SAIC-B-2001 Rev 2

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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - December 2005) Rev 2 31-Dec-05

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

SAIC-B-2001 1-Dec-06 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 ONLYSAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE

A General Requirements

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

Review Proprietary Fireproofing System & Procedure (Intumescent Epoxy Mastics & Lightweight Concretes)

ITEM No.

Proprietary Fireproofing Material System was approved by the Chief Fire Prevention Engineer as follows: A) Qualifying documentation of fireproofing material was submitted to the Chief Fire Prevention Engineer for approval. (Approval)B) Refer to Attachment 1 for proprietary fireproofing mat'l list for various applications in SA facilities. *Latest revision of SAES-B-006 is to be used with checklist.

SAES-B-006, Para. 8.2.1

See Note*

Application procedure approved by fireproofing manufacturer is submitted to Inspection Department (manager) for approval.

SAES-B-006, Para. 8.2.1

Procedure indicates the requirement for application personnel to be trained & certified by mat'l manufacturer. See Also SAIC-B-2002

SAES-B-006, Para. 8.2.2

Application section details: Application is in strict accordance with manufacturer's guidelines for temperatures, storage, materials, proportioning, mixing & other considerations (safety, cleaning, etc.)

SAES-B-006, Para. 8.2.3

Application procedure details QC steps & inspection points for inspection of surface preparation and reinforcement.

SAES-B-006, Para. 8.2.4

Application procedure details the required surface preparation of steel surface to be covered with intumescent or other proprietary fireproofing materials. (SAES-H-101, APCS-1B). Surface prep & coating system specified shall be referenced on all drawings.

SAES-B-006, Para. 8.4

Procedure application for intumescent material specifies a minimum wet thickness that will yield the required dry thickness (DFT). (API PUBL 2218, Para. 7.3.3.1) Note: Procedure details extent & location of checks to ensure adequate DFT (evaporation loss).

SAES-B-006, Para. 5.2 & 8.2.3

Procedure details top coating requirements & manner of application: A) See Attachment 1 (Cementitious per Para. 8.5) B) See Attachment 1 (Intumescent Epoxy per Para. 8.6)

SAES-B-006, Sect. 8.6

Procedure details the manner of applying the required top-coating approved by the fireproofing manufacturer.

SAES-B-006, Para. 8.6.4

Procedure Definition Section lists applicable SAES-B-006 & API Publication 2218 applicable definitions: A) Intumescent mastic: B) Fire-hazardous equipment: C) Fire-hazardous zone: D) Other applicable definitions (SAES-B-006, API 2218).

SAES-B-006, Section 4, Definitions

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A11

Procedure Mat'l Section lists applicable materials selected and states or infers (data sheet inference) their limits for application: A) Intumescent epoxy mastics (equipment or supports) such as Chartek 4, 7 (Int'l Coatings, Ltd.), Thermo-Lag 440 (Thermal Sci, Inc), Pitt-Char XP (PPG Industries, Inc.), or other approved material. B) Proprietary Intumescent epoxy coatings (Valve Actuators) like K-Mass® (Thermal Designs, Inc) or FR Coating™ (MOV Limited) C) Other proprietary coatings that meets Company requirements See also Sections B & C for specific application reqmts

SAES-B-006, Appendix 1

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A12

A13

A14

A15

A16

B Specific Requirements (Equipment & Supports)

B1

B2

C Specific Requirements (Actuators)


ITEM No.

Procedure Material Section lists material testing requirements for material qualification: A) Intumescent materials have been subjected to a test furnace environment per UL 1709 or equivalent fire exposure test procedure B) Fireproofing manufacturer has demonstrated no peel-back at edges or terminations in a fire situation for intended application. C) Other applicable tests performed to qualify materials


Procedure Material Section covers Top coating considerations (as required by Manufacturer). These are identified in procedure & Material Data sheet (two options): A) FP must be clean, dry & free of contaminants prior to top-coat.B) FP must be cured per mfg. recommendations prior to top-coat C) Top-coat with SA Stock No 1000194797 or 1000194960 applied to a dry-film thickness of 75 to 125 microns. (Option 1) D) Top-coat for proprietary fireproofing other than intumescent epoxy mastic as approved by fireproofing manufacturer & Company

SAES-B-006, Section 8.6

Material APPLICATION section is specific and breaks down the elements of the documentation package from manufacturer: A) Mfg. Data Sheet lists material's physical properties B) Mfg. Data Sheet lists specific applications & limits for materials C) Certified Report (fireproofing & environmental exposure tests) D) Material Safety Data Sheet (MSDS) listing hazards & precautions

SAES-B-006, Para. 8.2.1

Procedure details API Publication 2218 material application considerations (ensure checks by those responsible) as follows: A) Shelf life is determined and maintained.B) Material storage is per manufacturer’s recommendations. C) Temperature-sensitive material storage and shipping.D) Fireproofing materials are applied directly from original sealed containers to avoid contamination and changes in their formulation.E) Materials requiring controlled curing periods are identified F) Appliers & inspectors understand specified thickness is dry thickness, not wet thickness. Cured mastics shrink up to 30%.


Procedure details or infers API Publication 2218 material application Quality Control responsibilities/considerations: A) Qualified personnel familiar with job specs monitor mixing, density, substrate preparation, application thickness and finishing.B) Materials are applied per manufacturer’s recommendations for dry thickness. Small variations are significant to the fire-resistance of the finished coating when using thin mastics, and are most often found in parts of a structure that are congested or difficult to reach.C) Inspection is aware of user & applier agreements regarding theextent of random sampling necessary to verify coat thickness, proper bond, lack of voids & specific evaluation procedures used.


Intumescent materials have been subjected to a test furnace environment per UL 1709 or equivalent fire exposure test procedure accepted by the SA Chief Fire Prevention Engineer.


Fireproofing manufacturer has demonstrated no peel-back at edges or fireproofing terminations in fire situation for intended application.


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ITEM No.

C1

C2

C3

C4

D Quality Control (QC) Requirements (Procedure)

D1

D2

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D4

E Safety during Applications (SAES-H-102, Section 4)

E1

Fireproofing protects valve actuators for a minimum of 20 minutes when subjected to test furnace environment per the full-scale test method of UL 1709 or an equivalent "rapid-rise" fire test procedure

SAES-B-006 Para. 6.3.4

Newly constructed Emergency Isolation Valves (EIVs) that require actuator fireproofing have a vendor shop-applied intumescent fireproofing per 21-SAMSS-014 requirements as follows: A) Material is rated to withstand environmental conditions below:• UV irradiation by direct sunlight.• Relative humidity of 0 to 100% (condensing).• Wind velocity to 36 m/sec (130 km/h), gusts to 44 m/sec (160km/h)• Ambient temperatures range from 0°C (minimum for EIV actuators) to 50°C (for sheltered actuators), to max 80°C (exposed actuators)

SAES-B-006 Para. 6.3.4

The fireproofing fully covers the actuator body, excluding: A) Indicator lights B) Stem protector on top of the actuator C) Handwheel or declutch lever. Shaft extenders (where specified) are Type 316 SS Controls & Indicators shall be accessible for maintenance

21-SAMSS-014, Section 7.2

Actuator outer surface of fireproofing is a distinctive color or colors (agreeable to Chief Fire Prevention Engineer) to identify this special coating as fireproofing. The color is not a Safety color (per SAES-B-067). For example, purple is one acceptable color used.

21-SAMSS-014, Section 7.4

QC Equipment listed in SAES-H-100 Attachment A is listed for inspection of surface preparation & coatings application.

SAES-H-100, Section 9

QC Records section lists requirements & responsibility as follows: A) Equipment Check Sheet (Attachment B) B) In-process Inspection Sheet (Attachment C) C) Paints/Coatings & Equipment Log (Att D) D) Daily Job Log


Final Acceptance Report is listed. Report includes four (4) QC documents (Attachments B, C, D, Daily Logs) above.


Non Conformance Report is listed. Issued whenever any defect from coating material deficiency or/ and application malfunctioning. Remedial action & method of repair are defined & agreed upon.


Safety Requirements are detailed in procedure as follows: A) Fire and Explosion Prevention covers Smoking, hot work, designated areas, welding/heating coil use, electrical items (lighting equipment & connections), solvent/paint application, & work permits B) Ventilation (forced, natural) & equipment used covers fresh air inlets, discharge, added fans, confined spaces, air-fed hoods. C) Health Hazards cover Alkaline catalysts, skin contact, chemical burns, washing facilities, personnel protection equipment & MSDS


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ITEM No.

E2

REFERENCE DOCUMENTS:

2. SAES-H-100, Coating Materials & Application Requirements for Industrial Facilities (31 July 2004)

3. SAES-H-102, Safety Requirements for Coating Applications (31 July 2004)

5. 21-SAMSS-014 - Intumescent Fireproofing for Valve Actuators (30 June, 2003)

Contractor / Third-Party Saudi Aramco

Name, Initials and Date:Work is Complete and Ready for Inspection:

Name, Initials and Date:T&I Witnessed QC Record Reviewed Work Verified

QC Inspector PID Representative

Name, Initials and Date:Performed Inspection Work / Rework May Proceed

Name, Initials and Date:T&I Witnessed QC Record Reviewed Work Verified

QC Supervisor Proponent and Others

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

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

Safety Requirements (Equipment) are detailed in procedure:A) Airless spray gun basic safety, tip guards, leather glove use, trigger safety catches, pressure ratings (Hoses, pumps, etc) for operations, 5000 psi line limit, pump pressure relief valves, pump shut down & fluid pressure bleed before servicing/cleaning parts (clogged spray tips, etc), hose ground (anti-static type), equipment ground (AWG-4), equipment pressure component condition, solvent flushing safety, & emergency care for high pressure fluid injuries. B) Power Tool Equipment Hazards covers grounding, operation speeds, safety guards, hearing protection C) Vessel use (air receivers, surge tanks, etc) are code vessels stamped per ASME SEC VIII D1, hydrotested at 250 psig annually with vessel test certificates submitted to SA Inspector for review. D) Pressure relief valves, gauges & devices are tested/tagged E) Blasting/coating equipment grounding (electrostatic disch.)


REMARKS: *Always use latest approved revision of B-Std, not the Cut-off stds.

1. SAES-B-006, Fireproofing for Plants, (*18 July, 2006) See Remarks

4. API Publication 2218 - Fireproofing Practices in Petroleum & Petrochemical Processing Plants (2nd EDITION, AUG 1999)

ATTACHMENTS: 1. SAES-B-006 Appendix 1 - Approved Proprietary Fireproofing Materials

Construction Representative* PMT Representative

Name, Organization,Initials and Date:

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Attachment 1 -- Approved Proprietary FP Materials

APPLICATION NOTE (DESIGN):


Appendix 1 (Use SAES-B-006, July 2006 or latest revision)Ordinary dense concrete is the preferred fireproofing of structures and supports because of its proven economy, durability, and effectiveness in hydrocarbon fires. However, for some applications, alternative proprietary fireproofing mat'ls may be justified. This listing is intended to provide useful information on the available proprietary fireproofing materials to requisition originators and others responsible for the development and evaluation of bids. This is not intended to list all acceptable materials, nor are requisition originators restricted to the products of manufacturers or vendors on this list. Fireproofing may be purchased from any qualified source that can comply with the mandatory requirements. Verification of compliance shall be the responsibility of the requisition originator. Approval shall be received from Chief Fire Prevention Engineer for each product unless it is already listed. See Section 8 reqmts.

Refer to latest revision of SAES-A-006 available & utilize Appendix 1: A) Approved Material ... Is it on the list? B) Approved Manufacturer ... Is it on the list? C) Approved Material Supplier & Installer ... Are they on the list? Note: Any item "not on list" shall be appv'd by Chief Fire Prevention Engineer8.5 Top-Coating of Cementitious Fireproofing8.5.1 All cementitious fireproofing (whether dense or lightweight concrete) shall be provided with a top coat under any of the following conditions:• When top-coating is required by the manufacturer.• When fireproofing is installed within 3 m vertically from grade.• When fireproofing is installed on equipment that is protected by a fixed firewater spray or deluge system.• When fireproofing is installed below atmospheric drains or vents that are used during normal operations.8.5.2 When cementitious fireproofing is to be provided with a top coat, the following shall apply:• Surface shall be dry & loose contaminants shall have been removed by brushing (stiff bristle brush) & vacuuming.• Fireproofing must be fully cured in accordance with manufacturer's technical reqmts, prior to top-coat application.• First top coat, SA Stock # 1000194629 thinned 10% to 15% & applied to a dry-film thickness of 50 to 90 microns.• Second top coat, SA Stock Number 1000194797 shall be applied to dry-film thickness of 75 to 125 microns.

8.6 Top-Coating of Intumescent Epoxy Mastic Proprietary FireproofingIntumescent epoxy mastic and other noncementitious proprietary fireproofing shall be top-coated when it is required by the fireproofing manufacturer.8.6.1 Fireproofing must be clean, dry, and free of contaminants prior to top-coating.8.6.2 Fireproofing must be cured in accordance with the manufacturer's recommendations prior to top-coating.8.6.3 Top-coating of Saudi Aramco Stock Number 1000194797 or 1000194960 shall be applied to a dry-film thickness of 75 to 125 microns.8.6.4 Top-coating for proprietary fireproofing other than an intumescent epoxy mastic shall be approved by the fireproofing manufacturer and the Chief Fire Prevention Engineer. The coating shall be applied in a manner approved by the fireproofing manufacturer and by the Manger, Inspection Department, Dhahran.

8.3 Process InsulationVessels, exchangers, & equipment externally insulated for process reasons shall be considered to be fireproofed if process insulation per SAES-N-001, as a composite system, satisfies FP performance Stds in Section 7 below.

7.1 Dense concrete meeting the material requirements of Section 8 and applied with a minimum thickness of 50 mm is accepted as complying with the performance requirements for fireproofing without further testing. Dense concrete is the preferred fireproofing for onshore facility structures & supports because of its proven economy, durability, and effectiveness in hydrocarbon fires.7.2 Minimum thickness of fireproofing mat'ls for structural members & vessel supports, other than qualifying dense concrete, shall be installed with a thickness to provide a minimum fire-resistance rating of two (2) hours when subjected to a test furnace environment in accordance with UL 1709 or an equivalent fire exposure test procedure accepted by the Chief Fire Prevention Engineer.All materials and methods of fireproofing shall also be listed to meet the ASTM E119 Hose Test. Fireproofing manufacturer shall also demonstrate that there is no peel-back at the edges or terminations of the fireproofing in a fire situation for the intended application. Certified test reports shall be submitted to the Chief Fire Prevention Engineer for his approval. Refer to Appendix 1 for more info.

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SAIC-B-2001 1-Dec-06 MECH-Review Proprietary Fireproofing System & Procedure (Intumescent Epoxy Mastics & Lightweight Concretes)

7.1 Dense concrete meeting the material requirements of Section 8 and applied with a minimum thickness of 50 mm is accepted as complying with the performance requirements for fireproofing without further testing. Dense concrete is the preferred fireproofing for onshore facility structures & supports because of its proven economy, durability, and effectiveness in hydrocarbon fires.7.2 Minimum thickness of fireproofing mat'ls for structural members & vessel supports, other than qualifying dense concrete, shall be installed with a thickness to provide a minimum fire-resistance rating of two (2) hours when subjected to a test furnace environment in accordance with UL 1709 or an equivalent fire exposure test procedure accepted by the Chief Fire Prevention Engineer.All materials and methods of fireproofing shall also be listed to meet the ASTM E119 Hose Test. Fireproofing manufacturer shall also demonstrate that there is no peel-back at the edges or terminations of the fireproofing in a fire situation for the intended application. Certified test reports shall be submitted to the Chief Fire Prevention Engineer for his approval. Refer to Appendix 1 for more info.

SAIC-B-2001 Rev 2

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Transcript of SAIC-B-2001 Rev 2