:
CAPE RB HILTON SA LTD

TR

SAUDI ARAMCO

NAME:
SIGNATURE:
DATE :

Form No. 008

Page 5 of 13

Page 6 of 13

Project Name

Contract Number

Project Location

J. O. No.

INSPECTION RECORD FOR SURFACE PREPARATION

EQUIPMENT / TAG NO. :

AREA :

REPORT NO. :

DATE :

SERVICE DESCRIPTION :

SYSTEM

REF. DRWG NO. :

TYPE OF MATERIAL & MANUFACTURER

ITP NO. :
ITP STEP NO. :
COMPLIANCE
YES

1. INSPECTION REQUIREMENTS

NO

N/A

1.1 Weather Proofing of Work Area

1.2 Refractory anchors installed correcly
1.3 Hammer test of anchor (random selection)
1.4

Surface to be lined is free of oil, dust, loose mill scale or other foreign
materials.

1.5 Internal surface coating

1.6 Ventilation

For items marked "NO" raise punchlist and categories "A" for completion
as prior to next stage or "B" - those items which can be rectified after
completion of testing.

Punchlist Attached
YES
NO

P/list No.

REMARKS:

APPROVED BY:
CAPE RB HILTON SA LTD

TR

SAUDI ARAMCO

NAME:
SIGNATURE:
DATE :

Form No. 009

Page 7 of 13

Project Name

Contract Number

Project Location

J. O. No.

INSPECTION RECORD FOR REFRACTORY CASTING APPLICATION

EQUIPMENT / TAG NO. :

AREA :

REPORT NO. :

DATE :

SERVICE DESCRIPTION :

SYSTEM

REF. DRWG NO. :

TYPE OF MATERIAL & MANUFACTURER

ITP NO. :
ITP STEP NO. :
COMPLIANCE
YES

1. INSPECTION REQUIREMENTS
1.1

Check condition of refractory material

1.2

Check environmental conditions (I.e. ambient temp., equipment temp., water and dry
material temperature)

1.3

Check mixing of refractory castable

1.4

Check placement of refractory castable

1.5

Shuttering or Form Works

1.6

Vibration, spade or puddle rodding of castable

1.7

Check curing

1.8

Check presence of cracks (more than 3mm not acceptable)

1.9

Hammer Test

For items marked "NO" raise punchlist and categories "A" for completion
as prior to next stage or "B" - those items which can be rectified after
completion of testing.

NO

N/A

Punchlist Attached
YES
NO

P/list No.

REMARKS:

APPROVED BY:
CAPE RB HILTON SA LTD

TR

SAUDI ARAMCO

NAME:
SIGNATURE:
DATE :

Form No. 010

Page 8 of 13

Project Name

Contract Number

Project Location

J. O. No.

INSPECTION RECORD FOR REFRACTORY GUNNING APPLICATION

EQUIPMENT / TAG NO. :

AREA :

REPORT NO. :

DATE :

SERVICE DESCRIPTION :

SYSTEM

REF. DRWG NO. :

TYPE OF MATERIAL & MANUFACTURER

ITP NO. :
ITP STEP NO. :
COMPLIANCE
YES

1. INSPECTION REQUIREMENTS

NO

N/A

1.1 Application Prequalification

1.2

Check environmental conditions (I.e. ambient temp., equipment temp.,

water and dry material temperature)

1.3 Check proper consistancy of the material through gunning

1.4 Check placement of refractory castable
1.5 Trimming of surface and its roughness
1.6 Check curing
1.7 Check presence of unacceptable cracks
1.8 Hammer Test of refractory lining
1.9 Final Inspection

For items marked "NO" raise punchlist and categories "A" for completion
as prior to next stage or "B" - those items which can be rectified after
completion of testing.

Punchlist Attached
YES
NO

P/list No.

REMARKS:

APPROVED BY:
CAPE RB HILTON SA LTD

TR

SAUDI ARAMCO

NAME:
SIGNATURE:
DATE :

Form No. 011

Page 9 of 13

Project Name

Contract Number

Project Location

J. O. No.

INSPECTION RECORD FOR FORM WORK / SHUTTERING APPLICATION

EQUIPMENT / TAG NO. :

AREA :

REPORT NO. :

DATE :

SERVICE DESCRIPTION :

SYSTEM

REF. DRWG NO. :

TYPE OF MATERIAL & MANUFACTURER

ITP NO. :
ITP STEP NO. :
COMPLIANCE
YES

1. INSPECTION REQUIREMENTS
1.1

NO

N/A

Check for correct type, size and surface of formwork (for casting and gunning only)
coated with layer of releasing agent

1.2 Shuttering installed correctly (where required)

1.3 Verify thickness of installed formwork as per drawing

For items marked "NO" raise punchlist and categories "A" for completion
as prior to next stage or "B" - those items which can be rectified after
completion of testing.

Punchlist Attached
YES
NO

P/list No.

REMARKS:

APPROVED BY:
CAPE RB HILTON SA LTD

TR

SAUDI ARAMCO

NAME:
SIGNATURE:
DATE :

Form No. 012

Page 10 of 13

Project Name

Contract Number

Project Location

J. O. No.

INSPECTION RECORD FOR BRICK LINING APPLICATION

EQUIPMENT / TAG NO. :

AREA :

REPORT NO. :

DATE :

SERVICE DESCRIPTION :

SYSTEM

REF. DRWG NO. :

TYPE OF MATERIAL & MANUFACTURER

ITP NO. :
ITP STEP NO. :
COMPLIANCE
YES

1. INSPECTION REQUIREMENTS
1.1

Condition of refractory material

1.2

Mortar mixing

1.3

Brick handled carefully

1.4

Chipped or broken bricks not used

1.5

Brick laying as per specification and drawing

1.6

Sufficient mortar applied to each brick

1.7

Set bricks driven firmly into place

1.8

Excess mortar scraped off

1.9

Expansion joints left free of mortar,dust and other contaminants

For items marked "NO" raise punchlist and categories "A" for completion
as prior to next stage or "B" - those items which can be rectified after
completion of testing.

NO

Punchlist Attached
YES
NO

N/A

P/list No.

REMARKS:

APPROVED BY:
CAPE RB HILTON SA LTD

TR

SAUDI ARAMCO

NAME:
SIGNATURE:
DATE :

Form No. 013

Project Name

Contract Number

Project Location

J. O. No.

INSPECTION RECORD FOR RCF INSTALLATION

EQUIPMENT / TAG NO. :

AREA :

REPORT NO. :

DATE :

SERVICE DESCRIPTION :

SYSTEM

REF. DRWG NO. :

TYPE OF MATERIAL

MANUFACTURER

COMPLIANCE
YES

1. INSPECTION REQUIREMENTS
1.1

Condition of insulation material

1.2

Orientation of studs

1.3

Blankets installed in accordance with manufacturer's detailed drawing

1.4

Verify the thickness and securement of installed blanket / module

1.5

Method of joining (lap joint / butt joint method) used for installation of
blanket.

1.6

Surface Appearance

For items marked "NO" raise punchlist and categories "A" for completion
as prior to next stage or "B" - those items which can be rectified after
completion of testing.

NO

Punchlist Attached
YES
NO

N/A

P/list No.

REMARKS:

APPROVED BY:
CAPE RB HILTON SA LTD

TR

SAUDI ARAMCO

NAME:
SIGNATURE:
DATE :

Form No. 014

Castable & Gunning Refractory Production Sample Log Sheet

Site /Location:

ITP NO:

SN Sample
Number

Time
Sampled

Date
Sampled

Type of
Material

CAPE RB HILTON

Date:

Batch/Pallet
Number

Method of
Application

TR

Amb
Dry
Temp Temp

Steel
Temp

Water
Temp

Mixing
Temp

LOCATION

SAUDI ARAMCO

Name:
Signature:
Date
FORM NO: 015

Page 13 of 13