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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - March 2010)

Rev 4
SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


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

SAIC-B-2001
WBS / BI / JO NUMBER

EQUIPMENT ID NUMBER(S)

EQUIPMENT DESCRIPTION

LAYOUT DRAWING NUMBER

REV. NO.

SCHEDULED INSPECTION DATE & TIME

ACTUAL INSPECTION DATE & TIME

31-Mar-10
DATE APPROVED

31-Aug-11

QR NUMBER

MECH-

CONTRACTOR / SUBCONTRACTOR

EQPT CODE

SYSTEM ID.

PURCHASE ORDER NUMBER

PLANT NO.

EC / PMCC / MCC NO.


QUANTITY INSP.

MH's SPENT

TRAVEL TIME

SAUDI ARAMCO USE ONLY


SAUDI ARAMCO TIP NUMBER

SAUDI ARAMCO ACTIVITY NUMBER

SAUDI ARAMCO INSPECTION LEVEL

CONTRACTOR INSPECTION LEVEL

ITEM
No.
A

A1

A2

A3

ACCEPTANCE CRITERIA

REFERENCE

General Requirements
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.
B) Refer to Attachment 1 for proprietary fireproofing mat'l list for various
applications in SA facilities.
Proprietary fireproofing shall be approved by the Chief Fire Prevention
Engineer. The material shall be applied in a manner approved by the
fireproofing manufacturer and by the Manager, Inspection Department,
Application of intumescent mastics or other approved proprietary
fireproofing shall be performed only by personnel trained and certified by
the material manufacturer.

SAES-B-006,
Para. 8.2.1

SAES-B-006,
Para. 8.2.1
SAES-B-006,
Para. 8.2.2

A4

Application shall be made in strict accordance with the manufacturer's


guidelines regarding ambient temperature, storage temperature,
materials, proportioning, and mixing.

SAES-B-006,
Para. 8.2.3

A5

Quality control procedures and hold points for inspection of surface


preparation and reinforcement shall be approved by the Manager,
Inspection Department, Dhahran.

SAES-B-006,
Para. 8.2.4

A6

Steel surfaces that are to be insulated per 8.3, fireproofed with


cementitious materials or covered with intumescent or other proprietary
fireproofing such as lightweight concrete, shall be coated in accordance
with SAES-H-101, APCS-1B.
The surface preparation and coating system specified shall be
referenced on all applicable construction drawings.

SAES-B-006,
Para. 8.4

A7

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

A8

Procedure details top coating requirements & manner of application:


See Attachment 1 (Cementitious per Para. 8.5 and (Intumescent Epoxy
per Para. 8.6)

SAES-B-006,
Sect. 8.5 & 8.6

A9

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.

SAES-B-006,
Para. 8.6.4

A10

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

Page 1 of 6

WORK PERMIT REQUIRED?

PASS

FAIL

N/A

RE-INSP DATE

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 KMass (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

Page 2 of 6

SAES-B-006,
Appendix 1

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - March 2010)

Rev 4

SAUDI ARAMCO INSPECTION CHECKLIST


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

ITEM
No.

SAIC NUMBER

SAIC-B-2001
WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA

REFERENCE

A12

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

SAES-B-006,
Para. 7.2

A13

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

A14

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

A15

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 manufacturers 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% .

SAES-B-006,
Section 3.2

A16

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 manufacturers 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 the
extent of random sampling necessary to verify coat thickness, proper
bond, lack of voids & specific evaluation procedures used.

SAES-B-006,
Section 3.2

Specific Requirements (Equipment & Supports)

B1

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.

SAES-B-006,
Para. 7.2

B2

Fireproofing manufacturer has demonstrated no peel-back at edges or


fireproofing terminations in fire situation for intended application.

SAES-B-006,
Para. 7.2

Specific Requirements (Actuators)

Page 3 of 6

31-Mar-10
DATE APPROVED

31-Aug-11

QR NUMBER

MECH-

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - March 2010)

Rev 4

SAUDI ARAMCO INSPECTION CHECKLIST


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

ITEM
No.

SAIC NUMBER

SAIC-B-2001
WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA

REFERENCE

C1

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

C2

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 0C (minimum for EIV actuators) to
50C (for sheltered actuators), to max 80C (exposed actuators)

SAES-B-006
Para. 6.3.4

C3

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

C4

Actuator outer surface of fireproofing is a distinctive color or colors


21-SAMSS-014,
(agreeable to Chief Fire Prevention Engineer) to identify this special
Section 7.4
coating as fireproofing. The color is not a Safety color (per SAES-B-067).
For example, purple is one acceptable color used.

Quality Control (QC) Requirements (Procedure)

D1

QC Equipment listed in SAES-H-100 Attachment A is listed for


inspection of surface preparation & coatings application.

SAES-H-100,
Para 9.1

D2

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

SAES-H-100,
Para 9.2

D3

Final Acceptance Report is listed. Report includes four (4) QC


documents (Attachments B, C, D, Daily Logs) above.

SAES-H-100,
Para 9.2.5

D4

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.

SAES-H-100,
Para 9.2.6

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

E1

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

Page 4 of 6

21-SAMSS-014,
Section 7.2

SAES-H-102,
Section 4

31-Mar-10
DATE APPROVED

31-Aug-11

QR NUMBER

MECH-

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - March 2010)

Rev 4
SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST


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

SAIC-B-2001

PROJECT TITLE

ITEM
No.

E2

WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA

REFERENCE

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.)

31-Mar-10
DATE APPROVED

QR NUMBER

31-Aug-11

MECH-

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

SAES-H-102,
Section 4

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

REFERENCE DOCUMENTS:
1. SAES-B-006, Fireproofing for Plants, (18 July, 2006)
2. SAES-H-100, Coating Materials & Application Requirements for Industrial Facilities (31 July 2004)
3. SAES-H-102, Safety Requirements for Coating Applications (11 Aug 2007)
4. API Publication 2218 - Fireproofing Practices in Petroleum & Petrochemical Processing Plants (Latest Edition)
5. 21-SAMSS-014 - Intumescent Fireproofing for Valve Actuators (15 April 2009)
ATTACHMENTS:
1. SAES-B-006 Appendix 1 - Approved Proprietary Fireproofing Materials

Contractor / Third-Party

Saudi Aramco

Construction Representative*

PMT Representative

Work is Complete and Ready for Inspection:


Name, Initials and Date:

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

Name, Initials and Date:

QC Inspector

PID Representative
Performed Inspection

Work / Rework May Proceed

Name, Initials and Date:

Name, Initials and Date:

QC Supervisor

Proponent and Others


Quality Record Approved:

Name, Sign and Date:

Name, Organization,
Initials and Date:

*Person Responsible for Completion of Quality Work / Test

Y = YES

Page 5 of 6

N = NO F = FAILED

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - March 2010)

SAUDI ARAMCO INSPECTION CHECKLIST


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

Rev 4
SAIC NUMBER

SAIC-B-2001

31-Mar-10
DATE APPROVED

QR NUMBER

31-Aug-11

MECH-

Attachment 1 -- Approved Proprietary FP Materials


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.

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 Engineer
8.5 Top-Coating of Cementitious Fireproofing
8.5.1 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 Fireproofing
Intumescent 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.
APPLICATION NOTE (DESIGN):
8.3 Process Insulation
Vessels, 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.
Page 6 of 6