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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Top Coating Application (Intumescent Fireproofing Matls)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-B-2009
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

EQUIPMENT ID NUMBER(S) LAYOUT DRAWING NUMBER SCHEDULED INSPECTION DATE & TIME SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO INSPECTION LEVEL

EQUIPMENT DESCRIPTION REV. NO. PURCHASE ORDER NUMBER

EQPT CODE

SYSTEM ID.

PLANT NO.

EC / PMCC / MCC NO. QUANTITY INSP. MH's SPENT TRAVEL TIME

ACTUAL INSPECTION DATE & TIME SAUDI ARAMCO ACTIVITY NUMBER CONTRACTOR INSPECTION LEVEL

SAUDI ARAMCO USE ONLY

WORK PERMIT REQUIRED?

ITEM No.

ACCEPTANCE CRITERIA

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

Note Production work is complete except for top coat. Performs timely Inspections per this checklist using approved marking system A A1 A2 A3 General Requirements Top Coating of the proprietary Intumescent Fireproofing is specified by the fireproofing manufacturer (as approved by SA). Fireproofing has been properly cured per the manufacturer technical data sheet prior to the application of the top-coat. Fireproofing coating has been accepted by Inspection for dry film thickness & surface finish. All tests are completed & acceptable. Top coating applications (as required by Manufacturer) are identified on Material Data sheet (two requirements exist): A) Top-coat with SAMS Stock Nos. 1000194797 or 1000194960 or B) Top-coat for proprietary fireproofing other than intumescent epoxy mastic as approved by fireproofing manufacturer and the Chief Fire Prevention Engineer. The coating is applied in a manner approved by fireproofing manufacturer & Mgr. Insp Dept, Dhahran. Complete Section B or C below, whichever is applicable SA Stock Number 1000194797 or 1000194960 Epoxy Top Coat (Information per SAES-H-101V Data sheets) Epoxy top coat (SAMS Stock Nos. 09-612-369 or 09-612-375) selected is one of those shown from a SA approved vendor: A) Hempel (Hempadur Mastic 45881) B) International Paint Saudi Arabia Ltd (Interguard 410) C) Jotun (Penguard HB) D) Oasis Ameron (Amercoat 383 HS) E) SIPCO (Sipoxy-Shield 240) F) Sigma (Sigmacover CM 7456) Top Coat of SAMS Stock Nos. 09-612-369 or 09-612-375 (APCS 1 epoxy) is applied to a dry-film thickness of 75 to 125 microns. Top Coat of SAMS Stock Nos. 09-612-369 or 09-612-375 (APCS 1 epoxy) is applied to wet-film thickness of 100 to 150 microns to compensate for shrinkage & meet the dry film thickness required. Material components come from an approved manufacturer in two parts (base & hardener). Manufacturer compatible thinners are also used (airless spray, etc). ALL ITEMS ARE COMPATIBLE Storage of components meets the following specific requirements: A) Shelf life (expiry date) is not exceeded (generally 2 years) B) Storage temperature within specified range (generally 35 C limit) C) Storage environment is sheltered (climate controlled) Mixing of components is checked by inspection as follows: A) Correct number of components are as specified (stock numbers) B) Mixing Ratios (by volume) for base & hardeners are maintained C) Thinner used is compatible and as specified (stock number) D) Thinning requirement (percentages) are maintained as specified E) Induction Times are met as specified (as applicable) F) Pot Life (times @ temperatures) are strictly followed (document) SAES-B-006, Section 8.6 SAES-B-006, Section 8.6 SAES-B-006, Section 8.6

A4

SAES-B-006, Para. 8.6

B1

SAES-B-006, Section 8.6

B2

SAES-B-006, Section 8.6 SAES-B-006, Section 8.6 SAES-B-006, Section 8.6

B3

B4

B5

SAES-B-006, Section 8.6

B6

SAES-B-006, Section 8.6

Page 1 of 4

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Top Coating Application (Intumescent Fireproofing Matls)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-B-2009
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No.

ACCEPTANCE CRITERIA Application of components is checked by inspection as follows: A) Maximum allowable substrate temperature limits are met B) Typical wet film thickness per coat is achieved C) Typical dry film thickness per coat is achieved D) Minimum number of coats specified are applied. (one is possible) Drying Time of components is checked by inspection as follows: A) Recoat intervals (minimum & maximum) are based on substrate temperatures actually recorded (check) B) Extrapolate temps to determine actual recoat interval time (check) C) Final thickness readings are taken after drying has been verified Equipment used for Top Coat applications (for 6 manufacturers listed above) is available and limited (checked) as follows: A) Airless spray has specified tip size range & fluid pressure B) Conventional Spray has specified tip size for atomizing pressure C) Brush or trowel/hand touch up of small areas is as specified Top Coating of Proprietary Fireproofings (Non-Epoxy) Storage methods (shelf life, temperature, shelter, climate control) meets requirements listed in the approved Technical Data Sheet. Mixing methods (ratios, thinners, induction time, pot life, etc) meet requirements listed in the approved Technical Data Sheet. Application methods (temp limits, film thickness, number of coats applied, drying times, equipment required, equipment limits) meet requirements in the approved Technical Data Sheet. Weather & Preparation (Including Cleaning) Requirements Weather is dry, temperature (metal, ambient) is moderate, humidity is low to medium, & winds are not strong. Proper conditions exist. Weather forecast data is known to the responsible applicators. Preparation is based on forecast winds and temperatures, etc. Covering of work areas is properly done to prevent foreign matter (dust/sand) embedment & fouling of coatings. Overspray protection covering of work areas (plastic sheets, tarps, masking tape, etc) is completed. Clean & dry surface conditions exist on surfaces to be top coated prior to any top coat application. Dust, sand, water, oils & other contaminants have been removed by brushing, use of clean, dry air or wiping with clean cloths. No foreign matter exists atop or embedded in fireproofing. Any surface prep (scuffing, light sanding with specified grit, etc) as specified on Technical Data Sheet is complete before top coating. Substrate temperature is above 10C & within the temperature limits listed by the manufacturer on the applicable Data Sheet. The substrate temperature is less than 3C above the dew point & within limits listed by the manufacturer on the applicable data sheet. Material Staging areas remain organized and clean and permit continued proper and safe mixing of materials. Materials are applied directly from original sealed containers to avoid contamination and changes in their formulation. Separate topcoat component containers are labelled (Arabic & English) with name of Manufacturer, date of manufacture, expiry date, Batch Number, product ID number & SAMS stock number. Shelf life has been determined & maintained. Materials to be used have not passed expiration. First In - First Out system is run.

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

B7

SAES-B-006, Section 8.6

B8

SAES-B-006, Section 8.6

B9

SAES-B-006, Section 8.6

C C1 C2

SAES-B-006, Section 8.6 SAES-B-006, Section 8.6 SAES-B-006, Section 8.6

C3

D D1 D2 D3 D4 D5

SAES-B-006 Section 3.2 SAES-B-006 Section 3.2 SAES-B-006 Section 3.2 SAES-B-006 Section 3.2 SAES-B-006, Section 8.6 SAES-H-100, Section 8 SAES-B-006, Section 8.6 SAES-H-100, Section 8 SAES-H-100, Section 8 SAES-B-006, Section 3.2 SAES-B-006, Section 3.2 SAES-H-100, Section 6 SAES-H-100, Section 6

D6

D7 D8 D9 D10 D11

D12

D13

Page 2 of 4

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Top Coating Application (Intumescent Fireproofing Matls)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-B-2009
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No. D14 D15 D16 E E1

ACCEPTANCE CRITERIA Materials are stored upright & covered on site per manufacturers storage instructions. Temporary storage meets 14-day rule. Contrasting colors (black & grey, etc) are used where multiple coat applications are performed. Top coat is gray (or red or yellow). Paints to be sprayed are filtered (30 to 60-mesh screen) before use & continuously agitated (low-speed stirrer) during application. Application of Top Coating Technique used results in no significant coating defects such as sags, runs, drips or dry spray accumulation. Areas with defects (blisters, cracks, porous, below thickness, sags, runs, drips, dry spray, orange peel, etc) were properly repaired. Repaired areas are rechecked and are satisfactory. Finished coating dry film thickness is within minimum & maximum limits specified as checked in accordance with SSPC PA2 method. Congested & hard to reach areas (for dry film thickness) were checked & meet specified thickness of data sheet (API Pub. 2218). Uniform dry film appearance exists after fireproofing application Repair Procedure for top coat strictly follows surface prep and application requirements in the manufacturer's technical data sheet. Recoating intervals (if applicable) follow the top coating manufacturer's Technical Data Sheet. In all cases, workers certified for top coating perform the work. Adhesion strength of coating systems is not less than specified where suspect coating applications result in rejection, NCR and the follow-up performance of an adhesion test to resolve any dispute. Random sampling to verify coating thickness, proper bond, lack of voids is performed per specific evaluation procedures. Cross hatch (knife) test after allotted curing time shows good adhesion at substrate between top coat and fireproofing. Cut a cross hatch pattern X and perform a knife test Preservation & Storage of unused materials meets the manufacturer's instructions as listed on the technical data sheet. Clean-up on a daily basis is being performed per technical data sheet recommendation and SA Safety requirements SAES-H-102. Caulking & sealing (API 2218) sequence of installation is AFTER complete curing & acceptance of specified dry film thicknesses, adequate adhesion & surface finish of the top coat. Quality Control QC Equipment in SAES-H-100, Attachment A is available for inspection of coatings & calibration was performed before use. In-process Inspection Sheet (Attachment C) was completed and signed by contractor & Company. Paints/Coatings & Equipment Log (Attachment D) was completed and signed by contractor & Company. Non Conformance Report & Daily Job Log problems, noncompliances & corrective actions taken are documented. Any Remedial action & methods of repair were defined & agreed upon.

REFERENCE SAES-H-100, Section 6 SAES-H-100, Section 8 SAES-H-100, Section 8

PASS

FAIL

N/A

RE-INSP DATE

SAES-H-100, Para. 8.1.6 SAES-H-100, Section 8 SAES-H-100, Section 8 SAES-B-006, Section 3.2 SAES-H-100, Para. 8.1.6 SAES-H-100, Section 8 SAES-H-100, Section 8 SAES-B-006, Section 8 SAES-H-100, Section 8 SAES-H-100, Section 8 SAES-B-006, Section 3.2 SAES-B-006, Section 3.2 SAES-B-006, Section 3.2 SAES-B-006, Section 3.2

E2

E3 E4 E5 E6 E7 E8

E9

E10

E11

E12 E13

E14

F F1 F2 F3

SAES-H-100, Section 9 SAES-H-100, Section 9 SAES-H-100, Section 9 SAES-H-100, Section 9

F4

Page 3 of 4

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

Rev 2 SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Top Coating Application (Intumescent Fireproofing Matls)
PROJECT TITLE

31-Dec-05 DATE APPROVED QR NUMBER

SAIC-B-2009
WBS / BI / JO NUMBER

1-Dec-06

MECH-

CONTRACTOR / SUBCONTRACTOR

ITEM No. REMARKS:

ACCEPTANCE CRITERIA

REFERENCE

PASS

FAIL

N/A

RE-INSP DATE

NOTES: *Always use latest approved revision of B-Std, not the Cut-off stds. Note 1: Specific Inspection Requirements and acceptance Criteria for In-Process Application shall be listed in this sheet upon submittal of Manufacturer's Quality Control Plan or Procedure, IF ANY REVISIONS ARE NEEDED. REFERENCE DOCUMENTS: 1. SAES-B-006, Fireproofing for Plants, (*18 July, 2006) See Notes 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) 4. API Publication 2218 - Fireproofing Practices in Petroleum & Petrochemical Processing Plants (2nd EDITION, AUG 1999) ATTACHMENTS: N/A

Contractor / Third-Party
Construction Representative*
Work is Complete and Ready for Inspection: Name, Initials and Date: Name, Initials and Date:

Saudi Aramco
PMT Representative
T&I Witnessed QC Record Reviewed Work Verified

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

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

QC Supervisor
Quality Record Approved: Name, Sign and Date: *Person Responsible for Completion of Quality Work / Test

Proponent and Others

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

Y = YES

N = NO F = FAILED

Page 4 of 4