SAUDI ARAMCO ID/PID - 2/19/05 - REV 0 (Standards Cutoff - August 2004)

SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Furnace Dryout SAIC-N-2030 25-May-05 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.

LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.

SCHEDULED INSPECTION DATE & TIME ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

A. General Requirements (SAES-N-110 & SAES-N-120 Applications, See Note 1)

All new linings are cured & dried out per the Refractory Manufacturer's SAES-N-110,
A1
recommendations &/or standard procedures of SAES-N-110 Section 10 Para. 10.1.1

Checklists SAIC-N-2025, SAIC-N-2026 & SAIC-N-2027, SAIC-N-2028 &

A2 as referenced
SAIC-N-2029 are complete including In-process inspection/sampling.
Dryout by Furnace use is initial controlled heating of refractory linings SAES-N-110,
A3 raised to temperatures near their service temperature after curing to Section 4,
achieve required physical properties of lining at its service temperature. Definition

B. Furnace Dryout Specific Requirements (SAES-N-110 & SAES-N-120 Procedure, See Note 1)

New linings were first cured then dried out per Refractory Manufacturer SAES-N-110,
B1
recommendations and/or SAES-N-110/SAES-N-120 procedure. Para. 10.1.1

During dryout, the equipment is properly supported to prevent damage to SAES-N-110,

B2
the lining and equipment (at elevated temperatures). Para. 10.1.2

Adequately calibrated temperature measuring devices are installed to SAES-N-110,

B3
monitor the temperature. Para. 10.3.1

When dryout is by auxiliary burners, temperature monitoring is provided SAES-N-110,

B4
on the gas outlet and burner areas. Para. 10.3.1

The maximum dryout temperature is controlled* on lined equipment. SAES-N-110,

B5
See Note 2. Para. 10.3.2
When dryout is done in a furnace, the temperature measuring devices
SAES-N-110,
B6 are installed on the refractory side & on external surfaces of equipment
Para. 10.3.3
(Skin) to indicate differentials between metal & refractory temperatures.
Unless otherwise specified by the Refractory Manufacturer, minimum SAES-N-110,
B7
hold times during dryout are 1 hour per 25 mm of refractory thickness. Para. 10.3.4
SAES-N-110,
B8 Lined equipment is not moved during curing (& dryout).
Para. 10.2.4
Dryout inspection (SAES-N-110, Figure 1 Checklist) are as follows:
A) Firing equipment used is in good condition & meets procedure
B) Burner locations spacing relative to refractory is checked SAES-N-110,
B9
C) Dryout schedule is available & meets procedure Para. 11.6
D) Thermocouple locations are identified & meet the procedure
E) Recording equipment is available & calibrated & meets procedure

C. Inspection Requirements After Dryout (SAES-N-110 or SAES-N-120 Procedure, Attachment 1)

All inspection is performed per Saudi Aramco Inspection Requirement SAES-N-110,

C1
Form 175-328110 & SAES-N-110/120 procedure. See Attachment 1. Para. 11.1.1

Visual examination (Cracking evaluation) & Hammer Test is performed SAES-N-110,

C2
after the furnace dryout per SA Form 175-328110, Line Item 26. Para. 11.1.1

Lining cracks found AFTER DRYOUT are repaired when they are 3 mm SAES-N-110,
C3
wide and larger and when the depth exceeds 20% refractory thickness. Para. 11.5.4

Page 1 of 4
SAUDI ARAMCO ID/PID - 2/19/05 - REV 0 (Standards Cutoff - August 2004)
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Furnace Dryout SAIC-N-2030 25-May-05 MECH-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
At completion of furnace dryout, the lining is randomly checked for voids
or damaged areas by lightly striking it with a 1-pound hammer:
SAES-N-110,
C4 A) The refractory is free of voids (no dead, dull sounds)
Para. 11.3.6
B) The refractory has sufficient hardness (when struck).
C) The refractory has not disbonded from the equipment surface
The size of dull sounding areas are investigated & samples test results SAES-N-110,
C5
are compared before a decision is made on removal of the refractory. Para. 11.3.6
After Dryout, Refractory found to be defective due to presence of voids,
honeycombs, insufficient hardness, disbond & other damage* is marked SAES-N-110,
C6
by the Inspector for total removal to full thickness of lining layer. Para. 11.3.7
*See Note 3.

D. Inspection of Exterior Surfaces After Dryout

After Dryout, temporary supports are removed & surfaces have no heat SAES-N-110,
D1
distortion or mechanical damage from the Dryout procedure. Para. 10.1.2

Inspector checks all heated exterior surfaces closely for evidence of hot
SAES-N-110,
D2 spots, distortion in equipment surfaces, and other related heat damage
Para. 11.3.7
after Dryout operations have been completed.

REMARKS:

REFERENCE DOCUMENTS:
1. SAES-N-100 -- Refractory Systems (30 November 2004)
2. SAES-N-110 -- Installation Requirements-Castable Refractories (30 November 2004)
3. SAES-N-120 -- Installation Requirements-Extreme Erosion Resistant Refractories (30 November 2004)
4. API RP936 -- Refractory Installation Quality Control Guidelines—Inspection and Testing Monolithic Refractory Linings and Materials (Feb 2004)
ATTACHMENTS:
1. Attachment 1 -- SA Form 175-328110 Castable Refractories
2 Attachment 2 -- API RP 936 Table 5, Dryout Schedule
NOTES:
1. This checklist applies to Furnace Dryout inspection for castable refractory systems detailed in both procedure SAES-N-110 & SAES-N-120.
2. The dryout plan for newly installed refractory includes key control elements to be monitored by the INSPECTOR (API RP936, Section 6.2 ).
A) Heat up/cool down rates for all control temperature indicators
B) The maximum difference between temperature indicators.
C) Heating rates are monitored by thermocouples closest to the heat source.
D) The hold temperatures and durations are achieved at all thermocouples including those at gas exits of the newly installed refractory.
E) When specified by manufacturer, Table 5 of API RP936 shall be used. See Attachment # 2
F) When cool down is included in the dryout work scope, cooling rates shall not exceed 150°F (85°C) per hour.
3. Final visual inspection after furnace dryout identifies Hot or Explosive Spalling (trapped moisture explodes/dislodges refractory) & bloating/bulges.
The Inspector checks low points (floors) for evidence of spalling. Equipment & Low points are absolutely clean prior to dry-out. After dry-out, any
spalled concrete is easily identified by the presence of refractory chunks & debris on the floor or at low points. On finding evidence of such damage,
the Refractory Inspector can call for scaffolding to reach suspect areas for further investigation & any necessary repairs. A usual cause of explosive
spalling is too rapid a heating rate where entrapped water becomes steam & explodes. Bloating (bulges) occur in plastic subsurface lining systems.

Contractor / Third-Party Saudi Aramco

Construction Representative* PMT Representative
Work is Complete and Ready for Inspection: T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:

QC Inspector PID Representative

Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:

QC Supervisor Proponent and Others

Quality Record Approved: T&I Witnessed QC Record Reviewed Work Verified
Name, Organization,
Name, Sign and Date:
Initials and Date:

*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FAILED

Page 2 of 4
SAUDI ARAMCO ID/PID - 2/19/05 - REV 0 (Standards Cutoff - August 2004)
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Furnace Dryout SAIC-N-2030 25-May-05 MECH-

Attachment 1 -- SA Form 175-328110 Castable Refractories

Page 3 of 4
SAUDI ARAMCO ID/PID - 2/19/05 - REV 0 (Standards Cutoff - August 2004)
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Inspection of Furnace Dryout SAIC-N-2030 25-May-05 MECH-

Attachment 2 -- API RP 936 Table 5, Dryout Schedule

Page 4 of 4