EQUIPMENT INSPECTION RECORD-GENERAL SAUDI ARABIAN OIL COMPANY

Saudi Aramco 2093 (11/90)

Plant Number: J24 Service: Platforming Charge Heater
Item: J24-F-302 Location: Ras Tanura Refinery
Unit: NHT (CCR) Date: Jan, 2024 / Mar, 2024

SUMMARY:
During the plant J24 February 2024 T&I the J24-F-302 Platforming Charge Heater was removed from service
and inspection was performed. Through out floor surface observed with tight cracks, loose scales & debris. Radiant
section found with loose/damaged ceramic fiber refractory & exposed refractory anchors at roof and wall areas. It
was repaired with ceramic fiber refractory. Castable refractory repair were made in the radiant bottom floor, burner
area, separation brick wall and convection section. At all the damaged castable locations the refractory was
reinstated after hammer test/chipping. Ceramic fiber refractory removed at random locations from the radiant
section roof wall and minor corrosion observed which is satisfactory. However, at one location Ceramic fiber
refractory was found with damages, discoloration and leaking water at the roof top west side in the middle area.
After cleaning during the detailed inspection, Clustered multiple holes (10 no’s approximately) were noted with
varying diameters. It was repaired by fillet welding on top of the affected areas with 1/8” thickness CS square
plates of ASTM A36 with rounded corners as recommended by TSU. External top roof access door ceramic
refractory removed and found severe corrosion on both access doors towards north direction (east side and west
side) and after cleaning UT scanning performed at corroded area, thickness found low. At one location on the roof
top west side access door of the radiant box a through hole of 5mm diameter was noted. It was repaired by on
patch plate caulking with RTV high temperature silicone as recommended by TSU. But due to thickness reduction
and severe corrosion GME Specialist & CSD recommended to replace the doors with new in kind. This activity is
planned in the next shutdown. All manways, doorways and header box selected panel sections were removed and
inspected. Cover flanges were buff cleaned and fiber blanket gaskets were replaced with 6mm (1.6mm x 4 layers)
thick as recommended by TSU. UTG performed on radiant/convection section on all CML locations (Radiant
straight tubes, U-bends, shock tubes and convection U-bends). All UTG readings were reviewed by CMU and
found acceptable. Radiant straight tubes and u-bends random location were selected for DPT, PRT and replica. No
indication observed and the results found accepted. Radiant header box panels for inlet and outlet were opened
only at random locations and visual inspection, UTG at CML locations, Replica, DPT & Hardness were performed.
No findings noted and was accepted. Thermocouple replacement was not done for (TI-316, TI-317, TI-318, TI-
319, TI-320, TI-321, TI-322, TI-323, TI-324, TI-325, TI-326, TI-327) as per scope of work. Tubes spacer casting
support found dislocated and some of the U-Clamps found bent/broken at multiple locations. All of them were
reinstated to its original condition after coating. Tube external Cetek Ceramic coating was applied and after partial
dry out, DFT measurements were taken and was found to be between 1 mil to 3mils approx. as measured by
Aramco inspector and M/s. IGS QA/QC excluding top 2 ft area of the tubes. The DFT measurements are approved
by CSD for above mentioned thickness. Refractory repair was performed prior to coating application. Regidizer
followed by Cetek coating application performed on the refractory and accepted. All the main burner pipe and the
burner tips were dropped and inspected. Stack visual inspection was performed through manway for lower portion
and with cradle middle / upper portion. Minor hairline cracks and refractory damage noticed and found accepted.
West side duct castable refractory of the stack found bulged outwards at the slanting overhead location.
Detachment of the castable refractory from the slanting overhead wall of the duct was suspected. Recommended
for the erection of scaffolding for detailed inspection & light hammer test. However, it was decided to leave as is
as per the maintenance team. External paint peel off observed on shell, observation door, burners, manways &
convection door panels at random locations. External painting repair done followed by APCS-11C Aramco
standard. The furnace was assembled and is ready for another run.

RADIANT SECTION
Internal scaffolding was erected to allow access for detail inspection.

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 TUBES 4.5” Sch 40 9CR-1MO (A335-P9):
Radiant tubes external surfaces were observed with reddish brown oxidation scales. The oxidation scales found
tightly adhered although the tubes, but the overall surface was smooth. After grit blasting of the tube external
surfaces, Cetek Ceramic coating (Cetek M600 Ceramic Coating) was applied. Top 2 ft area of the tubes and the
Spacer casting support areas, are excluded from the coating due to limited access. After partial dry out, DFT
measurements were taken by the Aramco inspector and M/s. IGS QA/QC. DFT readings found to be in the range
of 1 to 3mils against the acceptance tolerance of 1 to 6 Mils as specified by the Product manufacturer. The DFT
measurements were approved by CSD for the above mentioned thickness. All the tubes were found free from any
sign of sagging, bowing, bulging and mechanical damage. UTG was performed on all tubes of the radiant section
at the CML locations (Radiant straight tubes & U-bends). All UTG readings were reviewed by CMU and found
acceptable. Random section of the tubes was selected for DPT, Replica and PRT. No findings observed and the
result found accepted. In general, the overall condition of tubes found acceptable for the continued service.

TUBE SUPPORTS:
Tubes spacer casting support found dislocated/misaligned at multiple locations. Tube spacer casting support U-
Clamps found bent at approximately 40% of the locations and some found broken. U-Clamps were replaced with
material in kind (ASTM A310; confirmed after PMI testing). The spacer casting supports were reinstated/aligned
to the original condition after coating of the tubes. All casting spacer support were found intact, free from damages
and acceptable for the continued service.

SNUFFING STEAM NOZZLES:

Snuffing steam nozzles were found partially chocked. After cleaning no sign of corrosion or damages noted and
visually found satisfactory.

BURNERS:
All Burner assembly was dropped and the burner tips were found with scales and deposits. After cleaning, visual
inspection was performed. Some of the burner tip gas pipe found eroded, broken and with thread damages. The
damaged burner tip gas pipes were repaired and reinstated (2 Nos). Some Burner tips with different hole sizes and
orientation noticed. For the Burner tips with different hole sizes and orientations, GME/ROED recommended
burner tips were installed. 60% tips were replaced with in-kind material as recommended by GME/ROED.

FLOOR:
During visual inspection, loose ceramic fiber debris, scales, dust and minor cracks at random locations on the floor
castable refractory observed. After vacuum cleaning cracks were repaired with refractory mortar and found
accepted. Regidizer followed by Cetek coating (Cetek R360 Ceramic coating) application performed on the bottom
floor after refractory repair and found accepted. No other major damage observed and the overall floor found in
healthy condition and accepted for the continued service.

REFRACTORY WALL & ROOF:

Radiant section noticed with loose /damaged ceramic fiber refractory and exposed refractory anchors at roof and
shell wall areas. It was repaired with ceramic fiber refractory and found accepted. Ceramic fiber refractory was
found with damages, discoloration and leaking water at the roof top west side in the middle area. Refractory
insulation was removed in this water leaking area and severe CUI along with a hole of approximately 3mm
diameter noted. High quantity of water accumulated on the roof was passing in through the hole. As per the
rcommendations, Ceramic fiber refractory was further removed considering the wet refractory insulation in a size
of 3m X 3m with the affected area being the centre. At the insulation removed areas severe CUI and scales noted.
All the scales were removed by mechanical cleaning for detailed inspection. During detailed inspection, Clustered
multiple holes (10 no’s approximately) were noted with variying diameters with the maximum size being 12mm
diameter. Significant corrosion was noted at the nearby areas of the holes with severe undulations. UTG scanning
was performed from roof top external surfaces after buffing. During UTG severe corrosion/ metal loss was noted.

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 It was repaired by fillet welding on top of the affected areas with 1/8” thickness CS square plates of ASTM A36
with rounded corners as recommended by TSU. Repair plate sizes were18” X 9” and 18” X 12”. Internally these
plates were coated with asphaltic paint and the refractory insulation was restored.

Ceramic fiber refractory was removed at 9 random locations from the the roof top as wet discoloured insulation
along with water leak was noted from one location on the west. This was done as part of the sampling due to the
leaks noted. The locations were (1) East side roof top area with a size of 0.3m X 0.3m towards North end, (2) East
side roof top Middle area 0.3m X 0.3m, (3) East side roof top area with a size of 0.3m X 0.3m towards South end,
(4) Middle section of radiant chamber roof top area with a size of 0.3m X 0.3m towards North end, (5) Middle
section of radiant chamber roof top area with a size of 0.3m X 0.3m towards central portion, (6) Middle section of
radiant chamber roof top area with a size of 0.3m X 0.3m towards South end, (7) West side roof top area with a
size of 0.3m X 0.3m towards North end, (8) West side roof top Middle area 0.3m X 0.3m & (9) West side roof top
area with a size of 0.3m X 0.3m towards South end. Asphaltic coating damages and generalized corrosion noted at
these locations along with broken refractory anchors (10 No’s on the West side out of which 5 no’s were on the
corroded area with leak i.e. 3m X 3m location, 4 No’s on the Middle Section & 8 No’s on the East side). However
roof top access door areas noted with heavy corrosion.

Broken refractory anchors were rewelded using approved WPS and repair procedure provided by TSU, and was
coated with Asphaltic paint prior to ceramic fiber refractory installation. After visual inspection refractory
reinstalled on all refractory insulation removal areas and found accepted. Refractory repair was performed prior to
coating application.

At one location on the roof top west side access door of the radiant box, a through hole of 5mm diameter was
noted. UT scanning was perfomed at this location and significant wall loss noted at the area surrounding the hole.
It was repaired by placing on top of the affected area a CS plate of ASTM A36 with 1/8” thickness square plate (6”
X 4”) with rounded corners and caulking with RTV high temperature silicone as recommended by TSU. However,
Due to thickness reduction and severe corrosion, GME specialist and inspection recommended to replace the doors
with new in kind and this replacement is pending.

Castable refractory repair were made in the radiant bottom floor, burner area and convection section. All damage
locations the castable refractory was repaired after hammer test/chipping.

Regidizer followed by Cetek coating application (Cetek R371 Ceramic fiber encapsulation coating) performed on
the ceramic fiber refractory of radiant walls including all access/observation doors. The center expansion joint had
aligned requiring stuffing with refractory fiber blanket. The refractory brick wall separating F-302 & F-301 were
aligned. Mortar repair completed and overall condition of wall found intact and in good condition and accepted.
Regidizer followed by Cetek coating application (Cetek R370 Ceramic coating) performed on refractory brick
center separation wall and found satisfactory.

RADIANT HEADERS:
Radiant header box for inlet and outlet headers were opened for inspection. Inlet and outlet header at the west side
plate segment 1st and 4th was opened and UTG at CML locations, DPT, replica and hardness test was performed at
random locations. All results found satisfactory and accepted. Opended segment header panels refractory found
damaged at random locations. Refractory repair was completed and found accepted.

COMMON CONVECTION SECTION:

The cover was removed on both sides and the convection tube U-bends noted with yellowish brownish color thin
layer of deposits and dust. Tube sheet and refractory area, no major abnormality observed. Convection side flange
bolts with broken tack welds and with corrosion were repaired / reinstated with new ones followed by refractory
reinstatement. The cover flange areas were cleaned and new gaskets were installed. Minor ceramic fiber and

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 castable refractory repair done inside the convection box, covers and breaching area. No major sign of mechanical
damage were observed on the flange and cover areas. All bolts were cleaned and observed in good condition.
Nozzles found chocked with deposit, after decoking/cleaning done and found accepted.

Tubes-4” Sch 80 (A 335 P11) 1 ¼ Cr, ½ Mo (Superheater)

Tubes-4” Sch 80 (A 106 Gr B) Steam generator
Tubes-4” Sch 80 (A 106 Gr B) Economizer

Tubes, U-bend external surface observed with yellowish brownish color, foreign debris and dusty but overall
surface was smooth. Finned tubes observed with debris and fouling, after vacuum cleaning it was inspected with
ROED/GME and cleaning found satisfactory. Random section of tubes to U-bend butt welds were selected and
DPT performed. No indication was observed and the result found accepted. Finned tubes and U-bends were
observed free from mechanical damage and in satisfactory condition up to the visible extent. East & West side
Convection box flange bolt’s tack welds found detached for 10 bolts on west side and 8 bolts on east side. It was
repaired by welding as per the appoved WPS. In general, overall visual condition of the tubes found acceptable for
the continued service.

REFRACTORY:
Minor ceramic fiber refractory observed damage and anchor washers exposed at random locations on convection
box and cover areas during visual inspection. Gaps were noticed in between tubes to tube sheet area and filled with
ceramic fiber. Convection box side wall observed with minor damage of castable refractory. All repair locations
were marked and it was repaired. Visual inspection done and found acceptable.

STACK
Stack visual inspection was performed through manway for lower portion and through cradle for upper portion.
During visual inspection of the stack through cradle, refractory found with minor hairline cracks and minor
refractory damages at random locations. Visual inspection of the bottom of the stack and walls was done through
the stack access manway. Minor refractory damages noted at random locations and the stack floor noted with
castable refractory debris. Visual inspection of the ducts were done using temporary access ladder from the bottom
floor manway of the stack. East side duct castable refractory found in order no major damages noticed. However,
West side duct castable refractory found to be bulged outwards at the slanting overhead location. Detachment of
the castable refractory from the slanting overhead wall of the duct was suspected. Recommended for the erection
of scaffolding for detailed inspection & light hammer test. However, it was decided to leave as is as per the
maintenance team. All nozzles found chocked with deposit. Accessible nozzles on the bottom floor was cleaned
and accepted and the remaining nozzles on the stack at the in accessibles areas were left as is. Damper, seat
damper, door, bolts and gasket found free from major abnormalities and was in good condition.

FIRE BOX
Manways, Burners, Nozzles, Refractory (ceramic fiber/castable), Walls, Tubes, Tube casting spacer supports and
support u bolts visually inspected and found free from major abnormalities and acceptable for continued service.

REPAIR COMPLETED DURING T/A 2024

1. Radiant and convection section walls, covers and anchor area ceramic fiber refractory repair. All gap
filled with ceramic fiber.
2. Castable refractory repair were made in the radiant bottom floor, burner casing area, convection
section, breaching section and observation door areas.
3. Damaged U-Clamps were replaced with material in kind (ASTM A310; confirmed after PMI
testing). The spacer casting supports were reinstated/aligned to the original condition after coating of
the tubes.
4. Cetek Ceramic coating application performed after refractory repair.
On the Radiant tubes (Cetek M600 Ceramic Coating)

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 On the bottom floor (Cetek R360 Ceramic coating)
On the Radiant ceramic fiber walls (Cetek R371 Ceramic fiber encapsulation coating)
On the Radiant Brick walls (Cetek R370 Ceramic coating)
5. As per drawing 6mm thickness ceramic fiber gasket required in one layer. Due to the unavailability
of material TSU approved to installed 1.6mm thk gasket in four layers.
6. The damaged burner tip gas pipes were repaired and reinstated. For the Burner tips with different
hole sizes and orientations, GME/ROED recommended burner tips were installed. 60% tips were
replaced with in-kind material as recommended by GME/ROED.
7. East & West side Convection box flange bolt’s tack welds that was found detached for 10 bolts on
west side and 8 bolts on east side was repaired by welding as per the appoved WPS.
8. External coating repair done on all damage locations followed by APCS-11C Aramco standard.

FUTURE RECOMMENDATIONS
1. Anticipated replacement of doors after thickness evaluation for next available opportunity.
2. Anticipated repair of roof plates after thickness evaluation for next available opportunity.
3. Anticipated refractory repair at radiant, convection, breaching section area, stack and stack ducts
including refractory anchors.
4. Anticipated U-clamp for castable spacer support replacement at radiant section tubes.
5. To keep spare tubes of in-kind material for tube replacements if any for the next available
opportunity.
6. Provide access for duct area, arch and convection column for inspection.
7. To arrange correct size gasket as per drawing 6mm for the next available opportunity.
8. To remove ceramic refrectory at roof random locations to check the plate condition.
9. Finned tube external cleaning to be done and cleaning method provided by TSU.
10. Recommended to perform hydro / Pneumatic test for heater tubes to check the tubes integrity.
11. Anticipated Skin type thermocouple replacement (TI-316, TI-317, TI-318, TI-319, TI-320, TI-321,
TI-322, TI-323, TI-324, TI-325, TI-326, TI-327) welded followed by DPT which was not done
during this 2024 T&I as per scope of work.
12. Replacement of the radiant section roof top access doors due to thickness reduction and severe
corrosion as recommended by GME Specialist & CSD.
13. Replacement of convection side flange bolts for broken /corroded ones in the next available
opportunity.
14. Associate structure platform external painting to be done followed by approved Aramco painting
specification.

Inspected By: Sulaiman/Jesus/Usman/Irfan/Vincent

Reviewed By:

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