Refractory Method Statement of Refractory Liquid Burn Pit

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METHOD STATEMENT-REFRACTORY INSTALLATION Rev. No 01
PROCEDURE Date 2-september-2019
Page 1 of 15
INDEX
1. OBJECTIVE 2
2. SCOPE 2
3. REFRENCES 2
4. RESPONSIBILITIES
3
5. DEFINITIONS 4
6. GENERAL INFORMATION ABOUT INSTALLATION 5
7. PROTECTION AGAINST ATMOSPHERIC EXPOSURE 7
8. MATERIALS
7
9. TOOLS
7
10. DESCRIPTION OF WORKS

8
11. QUALITY CONTROL (QA/QC)

12
12. HEALTH AND SAFETY PROTECTION

13
13. CHECK LIST 15

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1. OBJECTIVE
This method of statement describes the actions and works to install the refractory lining and refractory bricks in the
liquid back up burn pit project in Abqaiq, in the best conditions of work and safety.
2. SCOPE
This method of statement will/can be used as an installation procedure for installing the Refractory Lining and Bricks in
the Liquid Back Up Burn Pit Project.
3. REFERENCES
Supply and installation of refractory materials will be made according with the following Saudi Aramco Standards:
- SAES-N-100: Installation Requirements-Refractory Systems.
- SAES-N-110: Installation Requirements - Monolithic Refractories.
- SAES-N-130: Installation Requirements-Fireclay Bricks.
- SAES-N-140: Installation Requirements-Refractory Ceramic Fiber.
- SAIC-N-2027: In-process Inspection of Refractory Applied by Vibration Casting.
- SAIC-N-2040: In-process Inspection of Fireclay Brick Installation
- PIP RFEG 1000: Guidelines for use of Refractory Practices
- PIP RFSB 2000: Brick Refractory Installation Procedure
- API – 936: Refractory Installation Quality Control Guidelines-Inspection and Testing Monolithic Refractory
Linings and Materials
- GI - 2.100: Work Permit System
- Schedule Q – Quality Requirements
- Manufacturers ITP shall be aligned with Saudi Aramco Typical Inspection & Test plans
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4. RESPONSIBILITIES:
Operations Manager
The Operations Manager shall be responsible for scheduling and execution of all activities in the project, planning
required resources to complete the refractory installation, including documentation, verification by the owner and/or
owner's representative and ensuring the implementation of the Company’s Quality & Safety Policies and loss prevention
program for the entire project. He will control the entire gamut of site operations. Knowledgeable of Refractory
application techniques, specific client and Govt. regulations and enforce them in the assigned project. Prepares work
instructions for the employees in Management grade Controls emergency. Ensures that accident reports are prepared,
reviewed with root cause analysis, action plan for elimination and distribution of reports in time. Maintains discipline at
site. Communicates daily activities, accident report etc., to the client as per the client’s requirements and at regular
interval. Maintains close liaison with the client engineers and attends the meetings.
Quality Inspector
The inspector shall be responsible for monitoring the skill of applicators, quality of work, compliance with the project's
specifications, and review of all quality check list. Quality inspector shall be responsible for the effective implementation
of companies. Quality Policy at all levels in the assigned talk.
Site Supervisor
The Execution Supervisors will report to the Project Manager for the installation related matters. Enforces company’s
Safety, Quality policies at the assigned work site. Maintains discipline and initiates disciplinary action, wherever
necessary. Directly deals with emergencies. Conducts weekly and daily safety meetings. Continuous monitoring of the
work site and ensures productivity without compromising on Safety and quality. Provide guidance to the refractory
technicians (Masons, Carpenter & Helper etc.) with the help of installation drawings and method illustrations to fulfill
the requirements stipulated by client and refractory manufacturer. Knowledgeable of the client rules and regulations.
Maintains liaison with Site Manager and Safety Engineer/Officer in resolving safety issues.
All Other employees
Complies with client policies. Ensures that all activities performed fulfill the quality and safety requirement of client and
refractory manufacturer. Reports hazards. Reports injuries & near misses. Be physically fit and mentally alert. Operates
vehicles / equipment in a safe and prescribed manner. Operates or repairs equipment only when authorized. Follows
personnel safety and conduct rules at all times. Uses appropriate personal protective equipment
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5. DEFINITIONS
ANCHOR: Metallic or refractory device that holds the refractory or insulation in place.
BIO-SOLUBLE CERAMIC FIBER: Manmade vitreous fiber (MMVF) composed of at least 18 % alkaline earth oxides
developed to meet the fiber exemption requirements spelled out in 97/69/EC of the Dangerous Substances Initiative in
the EU. These fibers are exonerated from the EU carcinogen classification based on their low bio-persistence. They also
may be known as bio-fiber, bio-soluble, or low bio-persistence fiber.
BIO-SOLUBLE CERAMIC FIBER MODULE: Construction of fibrous refractory insulation in stacked/folded blankets or
monolithic form, commonly with an integrated attachment system.
CASTABLE: A combination of refractory grain (aggregate) and suitable bonding agent that, after the addition of a proper
liquid, is installed into place to form a refractory shape or structure that becomes rigid because of thermal or chemical
action.
CASTING: Installation system that is made by pouring the concrete in a formwork, floor or horizontal surface.
FORMWORK: Prefabricated piece (usually metallic or wooden) that allows reproducing the shape of a surface, part or
element, for the pouring of concrete.
GUNNING: Application of a dry monolithic refractory through a pressure system while water is injected into dry mix at
the point application. Unlike other processes, the refractory is pumped into a hose by an air pressure system as a dry
mix. The water does not enter or mix with the refractory until the dry mix is pumped into spray gun nozzle. The water
meets the dry mix just moments before it is applied to a surface
GUNNING MACHINE: Machine capable of moving compressed air through concrete and projecting it in its place of
installation.
MIXER: Machine capable of mixing and homogenizing concrete with water to give it the necessary properties for its
installation.
REFRACTORY: Non-metallic materials whose physical and chemical properties make them applicable for structures or as
components of systems exposed to temperatures above 540ºC. Although their primary function is resistance to high
temperatures, they are also installed as protection for abrasion, chemical attacks and thermal cycles.
SELF-LEVELING: Property of a material that allows the effect of gravity to position itself in such a way that it occupies a
perfect leveling in its upper part.
VIBROCASTING: Installation system in which, once the concrete has been poured into a formwork, vibration is applied to
increase the fluidity of the concrete and thus consolidate it into the shape of the formwork.
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6. GENERAL INFORMATION ABOUT INSTALLATION
6.1 MATERIAL STORAGE
The refractory castable shall be stored in a dry, well-ventilated area and separated from the ground by pallets. If stored
outdoors, the bags will be protected from rain or dripping water by a cover. Storage areas with high humidity or
stagnant water will be avoided.
The storage on site will be done in an orderly manner, to avoid mixing pallets of different lots, so that the consumption
of them will provide a clear traceability of the installed materials.
No more than 3 pallets should be stacked when stored. This is to prevent consolidation and compaction of material in
the lower rows of the pallets.
The original packaging will not be opened before use. Bags that appear open or damaged should be discarded.
Prior to placement, all refractory shall be protected from water and moisture and Materials shall be stored according to
the refractory manufacturer’s specifications in accordance with the paragraph 7.1 & 7.2 of specifications SAES-N-110.
The Refractory Manufacturer's precautions, as specified on the MSDS sheets, must be strictly followed in accordance
with the paragraph 7.3 of specifications SAES-N-110.
Prior to placement, refractory bricks shall be protected from mechanical and water damage as per the paragraph 7.1 of
specifications SAES-N-130.
The Refractory Manufacturer's precautions, as specified on the MSDS sheets, must be strictly followed in accordance
with the paragraph 7.2 0f specifications SAES-N-130.
6.2 MATERIAL INSPECTION
An inspection must be carried out regarding the completeness of all material according to shipping documents and parts
lists. Spot checks should be carried out in order to verify the proper condition of the materials.
An inspection of the material received at the site will be carried out to check the total accordance with the shipping
documents and the bill of materials (BOM).
The form of Receipt of Materials must be filled in and enclosed in the Quality Dossier and sent to the technical office if it
receives changes. Likewise, it will be immediately informed of the lack of material, damages or defects so that the
replacement of the materials can be done without delay. It will be verified that the material comes in packaging
according to the specifications and clearly identified with the lot number and the type/brand of product.
Random checks are also carried out to verify the correct situation of the materials.
Monitoring of material consumption is required. If more refractory material than estimated is used it’s required to
communicate this issue to the Project Manager specifying the reasons. All materials that show signs of being used
(hardness or lumps in the mixture) must be rejected and removed from the workplace.
The main problems that arise in the manipulation and use of materials are the mistake in their selection and the lack of
control of them, both reasons that always cause difficulties. The materials must be handled carefully and economically.
Poor installation increases the consumption of materials.
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6.3 SURFACE PREPERATION
All surfaces shall be clean, dry, and free from oil, grease, weld slag, and mil Scale prior to installation of refractory in
accordance with the paragraph 8.1 of specifications SAES-N-110.
For application not requiring coating, all metallic surfaces shall be blasted in accordance with Refractory
Designer/Manufacturer in accordance with the paragraph 8.2 of specifications SAES-N-110.
Surfaces that were previously coated with a vapor barrier or that are heavily corroded shall be brush blasted in
accordance with SSPC SP 7 in accordance with the paragraph 8.3 of specifications SAES-N-110.
Surface cleaning in accordance with SSPC SP 3 shall be acceptable only for limited area such as spot grinding for repairs
in accordance with the paragraph 8.4 of specifications SAES-N-110.
Surfaces to be lined shall be inspected and approved prior to refractory installation by Refractory Inspector as per the
paragraph 9.1.3 of specifications SAES-N-110.
Due to the relative humidity of the environment it is advisable not to delay the refractory installation beyond 30 days
after cleaning the surfaces.
Never clean with water.
6.4 ANCHORS
For concrete surface, holes shall be drilled as per the approved drawings and anchors shall be fixed in the using of steel
wall fisher/hollow screws.
Quality Inspector shall verify the anchors have been duly fixed by hammer test.
6.5 STEEL CONSTRUCTION
The superintendent responsible for the refractory works is not responsible for the correctness of the concrete structure.
However, he must verify the correct measurements of the concrete structure in the area of the refractory work prior to
commencing installation of the refractory materials. Mainly the diameters and the length of all the different pieces that
compound the thermal oxidizer and heater should be cross checked with the specific drawings.
The inaccuracies of the concrete in the area of the refractory lining affect the installation of the refractory materials, the
consumption, thicknesses, formwork, fittings, anchorages, etc. In case of deviation in any parameter, the work will be
paralyzed, and the circumstance should be reported to the project manager and to those responsible for the client or
the manufacturer metallurgical contractor.
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6.6 MIXING WATER
The liquid used to mix refractory shall comply with the manufacturer’s guidelines as per the SAES-N-110
Application of castable refractory shall be by the Refractory Manufacturer’s guidelines.
Surfaces to be lined shall be inspected and approved prior to refractory installation by Refractory Inspector.
The liquid used to mix refractory shall comply with the manufacturers’ guidelines.
The liquid ratios as specified by the Refractory Manufacturer shall be used.
The temperature of the liquid and refractory shall be controlled so that the mixed refractory is between 10°C and 25°C.
The water amount required for the specific refractory grade (except gunning refractory) is indicated in the datasheet of
the material. This amount may not be exceeded. If the right consistency has been attained, it will, in most cases, be
possible to form a ball with the fist which begins to flow upon slightly (ball in hand test). If the ball crumbles the mix is
too dry. If it flows immediately it is too wet. For gunning refractory material, the amount of water required is regulated
at the gunning nozzle.
6.7 FORMWORK
For installation work by casting, a formwork must be manufactured that reproduces the interior surface of the
equipment and serves as a complete mould of the piece to be able to make the pouring continuously until completion.
7.PROTECTION AGAINST ATMOSPHERIC EXPOSURE
The construction site must be protected for the duration of the installation in order to prevent damages to the
refractory lining. Further to that, appropriate measures must be taken to prevent water from penetrating the refractory
lining.
Prior to placement, all refractory shall be protected from water and moisture.
Materials shall be stored according to the refractory manufacturer’s specifications.
The Refractory Manufacturer's precautions, as specified on the MSDS sheets, must be strictly followed.
8.MATERIALS
All refractory shall be used on site, must be in suitable identified containers and hermetically closed. The people in
charge of the work, through the Work Order shall know the necessary data to the material’s suitable installation.
Once all the refractory material has been verified, the accepted material shall be gathered on site and will be protected
from weather (Rain or direct sunlight). The person in charge of the work shall take note the arrival date of each
refractory, writing the trade name and quantity.
The refractory material is supplied ready to use mixing with water only, packed in carton sacks of 25kg. There is no need
to mix any other component except water, prior to installation.
9.TOOLS
The following machinery shall be used in this project:

- Paddle Mixer 350 kg.
- Air compressor 7 kg/cm3; 10m3/min.
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- Diesel generator 80KVA; 380V-63A.

- Forklift 2.5 T.
- Brick Cutting machine
- Masonry Tools
- Carpentry tools
10. DESCRIPTION OF WORKS
10.1 CASTABLE INSTALLATION THROUGH CASTING
Cast able& water shall be mixed in a paddle type mixing machine in accordance with the
SAES-N-110, which is cleaned of previously mixed cast able prior to adding of materials for subsequent batch.
Mixing of refractory materials shall be done in a paddle type mixer.
Only full contents of refractory bags or drums shall be placed in the mixer. Fractional parts of a bag or drum shall not be
used.
When fiber reinforcement is added in the field, the fibers shall, be added to the mixer through a wire mesh screen with
approximately 12 mm openings in order to obtain proper fiber distribution.
All refractory shall be placed within the Refractory Manufacturer's recommended time limits. Refractory that is not used
within specified time limit shall be discarded.
The amount of liquid shall be as per the Refractory Manufacturer's specified amount.
Care must be taken not to mix cement & in-organic materials into cast able. The duration of paddle machine mixing shall
be kept to the minimum necessary for through mixing. Prolonged mixing shall be avoided.
Refractory Inspector shall monitor crew prequalification testing to be carried out by the Refractory Installer prior to any
lining. This requirement shall apply to gunning, casting or vibration casting a panel to the production thickness.
Only Qualified experienced with cast application of refractory lining shall be employed for this work in accordance with
the paragraph 9.4.1 of specifications SAES-N-110.
Forms shall be rigidly constructed and sufficiently tight to prevent excessive leakage. The surfaces that are in contact
with the lining shall be uniform, reasonably smooth, and suitably coated to prevent bonding of refractory to the forms.
Forms shall be designed to facilitate their removal without damage to the refractory.
Refractory shall be compacted by spading or vibrating. Compacting shall be done with care to avoid segregation, damage
to previously applied portions of the lining, and damage to the equipment.
Work shall not be terminated until a panel or section is complete. When work is resumed, the contact surface of the
lining that is in place shall be thoroughly cleaned, roughened, and wetted with liquid of a quality as outlined in 9.1.7. Any
excess liquid shall be removed.
The refractory materials to be used shall be manufactured specifically for vibration casting in accordance with the
paragraph 9.7.1 of specifications SAES-N-110.
Additives to promote flow shall not be used in the field and Forms used shall be rigidly constructed equipment in
accordance with the paragraph 9.7.2 & 9.7.3 of specifications SAES-N-110.
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10.2 Pre-Qualification Testing:
Two (2) Production test samples should be taken once per shift or each change of nozzle man/installer (1 sample to lab,
1 sample site stored & cured). The samples from materials being cast should be taken from mixer & cast into molds as
per the paragraph 11.3.1 & 11.3.2 of specifications SAES-N-110.
Samples taken during production are tested for cold crushing strength & density per ASTM C133, ASTM C134 & ASTM
C862 as per the paragraph 11.3.2 of specifications SAES-N-110.
Refractory Installer should keep 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 as per the paragraph
11.3.5 of specifications SAES-N-110.
As per the paragraph 11.6 of specifications SAES-N-110 should follow the check list for cast able refractory installation.
BRICKS WORK
Prior to starting brick application, main dimensions, e.g. data for brick laying shall be checked. Marking & layout shall be
in accordance with the installation drawing in accordance with the paragraph 8.3 of specifications SAES-N-130.
Bricks shall be handled carefully to avoid chipping of edges or cracking, or damaged bricks shall not be used.
Expansion joints shall be installed in accordance with the refractory design as per the paragraph 6.1 of specifications
SAES-N-130.
All brick lining shall be supported per the design drawings. All refractory supports shall be austenitic alloy material as per
the paragraph 6.2 of specifications of SAES-N-130
Mortar shall be mixed to a uniform toweling consistency using electric hand mixer machine with a clean stirring paddle.
Mortar thickness between bricks shall not exceed 2 mm in accordance with the paragraph 6.4 of specifications SAES-N-
130.
Care shall be exercised not to include such foreign matters as bricks chips & debris.
No bricks shall be cut and used below 50% of its original thickness or 50 mm whichever is greater. No two cut bricks shall
be installed adjacent to each other in accordance with the paragraph 6.6 of specifications SAES-N-130.
Manual cutting or chipping of bricks is not allowed, and the use of steel shims is prohibited in accordance with the
paragraph 6.7 & 6.5 specifications of SAES-N-130.
Bricks* (both dry laid & mortared) are installed plumb, straight & square per approved IFC drawings and the integrity of
the bricks used (complete or sections) is acceptable as per the paragraph 8.3 of specifications SAES-N-130.
Refractory bricks shall be laid tight against the shell or backup insulation & shall be laid staggered or in bonded
construction, through joints must be avoided.
As per the paragraph 6.8 specifications of SAES-N- 130, Key bricks position in adjacent rings shall be staggered.
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As per the paragraph 8.3 specifications of SAES-N- 130,

MATERIALS are checked as follows:
A) Types of materials supplied are correct B) Data sheets & mixing instructions are available C) MSDS sheets are
available D) Mortar shelf life
Installation procedure of Burn pit refractory
Front wall:
The following steps are involving in the application process according to specified thickness in the given drawing
Step 1: Surface preparation:
Clean the surface with brush or compressed air thoroughly before start application of refractory. The surface area must
free from foreign material as per surface preparation standards
Step 2: Anchor fixing:
Clean the surface thoroughly. Mark the location on the surface as specified in the drawing by given anchor spacing or
pitch. Drill the holes at the mark location. To ensure making orientation of the anchors as per drawing. Check the
dimension of the anchor before installation. Follow hammer test on fixed anchors with no failure.
Step 3: Calcium silicate board installation:
Check the thickness and product details of calcium silicate board before starting the installation. Cut into pieces as per
site requirement. Fix it tightly to the surface as per the drawing mentioned. Near the anchor, fill the gap with loose
ceramic blanket as per client requirement.
Step 4: Insulation castable installation (Alfran Lite 10-14):
Shutter preparation:
Plan for installation of refractory as per specifications (Shutter details, panel length, from which area lining must be
start. Make a shuttering in such a way that it’s not more than the expansion joints as per specifications. Shuttering
details can be either wooden or metal but ensure shuttering must strong enough to bear the load of material, if required
provide the further supports. Apply coat of grease/oil at shuttering surface for easy removal.
Mixing, casting and shutter removal:
Check the material details from the supplier datasheet. Charge by the known quantities of castable in the mixer. Clean
the mixer thoroughly before charging. Should follow the mixing instructions as per the manufacturer recommendation.
Use the right quality of water or refractory liquid to the refractory castable as per manufacturer standards and SAES.
Should follow and maintain this entire procedure in mentioned application temperatures
Add water slowly as per the requirement without stopping the mixer. Check the workability/consistency by ball in hand
method. Then pour the refractory wet mixed castable into the prepared forms and level by vibrator but shuttering
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should be straight and free from warpage. After casting process, observe the workability behavior of material to remove
the shutters. Check and ensure proper setting of castable to remove all supports provided for fixing the shuttering one
by one. Don’t apply heavy force for removing, if heavy force is applied for removing it will disturb the castable. Remove
shutter slowly.
Step 5: Dry out
Dry out shall be carried as per the submitted procedure AFN-DR-3007
Step 6: Brick lining (Alfran G30 + Alfran 40/42+ Sairset mortar):
Should check all the materials as per supplier data sheet before starting the installation. Refractory lining must be laid as
per drawing. Should follow the mixing instructions as per the datasheet and storage recommendation also. First layer
must install with extreme care in multi layers. The mortar must apply uniformly on the surface of the brick. Mortar
thickness should not be more than 2mm as per SAES. In any case of usage of cutting brick, the cutting brick should be
more than 50% of the brick from the original length as per SAES-N-130. Should follow and provide expansion joints and
free from any contamination also. Check the vertical and horizontal of brick lining for every layer of installation with the
help of straight edges, leveling instrument. For brick alignment and compactness use wooden hammer. Don’t apply too
much force for aligning and compactness the brick, it will damage the surface of the brick.
Side wall:
Step 7: Surface preparation
Step 8: Anchor fixing:
Clean the surface thoroughly. Mark the location on the surface as specified in the drawing by given anchor spacing or
pitch. Drill the holes at the mark location. To ensure making orientation of the anchors as per drawing. Check the
dimension of the anchor before installation. Follow hammer test on fixed anchors with no failure.
Step 9: Calcium silicate board installation:
Step 10: Brick lining (Alfran 40/42+ Sairset mortar):
Should check all the materials as per supplier data sheet before starting the installation. Refractory lining must be laid as
per drawing. Should follow the mixing instructions as per the datasheet and storage recommendation also. First layer
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must install with extreme care in multi layers. The mortar must apply uniformly on the surface of the brick. Mortar
thickness should not be more than 2mm as per SAES. In any case of usage of cutting brick, the cutting brick should be
more than 50% of the brick from the original length as per SAES-N-130. Should follow and provide expansion joints and
free from any contamination also. Check the vertical and horizontal of brick lining for every layer of installation with the
help of straight edges, leveling instrument. For brick alignment and compactness use wooden hammer. Don’t apply too
much force for aligning and compactness the brick; it will damage the surface of the brick.
Floor:
Step 11: Surface preparation
Step 12: Calcium silicate block:
Step 13: Installation procedure of Brick lining at Floor (Alfran 40/42):
The floor bricks are loosely applied (without mortar) as per SAES-N-130. The brick lining must be laid as per drawing.
Check the vertical and horizontal of brick lining for every layer of installation with the help of straight edges, leveling
instrument. For brick alignment and compactness use wooden hammer. Don’t apply too much force for aligning and
compactness the brick, it will damage the surface of the brick.
Inspection:
After lining installation check for uniformity and make inspection report. During the installation should maintain
document evidence log sheets for in process work
11. QUALITY ASSURANCE AND QUALITY CONTROL (QA/QC).
To control the outcome of the refractory lining installation is necessary check all the process during the preparation,
application and cleaning.
Is necessary to control the following points:
- Preparation of the wall surfaces and coating installation.

- Marking of Anchor and drilling.
- Production control of manufactured materials.
- Mixing of materials with water in proper quantities, use of water according to specifications.
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- Cleaning during and after the application.
- SATIP should be strictly followed.
12 HEALTH AND SAFETY PROTECTION GUIDELINES
12.1 Toolbox Meetings and Safety meetings
A Toolbox talk at work site and preparatory workshop are shall be performed before the start of work on a shift basis to
highlight the potential risks linked to the planned work. Alfran Project managers will attend all HSE meetings held by the
client. Provided information as well as all regulations and measures issued by the client will be promptly transmitted to
the Alfran workers.
12.2 Job site emergency plan
Assembly points are marked at Site & Camp. There will be "stop work alarm" or loudspeaker announcement in case of
Emergency. Employees are to follow the instructions listed below.
1. All work in progress is stopped immediately
2. All Equipment's, machineries, heating devices and Vehicle are stopped immediately.
3. All men are evacuated to pre–determined assembly point.
4. A roll call is taken, and every man has shall be accounted for.
5. No one is permitted to return to work until notification has been received from company representative that it is safe
to do so.
12.3 House Keeping
Alfran believes that Work safety at site can only be ensured if the site is properly maintained with good housekeeping.
Therefore, all material scrap, debris, packaging and other waste items will be removed regularly to the designated area
for waste disposal by the client. Equipment and machineries shall be arranged and placed such a way that no one can be
injured. Cables shall be routed, whenever possible in a manner that no access and transport path is hindered. All access
ways, stairs, ladders and work platforms shall always be kept clean and free for unhindered use.
12.4 Waste disposal
Generally, the waste disposal shall be organized in accordance to the guidelines for the specific waste disposal
requirements issued by the client. Besides this, a detailed guideline of the waste disposal practice is comprised in the
Alfran installation procedure. The resulting waste from the refractory installation job is collected separately and the
disposal is performed by as per the specific instruction of the client.
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12.5 Fall protect ion
Workplaces and access ways located 1.8 m above the ground need shall be secured against fall by means of a side
protection or barriers. Holes and openings in the ground shall always be covered in such a manner that their crossing is
secured, and no one is injured. All personnel working / accessing areas 1.8 m and higher above grade / continuous floor
level must wear a full body harness with double shock absorbing lanyards. When exposed to a potential free fall
exceeding 1.8 meters one lanyard must be secured to a suitable anchorage prior to the fall exposure and while exposed.
Every working level has to be arranged as a closed platform. The material transport slot has shall be secured by handrail
and the man way of the platform with bottom flap.
12.6 Personal protection equipment
Before starting the works, the supervisor will comprehensively inform all employees with regard to the usage and
handling of the personal protection equipment. The job site supervisor as walls the safety manager will be in charge of
monitoring whether the protection equipment is worn by the personnel.
Body protection: All employees shall wear at the job site the usual working gear made of cotton. Only in case of danger
related to a specific hazard, other gear shall be introduced.
Hand protection: For manual work, in case of injury risk for the hands, the wearing of leather work gloves is mandatory.
For works with liquids or acids, appropriate rubber gloves shall always be used.
Foot protection: appropriate safety work shoes with acid-resistant, firm sole and additional shoe upper-side
protection/Steel toe are mandatory.
Head protection: The wearing of hard hat is binding on the job site.
Eye protection: Approved Safety Glasses with side shields are required at all times in active construction areas.
Hearing protection: Wherever possible, noise will be kept low and hearing protection shall be used. The areas are
marked through respective signs.
Gas masks: In case of health danger through inhalation of hazards particles or hazardous gas, gas mask is mandatory.
The type of masks to be worn is dependent on the type of hazardous substance and its concentration in the surrounding
air. The following personnel protective equipment of brands approved by Client shall be made available to all the
employees at site always. Safety hats, Safety shoes, Safety belt, Dust Mask, Face shields, Goggles, Hand gloves.
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13. ATTACHEMENT (Check List)
- SAIC-N-2027: In-process Inspection of Refractory Applied by Vibration Casting.
- SAIC-N-2040: In-process Inspection of Fireclay Brick Installation

SAUDI ARAMCO ID/PID - 24-Mar-2016 - REV. 2015.09.01 (Standards Cutoff - September 6, 2015) Rev. 2015.09.01 6-Sep-15
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
In-Process Inspection of Refractory Applied by Vibration
SAIC-N-2027 24-Mar-16 CIVIL-IREF
Casting
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
INSTALL BACKUP LIQUID BURNPIT PROJECT AT ABQAIQ BI-10-02100 ODICO- ALFRAN
EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.
IN-PROCESS INSPECTION OF REFRACTORY APPLIED BY VIBRATION CASTING ABQ
LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.
429 - Q - TA - 271945 - 001 - 00 (ALFRAN NMR 601)
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?
SATIP-N-110-01 3.6
SAUDI ARAMCO INSPECTION LEVEL
W
CONTRACTOR INSPECTION LEVEL
H
YES
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
A. General Requirements (SAES-N-110 procedure, Section 9)
Checklist SAIC-N-2024 was completed & accepted for Pre-Application

A1 As Referenced
requirements related to casting of refractory.
Correct Material & Application Method is being used for equipment

A2 As Referenced
with casting of refractory per SAES-N-100, Tables 2 & 3. See Note 1.
B. Mixing Refractory for Casting Applications (SAES-N-110 Procedure, Section 9)
SAES-N-110,
B1 Mixing of refractory materials is done in a paddle type mixer.
Para. 9.5.1
Only full contents of refractory bags or drums are placed in the mixer. SAES-N-110,
B2
Fractional parts of the bag or drum are not used. Para. 9.5.2
When fiber reinforcement is used, the fibers are added to the mixer SAES-N-110,
B3
through a wire mesh screen with approximately 12 mm openings. Para. 9.5.3
All refractory shall be placed within the Refractory Manufacturer's

SAES-N-110,
B4 recommended time limits. Refractory that is not used within specified
Para. 9.5.4
time limit shall be discarded.
The amount of liquid shall be as per the Refractory Manufacturer's SAES-N-110,

B6
specified amount. Para. 9.5.5
C. Application of Refractory by (Vibration) Casting
The refractory materials to be used shall be manufactured specifically for SAES-N-110,

C1
vibration casting. Para. 9.7.1
SAES-N-110,
C2 Additives to promote flow shall not be used in the field.
Para. 9.7.2
SAES-N-110,
C3 Forms used shall be rigidly constructed.
Para. 9.7.3
Saudi Aramco: Company General Use

Casting
ITEM
No.
E. In-Process Inspection & Testing (COMPLETE SATR-N-2001)
Inspection & Testing was performed per SAES-N-110 Procedure & SA SAES-N-110,
E1
Inspection Requirement Form 175-328110. See Attachment 3. Para. 11.1.1
Two (2) Production test samples were taken once per shift or each
SAES-N-110,
change of nozzleman/installer (1 sample to lab, 1 sample site stored &
Para. 11.3.1
E2 cured)
&
The samples from materials being cast are taken from mixer & cast into
Para. 11.3.2
molds.
Samples taken during production are tested for cold crushing strength & SAES-N-110,
E3
density per ASTM C133, ASTM C134 & ASTM C862 . Para. 11.3.2
Refractory Installer keeps an accurate log of installation so that location

SAES-N-110,
E4 of refractory that is presented by the production samples can be
Para. 11.3.5
determined in case it becomes necessary to remove this refractory.
REMARKS:
REFERENCE DOCUMENTS:
1. SAES-N-100 -- Refractory Systems (15 August 2012)
2. SAES-N-110 -- Installation Requirements-Castable Refractories (22 July 2012)
3. SAES-N-120 -- Installation Requirements-Extreme Erosion Resistant Refractories (11 April 2012)
ATTACHMENTS:
1. Attachment 1 -- 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: T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:
YACOB MISFER ABDULLATIF
QC Inspector PID Representative
Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified
M.ABDUL NABI MARVIN MONTENEGRO
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:
SOHAIL AHMED KHAN
*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FAILED

Casting
Attachment 1 -- SA INSP FORM 175-328110

In-Process Inspection of Fireclay Brick Installation SAIC-N-2040 24-Mar-16 CIVIL-IREF
EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.
In-Process inspection of Fireclay brick installation ABQ
LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.
429 - Q - TA - 271945 - 001 - 00 (ALFRAN NMR 601)
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?
SATIP-N-130-01 3.3
SAUDI ARAMCO INSPECTION LEVEL
W
CONTRACTOR INSPECTION LEVEL
H
YES
ITEM
No.
A. General Requirements
Checklists SAIC-N-2037, SAIC-N-2038 & SAIC-N-2039 are complete &

As referenced
accepted. Materials are acceptable for use & properly staged for work.
B. Welded Support & Metal Enclosures for Firebrick (Prior to Brick Placement)
Welding is complete & accepted for firebrick support locations such as

SAES-N-130,
B1 lintels (metal shelves) & steel enclosures surrounding burners.
Para. 8.1
See Note 1.
PMI was performed on operationally important supports such as metal

support shelves (lintels) that support firebrick.
SAES-A-206,
B2 Note: PMI is required for operationally important nonpressure parts If
Para. 5.2.2
specified in a project design document, purchase order, or SAMS catalog
description,
The support shelf (lintel) material metallurgy is acceptable for surface

SAES-N-130,
B3 temperatures (per data sheet calculations) plus 10°C.
Para. 6.3
See Note 3.
Brick lining is supported by metal support shelves (lintels) welded to the

casing & centered a minimum 1.8 meters* - 6 feet (per API 560)
vertically. SAES-N-130,
B4
*Note: SAES-N-130 specifies 8 meters minimum which is a very high Para. 6.3
value while API-650 specifies 1.8 meters minimum, it appears there is an
error an inquiry will be made with the SAES-N-130 committee.
These metal support shelves (lintels) are slotted to provide differential SAES-N-130,
B5
thermal expansion. Para. 6.3
Brick lining on vertical flat casing is tied back & supported by structural SAES-N-130,
B6
steel framing members & tie members made of austenitic alloy material. Para. 6.2
Drawings show (Detail Note) that a minimum of 15 percent of the bricks SAES-N-130,
B7
are to be tied back. Verify this against the specification & drawings. Para. 6.2
Curved cylindrical casings where firebrick are installed with the "key" SAES-N-130,
B8
brick(s) do not require tie backs. Para. 6.2
C. Expansion Joint Details & Brick Layout (See Note 4)
Expansion joints shall be installed in accordance with refractory design.

SAES-N-130,
C1 Drawings must show Expansion joints provided in both vertical &
Para. 6.1
horizontal directions for walls, at edges, around burner tiles & doors.

ITEM
No.
D. Mixing Mortar & Work Set-up (For Installation Safeguards)
Brick mortar is mixed in a mechanical mortar mixer, not manually. SAES-N-130,

D1
Attachment 2 Para. 8.3
The quality of the mortar mixing water meets SA standards for water
SAES-N-130,
D2 quality (test certificate available) & is clean potable water.
Para. 8.1
(SA Form 175 - 328110 item 15) Attachment 2
The amount of potable water used is strictly controlled as per the

SAES-N-130,
D3 manufacturer's recommendations.
Para. 8.1
(SA Form 175 - 328110 item 16)m Attachment 2
Temperature of mortar is controlled & maintained between 10 ºc to 32ºc
SAES-N-130,
D4 or per manufacturer's recommendations.
Para. 8.1
(SA Form 175 - 328110 item 16) Attachment 2
SAES-N-130,
D5 Manual cutting or chipping of bricks is not allowed.
Para. 6.7
Samples are taken by independent lab & tested for quality (mortar, etc). SAES-N-130,
D6
(SA Form 175 - 328110 item 26) Attachment 2 Para. 8.1
E. Installation of Firebricks & Workmanship (SAES-N-130 Checklist)
SAES-N-130,
E1 Firebrick layout & installation meets detailed drawing dimensions.
Para. 8.3
SAES-N-130,
E2 Checklist for Refractory Brick Installation (refer to Attachment 1)
Para. 8.3
Bricks* (both dry laid & mortared) are installed plumb, straight & square SAES-N-130,
E3
per approved IFC drawings. *See Note 1. Para. 8.3
SAES-N-130,
E4 The integrity of the bricks used (complete or sections) is acceptable
Para. 8.3
REMARKS:
REFERENCE DOCUMENTS:
1. Schedule Q -- Quality Requirements (Project Specific)
2. SAES-N-100 -- Refractory Systems (15 Aug 2012)
3. SAES-N-130 -- Installation Requirements-Fireclay Bricks (11 April 2012)
3. SAES-A-206 -- Positive Material Identification (30 April 2011)
ATTACHMENTS:
NOTES:
1. The inspector ensures that firebrick floor installation inspections are performed "last" after completion of vertical & overhead work
and removal of scaffolding that can damage floor bricks & any refractory back up already set.
Contractor / Third-Party Saudi Aramco
Construction Representative* PMT Representative
Work is Complete and Ready for Inspection: T&I Witnessed QC Record Reviewed Work Verified
YACOB MISFER ABDULLATIF
QC Inspector PID Representative
Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified
M.ABDUL NABI MARVIN MONTENEGRO
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:
SOHAIL AHMED KHAN
*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FAILED

Attachment 1 -- CHECKLIST FOR REFRACTORY BRICk INSTALLATION

Attachment 1 -- SA INSP FORM 175-328110

Refractory Method Statement of Refractory Liquid Burn Pit

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6. GENERAL INFORMATION ABOUT INSTALLATION 5

7. PROTECTION AGAINST ATMOSPHERIC EXPOSURE 7

10. DESCRIPTION OF WORKS

11. QUALITY CONTROL (QA/QC)

12. HEALTH AND SAFETY PROTECTION

13. CHECK LIST 15

- SAES-N-100: Installation Requirements-Refractory Systems.

- SAES-N-110: Installation Requirements - Monolithic Refractories.

- SAES-N-130: Installation Requirements-Fireclay Bricks.

- SAES-N-140: Installation Requirements-Refractory Ceramic Fiber.

- SAIC-N-2027: In-process Inspection of Refractory Applied by Vibration Casting.

- SAIC-N-2040: In-process Inspection of Fireclay Brick Installation

- PIP RFEG 1000: Guidelines for use of Refractory Practices

- PIP RFSB 2000: Brick Refractory Installation Procedure

- GI - 2.100: Work Permit System

- Schedule Q – Quality Requirements

All Other employees

6. GENERAL INFORMATION ABOUT INSTALLATION

6.1 MATERIAL STORAGE

6.2 MATERIAL INSPECTION

6.3 SURFACE PREPERATION

Never clean with water.

6.5 STEEL CONSTRUCTION

6.6 MIXING WATER

Application of castable refractory shall be by the Refractory Manufacturer’s guidelines.

7.PROTECTION AGAINST ATMOSPHERIC EXPOSURE

The following machinery shall be used in this project:

- Diesel generator 80KVA; 380V-63A.

10. DESCRIPTION OF WORKS

10.1 CASTABLE INSTALLATION THROUGH CASTING

10.2 Pre-Qualification Testing:

As per the paragraph 8.3 specifications of SAES-N- 130,

Installation procedure of Burn pit refractory

Step 1: Surface preparation:

Step 2: Anchor fixing:

Step 3: Calcium silicate board installation:

Step 4: Insulation castable installation (Alfran Lite 10-14):

Mixing, casting and shutter removal:

Step 5: Dry out

Dry out shall be carried as per the submitted procedure AFN-DR-3007

Step 6: Brick lining (Alfran G30 + Alfran 40/42+ Sairset mortar):

Step 7: Surface preparation

Step 8: Anchor fixing:

Step 9: Calcium silicate board installation:

Step 10: Brick lining (Alfran 40/42+ Sairset mortar):

Step 11: Surface preparation

Step 12: Calcium silicate block:

Step 13: Installation procedure of Brick lining at Floor (Alfran 40/42):

11. QUALITY ASSURANCE AND QUALITY CONTROL (QA/QC).

Is necessary to control the following points:

- Preparation of the wall surfaces and coating installation.

- Cleaning during and after the application.

- SATIP should be strictly followed.

12 HEALTH AND SAFETY PROTECTION GUIDELINES

12.1 Toolbox Meetings and Safety meetings

12.2 Job site emergency plan

1. All work in progress is stopped immediately

3. All men are evacuated to pre–determined assembly point.

12.3 House Keeping

12.4 Waste disposal

12.5 Fall protect ion