Copy of 16 JRTP 02 ITP_rev01

8/18/2019 Copy of 16 JRTP 02 ITP_rev01

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Rev : 01 Date: 21/3/2016

CAPE RB H TR SAUDI ARAMCO

1.0 PRE-PRODUCTION REQUIREMENTS

1.1

1.1.1 Inspection and Test Plan (ITP) 16-JRTP-02-ITP S. ARAMCO Approved ITP H R R

1.1.2 Method Statement 16-JRTP-01-MS S. ARAMCO Approved M.S H R R

1.2

1.2.1 Material Storage SAES-N-110 Section 7 AFI / FORM NO: 008 W W S

1.2.2 Condition of refractory materials SAES-N-110Section 9.1.7 &

Product Data Sheet AFI / FORM NO: 008 W W S

2.0

2.1 SURFACE PREPARATION

2.1.1 Weather Protection of work area SAES-N-110 Section 9.1.6 AFI/FORM NO: 009 H W S

Surface free from oil, excessive rust, loose

mill scale.

2.1.3 Anchor Layout as per drawing (if provided) Anchor layout drawing Approved drawing AFI/FORM NO: 009 H W R

2.1.4 Application of surface coating to internal surface Anchor layout drawing Approved drawing AFI/FORM NO: 009 H W R

2.2

2.2.1 Correct type and size of Form work installed SAES-N-110 Section 11.2.3 AFI/FORM NO: 012 H R R

2.2.2 Correct method used for the formwork installation SAES-N-110 Section 9.6.2 & 11.2.3 AFI/FORM NO: 012 --- R R

2.3 GUNNITING APPLICATION

2.3.1 Verify water ratio and temperature of water SAES-N-110Section 9.1.11;

Section 9.1.12 AFI/FORM NO: 011 H W R

2.3.2 Verify lining surface temperature and ambient temperature SAES-N-110 Section 9.1 AFI/FORM NO: 011 H W R

2.3.3 Correct method used for gunning SAES-N-110 Section 9.4 AFI/FORM NO: 011 H S S

2.3.4 Verify thickness of refractory to be installed Approved drawing approved drawing AFI/FORM NO: 011 H W R

2.3.5 Production sample casting and marking SAES-N-110 Section 11.3 AFI/FORM NO: 015 W R R

2.3.6 Curing SAES-N-110 Section 10.2 AFI/FORM NO: 011 H W S

IN - PROCESS INSPECTION & TESTING

MATERIAL HANDLING AND STORAGE

Section 8.1 SSAES-N-110

FORM WORK / SHUTTERING APPLICATION

AFI/FORM NO: 009 H

SAES-N-130, SAES-N-140

W.P. / Description : REFRACTORY INSTALLATION

Inspection / Test Stage Acceptance Criteria Verifying Documents

Responsibility

2.1.2

SPECIFICATION: SAES-N-110Inspection and Test Plan

REFRACTORY INSTALLATION TO 8 HEATERS AT 2220 JIZAN

REFINERY

Reference Document

Doc. No: 16-JRTP-02-ITP

S

PROCEDURE SUBMITTALS

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Responsibility



REFINERY

Reference Document


2.4 CASTABLE REFRACTORY APPLICATION

2.4.1 Verify water ratio and temperature of water SAES-N-110Section 9.1.11;

Section 9.1.12 AFI/FORM NO: 010 H S S

2.4.2 Verify lining surface temperature and ambient tempure. SA ES-N-110 Section 9.1.4 & 9.1.5 AFI/FORM N O: 010 H R R

2.4.3 Mixing of refractory castable SAES-N-110 section 9.5 AFI/FORM NO: 010 W W S

2.4.4 Verify thickness of refractory to be installed Approv ed drawing Approved drawing AFI/FORM N O: 010 H W R

2.4.5 Production sample casting and marking SAES-N-110 Section 11.3 AFI/FORM NO: 015 W R R

2.4.6 Curing SAES-N-110 Section 10.2 AFI/FORM NO: 010 H W S

2.5

2.5.1 Type of material as per drawing / agreed for the contract Approved drawing ------ AFI/FORM NO:013 H W S

2.5.2 Brick lining method SAES-N-130 Section 6 AFI/FORM NO:013 S R R

2.5.3 Verify the staggering of bricks SAES-N-130 Section 6 AFI/FORM NO:013 H W R

2.5.4 Verify the thickness of installed bricklining Approved drawing ----- AFI/FORM NO:013 H W R

2.5.5 Excess mortar removed ------ ----- AFI/FORM NO:013 S W S

2.6 RCF APPLICATION

2.6.1 Orientation of studs As per approved drawing specification Approved drawing AFI/FORM NO:014 H W S

2.6.2 Type of ceramic fiber blanket As per approved drawing specification Approved drawing AFI/FORM NO:014 H W R

2.6.3 Joints (Lap / butt joint) SAES-N-140 Section 9.1.2 AFI/FORM NO:014 H S S

2.6.4 Verify thickness of installed blanket As per approv ed drawing specification Approved drawing A FI/F ORM NO:014 H W R

2.6.5 Verify Orientation / Securement of blanket lining ---- Approved drawing AFI/FORM NO:014 H R R

3.0

3.1 Visual inspection after curing of casting and gunniting ---- --- AFI/FORM NO: 010 & 011 H R R

3.2 SAES-N-110 Section 11.3.6 AFI/FORM NO: 010 & 011 H W WHammer Test

BRICK LINING APPLICATION

FINAL INSPECTION AND TESTING

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Responsibility



REFINERY

Reference Document


4.0

4.1 All Documents in file ---- All inspection documents signed

by client inspector ITP & Inspection forms H & R R R

4.2 ---- Final Acceptance Certificate ---- H & R R R

Cape RBH TR SAUDI ARAMCO Comments

Approved Approved with

comments

To be resubmittedDate

Legend :

H = Hold Point W = Witness (if no show, work may proceed) S =

Surveillance R = Record and/or review

Name

Final Acceptance & release

Sign

SAUDI ARAMCO

FINAL DOCUMENTATION AND PACKAGE REVIEW

Y N

Y

Y

N

N

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INSP. DATE:INSP. TIME:

RECEIVING INSP: IN-PROCESS INSP: FINAL INSPECTION: OTHER: (specify)

PROJECT: EQPT. TO BE INSPECTED:

CONTRACT NO: AREA LOCATION:

SITE LOCATION: REF. DWG. / SPECS.:

ATTENTION OF: DISCIPLINE:

REQUESTED BY:TYPE OF INSPECTION

VISUAL DIMENSIONAL WITNESS TEST

ITEM DESCRIPTION:

SUMMARY OF RESULTS:

APPLICATION FOR INSPECTION


5/13

Project Name :

Contract Numb :Project Location :

J. O. No. :

EQUIPMENT / TAG NO. : AREA : REPORT NO. :

DATE : SERVICE DESCRIPTION : SYSTEM

REF. DRWG NO. : TYPE OF MATERIAL & MANUFACTURER ITP NO. :

ITP STEP NO. :

YES NO N/A

Material conformity to specification.

Material conformity certificates (pre-shipment test certificates)

Material Data sheets

Visual condition of material acceptable upon receipt

Material stored properly

MATERIAL INSPECTION AND ACCEPTANCE RECORD

1. INSPECTION REQUIREMENTS

COMPLIANCE

1.1

1.5

1.2

1.3

1.4


6/13


7/13

Project Name :

Contract Numb :Project Location :

J. O. No. :




ITP STEP NO. :

YES NO N/A

Weather Proofing of Work Area

Refractory anchors installed correcly

Hammer test of anchor (random selection)

Internal surface coating

Ventilation

1.2

1.6

1.3

1.4

INSPECTION RECORD FOR SURFACE PREPARATION


COMPLIANCE

1.1

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

materials.

1.5


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Project Name :

Contract Number :

Project Location :

J. O. No. :




ITP STEP NO. :

YES NO N/A

Check condition of refractory material

Check mixing of refractory castable

Check placement of refractory castable

Shuttering or Form Works

Vibration, spade or puddle rodding of castable

Check curing

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

Hammer Test

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

material temperature)

1.4

1.2

1.3

INSPECTION RECORD FOR REFRACTORY CASTING APPLICATION


COMPLIANCE

1.1

1.5

1.6

1.7

1.9

1.8


9/13

Project Name :

Contract Number :

Project Locatio :J. O. No. :




ITP STEP NO. :

YES NO N/A

Application Prequalification

Check proper consistancy of the material through gunning

Check placement of refractory castable

Trimming of surface and its roughness

Check curing

Check presence of unacceptable cracks

Hammer Test of refractory liningFinal Inspection

1.2

1.3

1.4

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

water and dry material temperature)

INSPECTION RECORD FOR REFRACTORY GUNNING APPLICATION


COMPLIANCE

1.1

1.5

1.6

1.7

1.81.9


10/13

Project Name :

Contract Numbe :

Project Location :

J. O. No. :




ITP STEP NO. :

YES NO N/A

Shuttering installed correctly (where required)

INSPECTION RECORD FOR FORM WORK / SHUTTERING APPLICATION


COMPLIANCE

1.1Check for correct type, size and surface of formwork (for casting and gunning only)

coated with layer of releasing agent

1.2

1.3 Verify thickness of installed formwork as per drawing


11/13

Project Name :

Contract Number :Project Location :

J. O. No. :




ITP STEP NO. :

YES NO N/A

Condition of refractory material

Mortar mixing

Brick handled carefully

Chipped or broken bricks not used

Brick laying as per specification and drawing

Sufficient mortar applied to each brick

Set bricks driven firmly into place

Excess mortar scraped off Expansion joints left free of mortar,dust and other contaminants

INSPECTION RECORD FOR BRICK LINING APPLICATION


COMPLIANCE

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9


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Project Name :

Contract Number :

Project Location :

J. O. No. :



REF. DRWG NO. : TYPE OF MATERIAL MANUFACTURER

YES NO N/A

INSPECTION RECORD FOR RCF INSTALLATION


COMPLIANCE

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

1.5Method of joining (lap joint / butt joint method) used for installation of

blanket.

1.6 Sur face Appearance


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ITP NO: Site /Location: Date:

SN Sample Time Date Type of Batch/Pallet Method of Amb Dry Steel Water Mixing LOCATION

Number Sampled Sampled Material Number Application Temp Temp Temp Temp Temp

SAUDI ARAMCO

Name:

Signature:

Date

FORM NO: 015

Castable & Gunning Refractory Production Sample Log Sheet

TRCAPE RB HILTON

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