SATIP W 011 01 Welding of on Plot Piping

PROJECT PHASE TASK / ACTIVITY QUALITY

RECORDREMARKS

ITEM

NO.

QUALITY

PROCEDURE

Refer to SATIP No: W-015-01 & applicable SATIP-W series (as

required) *Rarely applies to Plant Piping

Refer to SATIP No: W-014-01(*Rare application)

1.12 Welding Strip Linings* (As Required) See Remarks See Remarks

RH

1.11 Welding Overlays & Clad Materials* See Remarks See Remarks

Refer to respective SATIP for NDE. (SATIP-NDE-UT-01, LPT-01 MPT-

01, RT-01) *QA/QC Mgr. action! SEE NOTICE

IN GENERAL NOTES SECTION!

1.10 Procedure for Control of Welding Consumables SAIC-W-2009 SAIC-W-2009 RH

RH

1.9

A) NDE Proc. (Technique) B) NDE Process Control

Proc. C) NDE Specification Review

D) NDE Kickoff Meeting

See Remarks See Remarks

Use SAIC-L-2015 during process(See SATIP-L-350-01)

1.8 Positive Material Identification Procedure (Alloy Verification) SAIC-L-2004 SAIC-L-2004 RH

RH

1.7Gap Control Procedure & Inspection of Welded Socket & Threaded

JointsSee Remarks See Remarks

RH

1.6Weld Hardness Testing Procedure & Proposed M&TE Equipment

RecordsSAIC-W-2012 SAIC-W-2012 RH

RH

1.5Post Weld Heat Treatment (PWHT) Procedure & Equipment

PackageSAIC-W-2003

SAIC-W-2003

SATR-W2004RH

RH

1.4Procedure & Weld Database for Weld ID, Traceability, Tracking &

Status Reporting (SAEP-1160*)SAIC-W-2008 SAIC-W-2008 RH

R

Use NOTIFICATION FOR WELDER QUALIFICATION TEST & SAIC-

W-2037* Welding Process Control (Procedural Element)

QA/QC Mgr. Action is required for SAIC-W-2035

*Socket Welding is now qualified per SAIC-W-2037;NOTIFICATION

FOR WELDER QUALIFICATION TEST follow S-EP-GC00-1520-

0006_R2

1.3

Method Statement & WPS for weld Repair, ie:

a.) Crack and other weld defects b.)

Welds mis-alignments

SAIC-W-2002 SAIC-W-2002 RH

RH

1.2Welder/Welding Operator Certification Review and Issuance of

JCCSAIC-W-2035 SAIC-W-2035 RH

1.0 DOCUMENT REVIEW SPECIAL PROCESS (WELDING) REQUIRES BEST QUALITY PRACTICE, CPI & EFFICIENT METHODS IN PROCEDURES. PROPOSE BEST METHODS.

1.1Welding Procedure Specifications/ Welding Procedure

Qualification Record (WPS /WPQR) SAIC-W-2001 SAIC-W-2001 RH

INSPECTION RESPONSIBILITY

ASSIGNMENTS

CNTRCTRSAUDI

ARAMCO

Welding of On-Plot Piping SATIP-W-011-01 11-Dec-13 MECHANICAL

PROJECT TITLE: CONTRACT NUMBER CONTRACTOR

SAUDI ARAMCO ID/PID FORM REV 1 - 010109 Rev 3 COS 06/30/2008

SAUDI ARAMCO TYPICAL INSPECTION PLAN SATIP No. APPROVED DATE DISCIPLINE:

Page 1 of 4


RECORDREMARKS

ITEM

NO.

QUALITY

PROCEDURE


ASSIGNMENTS

CNTRCTRSAUDI

ARAMCO





W / H

Saudi Aramco's responsibilities varies as follows:

a) "W" -for build-up thickness not exceeding 1/3 of the metal thickness

or 10mm whicever is less.

b) "H" - for build-up thickness exceeding the above and requiring

CSD's approval.

WWELDING CONSUMABLES ISSUANCE REPORT will follow S-EP-

GC00-1520-0007_R2

3.5 Buttering or Weld Build-Up of Joints SAIC-W-2033SAIC-W-2033

SATR-W-2006H

See SATIP No: W-016-01 (As Required)

3.4Welding Consumable Control (Storage, Handling, Issue &

Conditioning) SAIC-W-2032

SAIC-W-2032

ReportH

See SATIP N0: W-015-01, etc (As required)

3.3 Welding Special* Corr-Resistant Mat'ls See Remarks See Remarks

See SATIP No: W-014-01 (As Required)

3.2 Welding Strip Linings See Remarks See Remarks

3.1 Welding Overlays & Clad Materials See Remarks See Remarks

WRefer to Note 1 General Notes for SA Inspection responsibility, after

which pre-arranged witness is agreed upon.

3.0 INSTALLATION

W First Calibration witnessed, Random witnessing by SA thereafter.

2.3Verify Positive Material Identification of Low Alloy, Stainless Steel,

Nickel & Copper Based Materials (As Required)SAIC-L-2010

SAIC-L-2010

SATR-A-2012

SATR-A-2013

H

WSaudi aramco shall verify and inspect the first batch of

deliveredconsumables, then random inspection thereafter

2.2 Verify Welding Equipment Calibration SAIC-W-2011SAIC-W-2011

SATR-W-2011H

2.1

Receiving Inspection & Verification of Welding Consumable

Controls in Place (Properties, type, source, segregation, storage,

Issue, Handling, etc.)

SAIC-W-2010

SAIC-W-2010

SATR-W-2009

SATR-W-2020

H

Refer to SATIP No: W-016-01 *Applies to welds of certain P-No 8

Austenitic SS, P-No 10H or Duplex SS, & P-No 40 & above nickel

based alloys in high temp or severe corrosion service (Review scope)

2.0 MATERIAL RECEIVING

1.13 Welding Special* Corrosion-Resistant Materials (As Required) See Remarks See Remarks

Page 2 of 4


RECORDREMARKS

ITEM

NO.

QUALITY

PROCEDURE


ASSIGNMENTS

CNTRCTRSAUDI

ARAMCO





R Saudi Aramco reviews on weekly basis

W/R*

*Refer to the respective NDE SATIP

(SATIP-NDE-UT-01, LPT-01, MPT-01, RT-01, etc):

*Per NDE Special Process Control Procedure

3.13

Database Reporting (per SAEP-1160)

a) Production Weld Status,

b) Welder & Project Repair Rate

c) Welder's Individual Repair Rate d) NDE &

backlog of welds & status e) Special

Process* status per weld

SAIC-W-2016

SAIC-W-2016

SATR-W-2013

SATR-W-2018

SATR-W-2019

H

WSAIC-M-2012 (AWS D1.1) for structural SA Participates in

selection Process daily.

3.12Verify NDE Method Application and Evaluation, Documentation &

Reporting of Results*See Remarks See Remarks W/RH*

S

3.11Selection of Weld Joints for NDE* (Follow NDE

Process Control Proc.)SAIC-W-2015

SAIC-W-2015

SATR-W-2007

SAIC-M-2012

H

W

3.10Repair of Weld Joints or Base Metal by Welding (Prior to Weld

Acceptance)SAIC-W-2013 SAIC-W-2013 W

W

3.9 Post-Welding Visual Inspection SAIC-W-2007SAIC-W-2007

SATR-W-2007H

S/W

Saudi

Aramco's responsibilities varies as follows:

a) "S" - Generally is a surveillance activity for Saudi Aramco, except in

welding of stainless steel piping and piping in low temp service.

b) "W" - S. Aramco inspects and verifies Heat Input at random or on

routine basis for low temp service and for stainless steel welding.

3.8Inspect Welds for Socket Joints and Seal Welded Thread Jts. -

Gap ControlSAIC-W-2037 SAIC-W-2037 W

W / H

Saudi

Aramco's responsibilities varies as follows:

a) "W" - for Welding on normal services at normal conditions, refer to

Note 1 of the General Notes.

b) "H" - for critical welds, ie.; Tie-Ins, buttering, Hot Taps, NDE-In-Lieu

of Hydro & others as determined by project requirements.

3.7 In-Process Weld Inspection SAIC-W-2006SAIC-W-2006

SATR-W-2007W

3.6 Pre-Welding & Weld Joint Fit-Up Inspection SAIC-W-2005SAIC-W-2005

SATR-W-2006H

Page 3 of 4


RECORDREMARKS

ITEM

NO.

QUALITY

PROCEDURE


ASSIGNMENTS

CNTRCTRSAUDI

ARAMCO





S Surveillance I 100% Contractor Inspection

H Hold Point for QC Inspection/ Test R Review of Documents

W Witness Inspection/Test RH Review and Approval of Documents

4Hold: QA/QC organization shall be notified of the timing of inspection or test in advance. Inspection or test shall not be carried out without the QA/QC organization

representative in attendance.

5 If the Main Contractor delegates the assigned responsibility to the Subcontractor, then the Main Contractor will have the same degree of responsibility as assigned to Saudi Aramco.

LEGEND

1The first three incidents of each Inspection or testing activity listed require 100 % participation by Saudi Aramco Site Inspection Personnel. After this period, Saudi Aramco Inspection may adjust the levels of Saudi Aramco participation based

upon the Contractor’s performance.

2 Surveillance: QA/QC organization to monitor work in progress without notice from Construction Organization

3Witness: QA/QC organization shall be notified of the timing of Inspection or test in advance. However, the inspection or test shall be performed as scheduled if the QA/QC

organization representative is not present.

Refer to Applicable SATIP for Pressure Testing. Test Pkg

Documentation (per weld) shall contain final welding & special process

acceptance docs.

GENERAL NOTES

NOTICE (SAEP-1160, Section 9.2): Use of Welding and NDT SAICS 9.2.1 One SAIC per day per activity is required for production welding on a daily or continual basis, e.g., fit-up, in-process, and final inspection. Applicable weld numbers must be

entered in the Remarks Box on the appropriate SAIC. 9.2.2 Special welding activities such as branch connections, tie-ins, sleeve installation, hot-tap welding, and temperature tie-ins will require a separate IR per weld per activity in accordance with

the applicable SATIP. 9.2.3 NDT subcontractors must complete NDT Checklists on a daily basis per above but not as an IR with the exception of the start of NDT activities. START OF NEW WELDING ACTIVITIES IN NEW AREAS REQUIRES

NOTIFICATION.

4.1Final Welding Insp & Documentation (Database Report, Welding

Summary/ Record & Weld Map) per SAEP-1160SAIC-W-2008

SAIC-W-2008

SATR-W-2008

H

4.0 PRE-COMMISSIONING *NOTE: SAUDI ARAMCO CONSIDERS PRESSURE TESTING PART OF CONSTRUCTION, NOT A PRE-COMMISSIONING ACTIVITY

H W

W & R

3.17Modification or Re-Work After Weld Acceptance (Use with SAIC-W-

2013)SAIC-W-2036 SAIC-W-2036 H

W & R

3.16Positive Material Identification (PMI) of Deposited Weld for alloyed

materials within the scope of SAES-A-206. SAIC-L-2010

SAIC-L-2010

SATR-A-2012

SATR-A-2013

H

W & R

3.15 Verification of Hardness Testing Application and Results SAIC-W-2014SAIC-W-2014

SATR-W-2012H

3.14 Post Weld Heat Treatment Inspection SAIC-W-2004SAIC-W-2004

SATR-W-2005H

Page 4 of 4

PASS FAIL N/A RE-INSP DATEITEM

No.ACCEPTANCE CRITERIA REFERENCE

B PMI Extent & Timeliness ... Use Attachments

A9

A quarantine area has been established and procedures in place ensure

that rejected components are segregated and properly identified to

prevent reuse.

S-PM-G000-1520-

0008,

para 13.3

A8

The instrument operator works to his written procedure and has been

trained to use the particular instrument with the procedure. Training was

documented. Certified Operators have demonstrated ability (on approved

equipment on alloy calibration samples) and tested 100% correct in

witness of Company Inspection personnel.

S-PM-G000-1520-

0008,

Section 11

A7Calibration records for the PMI instrument are available and current as

required by manufacturer's documentation for calibrations.

S-PM-G000-1520-

0008,

Section 11

A6

Manufacturer's standard calibration samples and certified samples with

the traceability of "known" materials are available for random (spot)

checks. A test record of calibration samples is available

S-PM-G000-1520-

0008,

Section 11

A5

An optical emission spectrograph that can be used to check for all

required elements, including carbon (The method gives burn damage on

the product so COMPANY approval shall be required prior to use) or

COMPANY approved (XRF) analysis with a calibrated portable

instrument.

S-PM-G000-1520-

0008,

Section 11

A4Operator training, Qualification and experience record shall be available

for COMPANY review and approval.

S-PM-G000-1520-

0008,

para 10.6

A3

Prior to the commencement of fabrication, the field Fabricator has

performed the following:

A) Fabricator has identified, established & presented to COMPANY for

review (two weeks before fabrication begins) a proposed testing, logging,

identification, and final installation procedure for all components requiring

PMI testing onsite (fabricated pressured equipment & internal

components, piping, valves, welds, ETC.).

B) Fabricator has a detailed dwg (PMI map) of pressured equipment (All

applications) being fabricated. Map shows alloy material specs, the extent

(100%, etc) of PMI required, providing "field direction".

An efficient system can be a single map (dwg) for NDT, PMI, etc .

C) QMIS/RFI system allows COMPANY to "WITNESS" any PMI tests.

S-PM-G000-1520-

0008,

Section 14

A2

PMI is integrated with Weld ID system & Database as an element per S-

PM-G000-1520-0006 Tables. Results are logged/tracked/reported

daily.

S-PM-G000-1520-

0006,

Section 8

A General Requirements (Prior to Start of Work) ... See Notes & Attachments 1, 2 & 3

A1PMI procedure is approved by COMPANY. Controlled copy (latest

revision) is available. See SAIC-L-2004.

S-PM-G000-1520-

0008,

Para. 10.1

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?

SCHEDULED INSPECTION DATE & TIME ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME

LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.

EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.

Positive Material Identification (PMI) of Alloy Piping & Alloy

Components (All Applications)SAIC-L-2010 12/11/2013 MECH-

PROJECT TITLE CONTRACT NUMBER CONTRACTOR

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008) Rev 3 30-Jun-08

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Page 1 of 22

B1

PMI is implemented as follows:

A) PMI program covers testing alloy material, pressure-containing

components in shop and field fabricated equipment and piping

• Base metal testing (See Att. 1) of new materials, repair/replacement of

existing materials (including Tie-Ins)

• Weld metal testing (See Att. 1) of new welds, repair/replacement

welds (including Tie-Ins) NOTE: Repair Welds = 2 TESTS!

S-PM-G000-1520-

0008,

Section 7,

Section 8

Page 2 of 22

ITEM

No.ACCEPTANCE CRITERIA REFERENCE PASS FAIL

B12

Elements of the basic alloy materials to be verified is identified prior to

testing. Basic elements are shown in Attachment 1, Table 1.

Attachment 2 is provided to assist. Ensure the following:

A) The Chemical Composition is available for PMI Techs

1) Base Metal ASME II Part A or B or equivalent ASTM spec or

Attachment 3 (UNS Designation listing ASME/ASTM)

2) Weld Metal Spec (AWS Spec or ASME II C Spec)

3) Copy of the WPS (Crosscheck to verify base/weld mat'l)

4) SATR-A-2013 & SATR-A-2014 are available as needed

S-PM-G000-1520-

0008,

para 7.5

B11

The surface to be analyzed is clean bare metal, free of grease or oil, with

a surface finish as specified by instrument manufacturer. Note:Generally

a fresh 60 grit finish & flat surface are req'd for the optical emission

spectrograph, while no minimum surface finish is required for portable

XRF analysis (surface is clean bare metal. )

S-PM-G000-1520-

0008,

para 11.9

B10PMI testing of welds shall be done after removal of slag and/or oxide from

the weld surface.

S-PM-G000-1520-

0008,

para 11.8

B9

If sample removal is used, a written procedure for identification and

traceability to original material is submitted to Saudi Aramco and

approved. Any Overlay Testing (Drillings, etc)

S-PM-G000-1520-

0008,

para 11.8

B8

In cases where PMI testing of the completed weld is not possible because

of geometry (small fillet welds & narrow root beads), PMI testing of filler

metal lots & visual inspection of electrode markings are performed to

verify markings of electrodes or wires are correct

SAES-A-206,

Para. 7.7.4

B7Both inside & outside weld surfaces are tested, only where these are

accessible. TEST ROOT PASSES WHENEVER POSSIBLE.

S-PM-G000-1520-

0008,

para 11.8

B6

PMI testing of weld metal (e.g. deposited or undiluted weld "buttons") is

performed as an alternative to PMI testing of an electrode or wire sample.

Acceptable only when conducted immediately prior to welding or

during welding process.

SAES-A-206,

Para. 7.7.3

B5

One consumable (electrode) from each lot is PMI-tested.

The remainder of the lot is compared to the identified consumable to

verify that the markings of the electrodes/wires are correct .

S-PM-G000-1520-

0008, Section 8

B4

PMI testing is performed during fabrication or immediately prior to

fabrication. PMI testing performed by a manufacturer or supplier

of raw material or loose components is not considered PMI testing

Do timely PMI on receipt & after welding. Best Practice!

S-PM-G000-1520-

0008,

para 8.3

B3

A section by section strategy has been worked out for Vessel Internal

Installation where PMI is required for operationally important nonpressure

components such as trays for distillation columns, internal attachment

welds, certain load bearing supports and hardware. Staging areas are

set up and PMI is well planned.

S-PM-G000-1520-

0008,

Section 7

B2

PMI requirements are met relative to Exceptions from 100% PMI :

A) Tubes for shell and tube and air-cooled heat exchangers and for fired

process heaters and boilers:

• 10 tubes or 10%, (the greater) every heat number at random and tested

prior to the installation of tubes into tube sheets.

B) Alloy bolting is randomly 2% PMI examined if:

• The project Quality Plan has specific provisions for color coding,

segregation, and visual inspection that were acceptable to Project

Inspection and the proponent organization.

• The quality procedures are adequate and are being observed.

Rejected components or failure to follow procedures shall be cause

for PMI examination to be increased to 100% at Inspector discretion. All

replacement components are tested 100% .

S-PM-G000-1520-

0008,

para 7.2



N/A RE-INSP DATE




Page 3 of 22

ITEM




N/A RE-INSP DATE




D Markings of PMI Verified Materials

D1

Paint marking material shall be free of lead, sulfur, zinc, cadmium,

mercury, chlorine, or other halogens.

Low Chloride markers are those with residuals of 50ppm or less.

S-PM-G000-1520-

0008,

para 16.1.1

C8

All components, and welds that are found unacceptable shall be marked

immediately with a circled red "X" pending resolution in accordance with

Item C5 above.

S-PM-G000-1520-

0008,

para 16.1.2

C7

Rejected components are dispositioned as follows:

A) Retest by Equipment Manufacturer or the Fabricator to obtain a more

accurate analysis (at his own expense) by chemical analysis performed

by an independent testing laboratory acceptable to the Saudi Aramco

Inspector. The results of the more accurate test method or independent

chemical analysis will govern.

B) Replace the rejected component and PMI the replacement

C) Rejected items shall be recorded and disposed as per Non Conformity

Control Procedure S-PM-G000-1520-0005.

Technicians follow procedure & record results on SATR (Report)

applicable to the work. Engineer & COMPANY Assigned Inspector

review recorded results & witness "retesting" to verify any unacceptable

results. HOLD

POINT: Retest to verify unacceptable PMI results. A COMPANY

Assigned Inspector responsible for PMI shall be contacted immediately.

S-PM-G000-1520-

0008,

Section 13

C6

Technicians follow procedure & record results on SATR (Report)

applicable to the work. Engineer & COMPANY review recorded results &

witness "retesting" to verify unacceptable results.

HOLD POINT: Retest to verify suspect/unacceptable results. A

COMPANY Inspector responsible for PMI (if he is not present) is

contacted immediately as agreed upon at the start of PMI Testing

Activities.

Procedure & S-

PM-G000-1520-

0008, Section 12

HOLD POINT

C5

For dissimilar metal alloy welds (other than weld overlays), the effects of

dilution from the different base metals and the filler metal are taken into

account for determining the nominal as-deposited weld metal

composition.

S-PM-G000-1520-

0008,

para 12.3

C4

For weld overlays, the chemistry on the surface of overlays shall be in

accordance with the welding consumable specified in the approved

welding procedure.

S-PM-G000-1520-

0008,

para 12.3

C3

Welds with consumables that match, or nearly match, the base metal

composition shall be within ±12.5% of the ranges allowed in ASME SEC

IIC for each element.

S-PM-G000-1520-

0008,

para 12.2

C2

Alloys shall be acceptable if the alloying elements are each within 10% of

the specified range of values of alloying elements shown in the material

specification and as determined in Item A11.

S-PM-G000-1520-

0008,

para 12.1

C Evaluation of Results (Acceptance Criteria) … See Attachment 3 (PMI Failure & Inspection Tips, Lessons Learned)

C1 Attachment 3 Inspection Tips were used!LESSONS

LEARNED

B14

Quarantine area & procedures are established to ensure that any rejected

components are segregated & identified to prevent reuse.

An ID Tag shall be affixed to any PMI rejected material also.

S-PM-G000-1520-

0008,

para 13.3

B13

Amounts of alloying elements as shown in the material specification has

been determined and listed for the acceptance criteria.

Inspectors know the alloy elements & % range. They can check, verify &

if a result is outside normal range, reverify & report result.

S-PM-G000-1520-

0008,

para 12.1

Page 4 of 22

ITEM




N/A RE-INSP DATE




Quality Record Approved:Name, Organization,

Initials and Date:

Name, Initials and Date: Name, Initials and Date:

Contractor QC Inspector COMPANY InspectorT&I Witnessed QC Record Reviewed Work Verified

Performed Inspection

Contractor QC Supervisor Proponent and OthersT&I Witnessed QC Record Reviewed Work Verified


Name, Initials and Date:

Performed Inspection Work / Rework May Proceed

Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified

Attachment 3 - PMI Failures & Inspection Tips, Lessons Learned

REFERENCE DOCUMENTS: 1. S-PM-G000-1520-0008, Positive Material Identification

Contractor / Subcontractor Saudi AramcoSubcontractor QC Inspector COMPANY PMT Representative

2) See Attachment 2 for S-PM-G000-1520-0008 PMI PROGRAM REQMTS, ELEMENT TABLE & SA Form 175

3) QC Forms SATR-A-2012 & SATR-A-2013 or approved equivalency shall be utilized with the work

4) BASIC ALLOYS IN TABLE 1 ARE IDENTIFIED BY SPEC & TYPE. ASSURE ENGINEER & INSPECTORS KNOW CRITICAL DETAILS

ATTACHMENTS:

Attachment 1 - S-PM-G000-1520-0008 PMI PROGRAM REQMTS, ELEMENT TABLE & SA Form 175

Attachment 2 - PMI QUALITY CONCERNS & TABLE 1 ASSISTANCE

REMARKS:

NOTES: 1. Per S-PM-G000-1520-0006 PMI Reqmts, PMI is tracked on a Per weld Basis and reported as per S-PM-G000-1520-0006. See SAIC-

L-2004. This shall include Repairs, that receive a Unique ID Number or designation. Also, Reporting status & backlog reporting is required.

E3Paints are free of lead, sulfur, zinc, cadmium, mercury, chlorine, and

other halogens.

S-PM-G000-1520-

0008,

Para. 16.2.4

E2Permanent manufacturers' markings shall not be obscured by color

coding.

S-PM-G000-1520-

0008,

Para. 16.2.2

E

Material Identification by Color Coding : The color coding system for

material identification described his intended to help prevent fabricators

from using incorrect alloy material. The principal purpose of color coding

is visual identification during storage and after the components have

been cut for fabrication.

E1

Color coding scheme is prepared and submitted to COMPANY approval.

The Color coding scheme should identify the colors to be used and the

method of color application should follow the procedure stated in S-PM-

G000-1520-0008, Sec. 16.2.

S-PM-G000-1520-

0008,

Para. 16.2

D4 PMI markings are transferred when a plate or pipe is cut.

S-PM-G000-1520-

0008,

para 16.1.4

D3

When heat treating is performed after PMI, the identification marking

must be recognizable after heat treatment. PMI markings shall be

transferred when a plate or pipe is cut.

S-PM-G000-1520-

0008,

para 16.1.4

D2

All verified materials with an acceptable analysis are marked with the

letters "PMI" using a certified low-stress stamp. The marking shall be

placed as follows:

• Pipe: One mark, 75 mm from one end on the outer surface of the pipe.

This marking shall be in addition to PFI ES-22 reqmts.

• Welds: Adjacent to the welder's mark on the weld. (Welds on tubes for

heat transfer equipment shall be marked by either stenciling or vibro-

etching on the tube sheet).

• Fittings and Forgings: Adjacent to the manufacturer's markings.

• Valves: Adjacent to the valve manufacturer's markings on bodies and

other pressure parts.

• Castings: Adjacent to manufacturer's markings and heat numbers.

• Plates: 75 mm from one edge, adjacent to mfg's markings.

• Tubes: Stenciled, 300 mm from each end.

S-PM-G000-1520-

0008,

para 16.1.3

Page 5 of 22

ITEM




N/A RE-INSP DATE





Initials and Date:

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


Page 6 of 22


Components (All Applications)SAIC-L-2010 11-Dec-13 PIPING-

Attachment 1 - S-PM-G000-1520-0008 PMI PROGRAM REQMTS


SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER DATE APPROVED QR NUMBER

Page 7 of 22

Attachment 1 - S-PM-G000-1520-0008 PMI PROGRAM REQMTS & ELEMENT TABLE

Page 8 of 22


Page 9 of 22


Page 10 of 22


Page 11 of 22

Page 12 of 22

Page 13 of 22

Page 14 of 22


Page 15 of 22

Weld Metal per ASME II C is acceptable if each alloying element is within 12.5% of the specified range.

Note: Dilution can occur when composition of base matl (ASME II Part A, B) & Weld Metal (ASME II Part C) varies.

321 SS and others utilize Titanium & Niobium to "stabilize" the SS during manufacturing process.

Method to Evaluate PMI Results

WORK SHALL BE DONE WITH A COPY OF ALL APPLICABLE SPECS (CHEMICAL COMPOSITION CHARTS)

USE ASME SEC II PART A (Ferrous Base Matls), B (Non-Ferrous Base Matls), C (Welding Consumables)

COMPARE ELEMENTS IN CHEMICAL COMPOSITION TABLES (ASME II C HAS 3 PARTS) TO TEST RESULTS

Base matl per ASME II, A or B) is acceptable if each alloy element is within 10% of the specified range.

positively identified. Remainder of the lot shall be checked (markings) and measures taken to assure substitution

of electrodes is "PREVENTED". Preventive Measures include training for welders (color code & electrode familiarity).

Guide for Usage of This TableNOTE: THIS IS NOT A USER "FRIENDLY" TABLE FOR INSPECTION & ENGINEERS ALIKE.

It is difficult for Inspectors or PMI technicians to tell what materials "FALL INTO WHAT CATEGORY".

Not surprisingly, many tests are performed incorrectly. Example: Can you identify "stabilized SS" from other SS?

weldability issues. (API 578, Section 4). This includes Low Temp service electrode (1% Ni) improper substitutions.

Tacking of SS using incorrect electrodes is another serious & common problem.Use Training & Vigilance.

Requirement: Extremely Tight controls of Welding Consumables for Low-Alloys & Nickel based alloys.

Many of these electrodes look alike and have similar designations. E-7018, E7018-1, E7018M, per AWS A5.1 can

can be mixed by the poorly trained with AWS A5.1 Low Alloy E-7018A1 Carbon Moly or E-7018 B2L Cr moly, etc).

When welding is conducted, one new electrode or wire sample from each lot or package of alloy weld rod shall be

NOTICE TO QUALITY MANAGERS & INSPECTORSCarbon Steel Substitutions in Low Alloy Steel Systems

In determining the likelihood of material nonconformances, it is worth noting that historically the greatest number of

material nonconformances with serious consequences have involved carbon steel components in low alloy steel

(e.g., 1-1⁄4Cr–1/2Mo, 2-1⁄4Cr–1 Mo, 5 Cr–1⁄2Mo, 9 Cr–1 Mo) piping systems. There have been relatively fewer

nonconformances in stainless steel and nonferrous (e.g. Monel, Inconel) systems because of appearance and


Components (All Applications)SAIC-L-2010 MECH-

Attachment 2 - PMI QUALITY CONCERNS & TABLE 1 ASSISTANCE



Page 16 of 22

PMI Table for Engineers, PMI Technicians & Welding Inspectors on IK Projects

Attachment 2 - SAES-A-206 PMI QUALITY CONCERNS & TABLE 1 ASSISTANCE

Mat’l / Grade UNS/Spec

& P-No Cr Ni Mo C Nb Ti Cu Zn W Al V Fe

BASE MATERIALS PER SAES-L-132 USED ON SA PROJECTS IN BOLD LETTERS

WELDING CONSUMABLES – CHECK WPS & USE ASME SECTION II PART C

Chrome-Molybdenum, Carbon-Molybdenum, Manganese-Molybdenum 1⁄2Cr–1⁄2Mo

(Grade P-2)

C–1⁄2Mo

(Grade P-1)

A 335

P- No 3

X X NOTE: NO BACK-PURGE NECESSARY FOR WELDS

1-1⁄4Cr–1⁄2Mo

(Grade P11)

1Cr–1⁄2Mo

(Grade P12)

A 335

P- No 4

X X NOTE: NO BACK-PURGE NECESSARY FOR WELDS

2-1⁄4Cr–1Mo

(Grade P-22)

3Cr–1Mo

(Grade P-21)

A 335

P-No 5A

X X NOTE: NO BACK-PURGE NECESSARY FOR WELDS.

2-1/4 Cr = Limit for No Back Purge Requirement.

3% Cr = CSD will determine need for Back Purge If any

Note: 3% Cr is rarely used if ever on SA Projects. 5Cr–1⁄2Mo

(Grade P-5) A 335

P-No 5B

X X NOTE: BACK-PURGE ALL WELDS ABOVE 2-1/4% Cr

5% Cr = Back Purge Necessary 9 Cr, 1 Mo

(Grade P-9) A 335

P-No 5B

X X NOTE: BACK-PURGE ALL WELDS ABOVE 2-1/4% Cr

9% Cr = Back Purge Necessary

Mat’l / Grade UNS/Spec

& P-No Cr Ni Mo C Nb Ti Cu Zn W Al V Fe

Copper Based Alloys (Note: This is not a Nickel Alloy, UNS prefix designation is “C”) 90/10 CuNi

(Gr. B466/67)

C70600

P-No34 X X X

70/30 CuNi

(Gr B467)

C70600

P-No34 X X X

Regular Carbon Grade SS 304 S30400 X X X

309 S30900 X X X

310 S31000 X X X

316 S31600 X X X

317 S31700 X X X

NOTE: Any of the above with an “L” or “H” Suffix requires the Carbon Content “C” also. These are Low & High

Carbon Steels. THEY ARE CHECKED FOR CARBON CONTENT.

TIP: E-LIBRARY ASME FOLDER HAS “UNS” FOLDER & TABLES & DESIGNATES ALL ELEMENTS

FOR EASY CHEM COMP ASSESSMENT, INCL. CARBON & STABILIZED STEEL DESIGNATIONS

Stabilized Stainless Steels ... may include 347 ... High Temp Service 321

(stabilized SS) S32100 X X X C 0.08 max Cr 17.00-19.00 Mn 2.00 max

Ni 9.00-12.00 P 0.045 max S 0.030 max Si 1 .O0 max Ti 5XC min

Super Austenitic (Corrosion resistant) & Austenitic-Ferritic SS

SMO254 Austenitic Cr-Ni-Mo-Cu-N Stainless Steel

S31254 X X X C 0.020 max, Cr 19.50-20.50, Cu 0.50-1 .O0,

Mn 1 .O0 max, Mo 6.00-6.50 max, S 0.010 max, Si 0.80 max, N 0.180-0.220,

Ni 17.50-18.50 P 0.030

2205 Duplex

SS-P-No 10H (Austen-Ferritic) Cr-Ni-Mo-N

S31803 X X X C 0.030 max Cr 21.0-23.0, Mn 2.00 max Mo 2.50-3.50, N 0.08-0.20 Ni 4.50-6.50,

P 0.030 max S 0.020 max Si 1 .O0 max

Page 17 of 22

PMI Table for Engineers, PMI Technicians & Welding Inspectors on IK Projects

Attachment 2 - SAES-A-206 PMI QUALITY CONCERNS & TABLE 1 ASSISTANCE

Nickel Based Alloys ... Check for Nickel , Iron, Copper, Chromium, Molybdenum

Hastelloy B2 or Alloy B-2

(Ni–Mo = B 619)

N10665 P- No 44

C 0.02 max Co 1 .O max Cr 1 .O max Fe 2.0 max Mn 1 .O max Mo 26.0-30.0 Ni Remaining P 0.04 S 0.03 max Ci 0.10 max - ASME SB333; SB335; SB366; SB619; SB622; SB626; SFA5.14 (ERNiMo-7) ASTM B333; B335; B366; B619; B622; B626 AWS A5.14 (ERNiMO-7)

Alloy 600 or Inconel 600

Ni-Cr

N06600 C 0.15 max Cr 14.00-17.00 Cu 0.50 max Fe 6.00-10.00 Mn 1.00 max Ni 72.0 min S 0.015 max Ci 0.50 max - ASME SB163; SB166; SB167; SB168; SB564 ASTM B163; B166; B167; B168; B366; B516; B517; B564; B751 Other: NACE MR-01-75

Alloy 400 or Monel 400

Ni-Cu Alloy

N04400 C 0.3 max Cu Remaining Fe 2.50 max Mn 2.00 max Ni 63.00-70.00 S 0.024 max Si 0.50 max - ASME SB127; SB163; SB164; SB165; SB564 ASTM B127; B163; B164; B165; B366; B564 Other: NACE MR-01-75

Alloy 20 Ni-Fe-Cr Alloy (Carpenter 20Cb3)

N08020 P-No 45

C 0.07 max Cb 8xC-1 .O0 Cr 19.00-21.00 Co 3.00-4.00 Fe Remaining Mn 2.00 max Mo 2.00-3.00 Ni 32.00-38.00 P 0.045max S 0.035 max Si 1.00 max ASME SB462; SB463; SB464 ASTM A358; 8366; 8462; 8463; 8464; 8468; 8471; 8472; 8473; 8474; 8475; 8729 Other: NACE MR-01-75

Alloy C-276

(Ni–Mo–Cr = B366 or B564

N10276

P-No 44

C 0.02 max Co 2.5 max Cr 14.5-16.5 Fe 4.0-7.0 Mn 1.0 max Mo 15.0-17.0 Ni Remaining P 0.030 max C 0.030 max Si 0.08 max V 0.35 max W 3.0-4.5 - ASME SB366; SB574; SB575; SB619; SB622; SB626; SFA5.14 (ERNiCrMo-4) ASTM B366; B564; B574; B575; B619; B622; B626; F467 (276); F468 (276) AWS A5.14 (ERNiCrMo-4) NACE MR-01-75

Alloy C-22 or Hastelloy C-22 (Ni–Cr-Mo) B619 or B622)

N06022 P- No 44

C 0.015 max Co 2.5 max Cr 20.0-22.5 Fe 2.0-6.0 Mn 0.50 max Mo 12.5-14.5 Ni Remaining P 0.02 max C 0.02 max Ci 0.08 max V 0.35 max W 2.5-3.5 - ASME SB366; SB574; SB575; SB619; SB622; SB626; ASTM B366; B564; B574; B575; B619; B622; B626 AWS A5.14 (ERNiCrMo-10) NACE MR01-75

Alloy 625 Ni-Cr-Mo-Cb (Nb)

N06625 AI 0.40 max C 0.10 max Cb 3.15-4.15 Cr 20.0-23.0 Fe 5.0 max Mn 0.50 max Mo 8.0-10.0 Ni Remaining P 0.015 max S 0.015 max Si 0.50 max Ti 0.40 max ASME SB443; SB444; SB446; SFA5.14 (ERNiCrMo-3) ASTM B366; B443; B444; B446; B564; B704; B705; B751 AWS A5.14 (ERNiCrMo-3) Other: NACE MR-OI-75

Alloy 800 Fe-Ni-Cr Alloy

N08800 AI 0.15-0.60 C 0.10 max Cr 19.0-23.0 Cu 0.75 max Fe rem Mn 1.5 max Ni 30.0-35.0 P 0.045 max S 0.015 max Si 1.0 max Ti 0.15-0.60 - ASME SB163; SB407; SB408; SB409; SB564 ASTM A240; A358; B163; B366; B407; B408; B409; B514; B515; B564 Other: NACE MR-01-75 ... ASTM A240 lists N08800

Alloy 825 or Incoloy 825

Ni-Fe-Cr Alloy

N08825 AI 0.2 max C 0.05 max Cr 19.5-23.5 Cu 1.5-3.0 Fe Remaining Mn 1 .O max Mo 2.5-3.5 Ni 38.0-46.0 P 0.03 max S 0.03 max Ci 0.5 max Ti 0.6-1.2 - ASME SB163; SB423; SB424; SB425 ASTM B163; B423; B424; B425; B564; B704; B705 - NACE MR-01-75

Page 18 of 22

Attachment 2 - SAES-A-206 PMI PROGRAM REQMTS & ELEMENT TABLE (API 582 Guide)

Page 19 of 22

21. ALWAYS KNOW THE MATERIAL SPECIFICATION MAGNETIC PROPERTIES BEFORE INSPECTING IT.

11. COUNTERFEIT HARDWARE IS COMMON NOW IN SAUDI ARAMCO IN ALL CONSTRUCTION DISCIPLINES

12. NEVER "ASSUME" VENDOR PMI TESTS ARE CORRECT, AS MOST PMI IS "VERIFIED" NOT WITNESSED.

14. IF MATERIALS ARRIVE WITHOUT REQD "PMI OK" MARKINGS PER SAES-A-206, REJECT THEM/VERIFY.

15. ON VESSEL INTERNAL INSTALLATIONS, USE A MAGNET TO FIND MIXED SS HARDWARE.

18. NEVER "ASSUME" VENDOR PMI TESTS ARE CORRECT, USE A MAGNET ANYWAY.

19. ALWAYS KNOW THE MATERIAL SPECIFICATION REQUIRED BEFORE INSPECTING IT.

20. ALWAYS KNOW THE MATERIAL SPECIFICATION MARKINGS REQUIRED BEFORE INSPECTING IT.

1. NEVER ALLOW CuNi & SS (316, etc) to be done in same shop without careful consumable segregation.

8. 400 SERIES STAINLESS STEEL (High % Cr & 1% or Low % Nickel) IS "VERY SLIGHTLY" MAGNETIC

2. CONSUMABLES & GRINDERS/BRUSHES/FILES MUST BE "COLOR CODED" FOR EACH DIFFERENT MATL

3. NEVER ALLOW grinders used on CuNi to be used on SS (316, etc). This can cause PMI failures/cracks.

4. ALWAYS VERIFY Cu (Copper) content in SS when performing PMI … If ANY possibility of mixing exists.

5. Cu (Copper) content in SS (316, etc) SHOULD NEVER EXCEED 0.7% IN ANY CASE. Lessons Learned.

6. ALWAYS USE A MAGNET TO CHECK RECEIVED SS HARWARE & SS MATERIALS & WELDS

25. THE # 1 CAUSE OF PMI FAILURES = CS CONSUMABLE (P-1) MIXING WITH LOW ALLOY STEEL (P-3/4/5)

7. 300 SERIES STAINLESS STEEL (High % Cr & Ni) DOES NOT ATTRACT A MAGNET (NON-MAGNETIC)

22. ALWAYS KNOW YOUR CHEMICAL COMPOSITION REQUIREMENTS BEFORE REVIEWING RESULTS.

23. WHEN WELDING WITH 1% Ni or OTHER ALLOY ELECTRODES, PMI MUST BE DONE.

24. WHEN ANY POSSIBILITY OF CONSUMABLE MIXING EXISTS, EVALUATE / REVIEW OTHER ELEMENTS

16. ON SKID MOUNTED EQUIPMENT, USE A MAGNET TO FIND MIXED SS MATLS / HARDWARE.

17. ON RECEIVED FABRICATED PIPING, MAGNETS CAN IDENTIFY MIXED CONSUMABLES.

13. PMI SHOULD BE DONE ON 100% OF ALL FITTINGS & PIPE "BEFORE FABRICATION" (TEST WELD ONLY)

9. Electroplated CS (Counterfeits substituted for SS) are strongly magnetic along with zinc plated items.

10. MARKINGS ON MATERIALS / HARDWARE / BOLTING ARE OFTEN WRONG (COUNTERFEIT ITEMS)


Components (All Applications)SAIC-L-2010 MECH-

Attachment 3 - PMI FAILURES, INSPECTION TIPS, & PREVENTION (LESSONS LEARNED)



Page 20 of 22

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 2 (Standards Cutoff - June 2008) REV 3 30-Jun-08


Inspection of Structural Welding (Per AWS D1.1) SAIC-M-2012 11-Dec-13 MECH -PROJECT TITLE CONTRACT NUMBER CONTRACTOR






A General Requirements

A1

Procedure (Prequalified per AWS D1.1 2004 or earlier edition) has been

reviewed and approved for application by Project Inspection.

Welders have valid JCCs and are qualified for structural welding.

12-SAMSS-007,

Para. 7.5



A2

Materials to be welded have been received & inspected and are properly

identified & traceable to Certified Mill Test Reports or Certificate of

Compliance (Specification). SAIC-M-2003

12-SAMSS-007,

Material

Specifications

A3

Approved Drawings are available for the work and provide detailed

instruction for the weld joint & weld dimensions.

Shop drawings and erection drawings shall be prepared per the AISC

documents listed in 12-SAMSS-007.

12-SAMSS-007,

Para. 6.4.1

& Para. 7.10

B Pre-Welding Inspection ... Assumes Equipment Checks are accepted for Associated Welding (Piping, Vessels, etc)

B1

Preparation of Base Metal & cleanliness met AWS Section 5.15:

A) Cleaning removed any scale, oils, rust, foreign matter (Clean)

B) Joint Preparation exhibited good workmanship (free of notches)

C) Checks for laminations

Observance of smoke with objectionable fumes may indicate welding is

being done on fouled surfaces (Cleaning inadequate)

12-SAMSS-007,

Para. 7.5

Attachment 2

B2

Joint alignment for Butt Welds shall be 10% offset or 1/8" (3mm)

whichever is smaller. Stiffener & gusset plates shall be fitted per dwg

tolerances (max gap 1/16" or 2mm) See Attachment 4.

AWS D1.1,

Section 5.22

& Section 5.23

B3Welding environment is acceptable for welding. Attachment 2.

Similar rules for Piping are followed (Same Procedure)

AWS D1.1,

Para. 5.12

B4

Preheat has been performed on damp steel & as req'd based on

WPS & AWS D1.1 Preheat Table 3.2 Reqmts for steel type.

This preheat & all subsequent minimum interpass temps shall be

maintained during the welding operation for a distance at least equal to

the thickness of the thickest welded part (not less than 3 in. [75 mm]) in

all directions from the point of welding.

AWS D1.1,

Para. 5.6 &

Para. 3.2

(Preheat Tables)

B5

Electrode selected was based on WPS and AWS Table 3.1.

Consumable Control Practices associated with Pipe & Equipment

Welding are followed. Cellulose Electrodes (E6010) are not used.

AWS D1.1,

Para. 5.3 &

Table 3.1

B6

MEASURES TO MAINTAIN EFFECTIVE TOLERANCES FOR ASSY &

PREVENT WELDING DISTORTION have been taken on the structural

items being welded. Such measures include the use of strongbacks &

carefully sequenced welding for "Best Practice". A

final assessment for welding distortion shall be required

AWS D1.1,

Section 5.23

B7

WELDERS HAVE RECEIVED INSTRUCTION ON FIGURE 5.4

Workmanship & weld Profiles shall be per Attachment 3.

A final assessment for welding workmanship is performed.

AWS D1.1,

Section 5.24

C In-Process Welding Inspection

C1

Tack welds shall be subject to the same quality reqmts as the final welds

and shall exhibit good workmanship. Tack welds that are incorporated

into the final weld shall be cleaned thoroughly. Multiple-pass tack welds

shall have cascaded ends.

AWS D1.1,

Section 5.18

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Inspection of Structural Welding (Per AWS D1.1) SAIC-M-2012 12/11/2013 MECH -PROJECT TITLE CONTRACT NUMBER CONTRACTOR

C2

Weld Profiles - All welds, except as otherwise allowed below, shall be

free from cracks, overlap, and the unacceptable profile discontinuities

exhibited in Figure 5.4. (Butts & Fillets)

Weld Profiles are acceptable per Attachment 3.

Butt weld reinforcement does not exceed 3mm

Grinding to achieve requirements is acceptable.

AWS D1.1,

Section 5.18

C3In addition, any strikes, gouges, and other indications of careless

workmanship (such as surface porosity) shall be removed by grinding.

12-SAMSS-007,

Para. 7.6 (a)

D FINAL Welding Inspection & Acceptance

D1Repairs were identified and treated per the requirements of Attachment

2.

AWS D1.1,

Section 5.26

D2

Any NDE required was selected, completed and accepted.

See Attachment 5.

NDE was witnessed and completed reports are available.

12-SAMSS-007,

Para. 7.6 (a)

AWS D1.1,

Sect 6

D3Visible & measured welding distortion is within AWS D1.1 tolerances

listed in Attachment 4.

AWS D1.1,

Section 5.23

D4

VISUAL EXAMINATION CRITERIA (Use Attachment 3):

A) Weld Profiles are acceptable per Attachment 3.

B) Table 6.1 Visual acceptance criteria was met

8 Imperfections are listed. Welds were gauged & accepted

AWS D1.1,

Section 5.18

REMARKS:

NOTES: 1. This Checklist is efficiently streamlined. The intention of this checklist is to accompany associated Process welding & meet code.

ATTACHMENTS:

Attachment 1 - ASTM A6 / ASTM A6M Structural Steel Tolerance Tables (Str. Shapes, Flanged Sections)

Attachment 2 - Structural Steel Pre-Welding, In-Process Inspection & Repair Requirements (AWS D1.1)

Attachment 3 - Structural Steel Welding Acceptance Criteria (AWS D1.1)

Attachment 4 - Structural Steel Welding Reqmts & Tolerances at Saudi Aramco (Per AWS D1.1)

Attachment 5 - Structural Steel Welding Requirements, Selection of NDE (AWS D1.1)

REFERENCE DOCUMENTS:

2- 12-SAMSS-007 -- Fabrication of Structural and Miscellaneous Steel, (3 September 2006)

3- 12-SAMSS-008 -- Erection of Structural and Miscellaneous Steel, 28 January 2004

4- PIP STS05130 -- Erection of Structural and Miscellaneous Steel Specification, February 2002

5- ASTM A6/A6M -- Standard Spec for General Reqmts for Rolled Structural Steel Bars, Plates, Shapes & Sheet Piling, 1 March 2004

Contractor / Subcontractor Saudi Aramco

Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified

Subcontractor QC Inspector COMPANY PMT Representative Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified



ACCEPTANCE CRITERIA REFERENCE



Initials and Date:

PASS FAIL N/A RE-INSP DATE


ITEM

No.


Contractor QC Inspector COMPANY Inspector

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Inspection of Structural Welding (Per AWS D1.1) SAIC-M-2012 12/11/2013 MECH -

Attachment - ASTM A6 / ASTM A6M Structural Steel Tolerance Tables (Str. Shapes, Flanged Sections)

Page 3 of 29

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Inspection of Structural Welding (Per AWS D1.1) SAIC-M-2012 11-Dec-13 MECH -


Joint preparation & cleanliness meets the detailed requirements of Section 5.15 below:

INSPECTION POINTS (VERIFY)

1. Observance of smoke with objectionable fumes may indicate welding is being done on fouled surfaces.

2. Joint Prep method, i.e., thermal cutting, gouging, and grinding results in a workmanlike profile & finish.

5.15.4.4 Gouge or Notch Limitation: Roughness exceeding these values & notches or gouges not more than 3/16

in. [5 mm] deep on other wise satisfactory surfaces shall be removed by machining or grinding. Notches or gouges

exceeding 3/16 in. [5 mm] deep may be repaired by grinding if the nominal cross-sectional area is not reduced by

more than 2%. Ground or machined surfaces shall be fared to the original surface with a slope not exceeding one in

ten. Cut surfaces & adjacent edges shall be left free of slag. In thermal-cut surfaces, occasional notches or gouges

may, with approval of the Engineer, be repaired by welding.

3. Any Mill Discontinuities are resolved per AWS D1.1, dispositioned & repaired as per Table 5.4 below.

POINT 1: Welding Joint preparation & cleanliness meets AWS D1.1 requirements ........... PASS or FAIL

Page 12 of 29


Welding Environment & Preheat is acceptable per requirements of Section 5.12 below:

INSPECTION POINTS TO WATCH

A quick look at this and you can see where the 8 Km / hour wind rule in SAES-W-011/012/etc comes from.

BIG POINT OF DIFFERENCE (OMISSION): NO MENTION IS MADE OF THE SMAW PROCESS.

SO ... WELDERS CAN WELD SMAW (AWS D1.1 APPLICATIONS ONLY) IN WINDS ABOVE 8 KM/Hr ... RIGHT?

ANSWER: AS LONG AS WELD QUALITY MEETS ATTACHMENT 2 FOR FILLET & GROOVE WELDS AND THE

WELDING PROCESS CONTROL PROCEDURE DOES NOT SPECIFY A MAXIMUM LIMIT FOR WIND SPEED.

REQUIREMENT: With SMAW, unshielded work shall not be subject to excessive* arc fluctuations.

* This varies from welder to welder depending on skill level in wind & how wide his butt is to keep wind off the work.

WINDBORNE DUST/SAND (ELEMENT OF HIGH WINDS) SHALL ALSO REQUIRE PROTECTIVE MEASURES.

5.6 Preheat and Interpass Temperatures

Base metal shall be preheated, if required, to temperature not less than minimum value listed on WPS (see 3.5 for

prequalified WPS limitations & Table 4.5 for qualified WPS essential variable limitations). For combinations of base

metals, the minimum preheat shall be based on the highest minimum preheat. This preheat and all subsequent

minimum interpass temperatures shall be maintained during the welding operation for a distance at least equal to the

thickness of thickest welded part but not less than 75 mm all directions from point of welding. Minimum interpass

temperature requirements shall considered equal to the preheat requirements, unless otherwise indicated on WPS.

PREHEAT & INTERPASS TEMPS SHALL BE CHECKED JUST PRIOR TO INITIATING ARC FOR EACH PASS.

THIS MEANS EACH WELDER KNOWS THE PREHEAT REQMTS & HAS THE CORRECT TEMP CRAYON (ETC)

POINT 2: Welding Environment & Preheat meets AWS D1.1 requirements ........... PASS or FAIL

Page 13 of 29


Welding Consumables (Section 5.3):

5.3.2 SMAW Electrodes. Electrodes for SMAW shall conform to the requirements of the latest edition of AWS A5.1,

Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding, or to the requirements of AWS A5.5,

Specification for Low-Alloy Steel Electrodes for Shielded Metal Arc Welding.

NO SIGNIFICANT CHANGES EXIST FOR CONSUMABLE CONTROL & CONSUMABLES USED FOR PIPING

Utilize the applicable checklists for Consumable Control & an approved Procedure detailing controls.

POINT 3: Welding Consumables & Controls followed an approved procedure ........... PASS or FAIL

Welding Execution (Procedure):Welding Activities shall follow an approved or pre-approved WPS that has been submitted to SA PID & approved

per the requirements of SAEP-352.

Where details of welding are unknown (unspecified), ENGINEER & QUALITY MANAGER shall make these KNOWN

This shall be done to provide adequate Field Instructions to Inspectors & Welders. Quality Mgr. Action.

NDT Specs (Section 6, Part C & See Repairs Below):SECTION 6 Part C Acceptance Criteria (Visual & NDT)

6.7 Scope - Acceptance criteria for visual and NDT inspection of tubular connections and statically and cyclically

loaded nontubular connections are described in Part C. The extent of examination & acceptance criteria shall

be specified in the contract documents on information furnished to the bidder. Quality Mgr. Action!

Allowable Repairs (Summary)

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AWS D1.1 --- 5.24 Weld Profiles - All welds, except as otherwise allowed below, shall be free from cracks, overlap,

and the unacceptable profile discontinuities exhibited in Figure 5.4. FILLET SIZE SHALL BE MEASURED (GAGE).

5.24.1 Fillet Welds: The faces of fillet welds may be slightly convex, flat, or slightly concave as shown in Figure 5.4

Figure 5.4(C) shows UNACCEPTABLE FILLET WELD PROFILES. THESE ARE NEVER* ALLOWED AT SA.

* Inspectors accepting such welds are subject to "Retraining for Field Performance".

* Inspectors shall identify welders with Poor Workmanship early in the Welding Process

5.24.3 Convexity:. Except at outside welds in corner joints, the convexity C of a weld or individual surface bead

shall not exceed the values given in Figure 5.4.(1/16" to 3/16" per Table) --> FILLET SIZES SHALL BE SPECIFIED

IF FILLET SIZE IS UNKNOWN, INSPECTOR ENSURES ENGINEERING DIRECTION IS PROVIDED AS NEEDED.

5.14 Minimum Fillet Weld Sizes - The minimum fillet weld size, except for fillet welds used to reinforce groove

welds, shall be as shown in Table 5.8. The minimum fillet weld size shall apply in all cases, unless the design

drawings specify welds of a larger size. AGAIN, DESIGN DRAWINGS SHALL SPECIFY A FILLET SIZE!

CAUTION: MANDATORY HOLD POINT FOR DWG & SPECIFICATION CHECK FOR CORRECT FILLET SIZE

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AWS D1.1 - Section 6.9 (Visual Inspection)

All welds shall be visually inspected and shall be acceptable if the criteria of Table 6.1 are satisfied.

LOAD TYPE CONNECTIONS SHALL BE SPECIFIED (PROVIDE ADEQUATE EVALUATION CRITERIA)

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5.24.4 Groove or Butt Welds: Groove welds shall be made with minimum face reinforcement unless otherwise

5.23.8 - FLANGE WARPAGE & TILT (WELDING DISTORTION)

1% of total flg width or 1/4" (6mm) whichever is greater & "Exception"

THEY WELDED IT & NOW IT LOOKS LIKE A BANANA*

* Splice welds and welding of gusset plates and other members shall require proper use of "strongbacks" and

other means to prevent distortion during welding. This is critical when welding will be concentrated in one side

or area of a member. WELD PASS SEQUENCE CAN ALSO REDUCE DISTORTION.

See Section 5.23 for applications other than Columns & Trusses (Beams)

specified. In the case of butt and corner joints, face reinforcement shall not exceed 1/8 in. [3 mm] in height.

All welds shall have a gradual transition to the plane of base-metal surfaces with transition areas free from undercut

except as allowed by this code. Figure 5.4(D) shows typically acceptable groove weld profiles in butt joints.

Figure 5.4(E) shows typically unacceptable weld profiles for groove weld butt joints. *NEVER ALLOWED.

Butt Joint Misalignment (5.22.3)

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Inspection of Structural Welding (Per AWS D1.1) SAIC-M-2012 11-Dec-13 MECH -


Erection Tolerances are in Attachment 1 (Per AISC Code). This is for Information Only.

AWS D1.1 WELDING DISTORTION TOLERANCES ARE LISTED BELOW (& 12-SAMSS-007 BASIS)

Page 22 of 29


Page 23 of 29


Page 24 of 29





Mill Discontinuities are resolved per AWS D1.1, NDE dispositioned & repaired as per Table 5.4 below.

AWS D1.1 Allowable Repairs (Note NDE Required)

NOTICE: ENGINEER & SA AUTHORIZED INSPECTOR* APPROVAL REQ'D. (AWS D1.1)

Page 25 of 29


Mislocated Holes (Common Repair in Plants)

526.5 (1) = VT, MT or PT .... 526.5 (2) = VT, MT or PT & RT (depending on location, severity) ... 526.5 (3) = VT, MT or PT & RT

Measurement shall be per calipers or Ultrasonic Thickness Meter if excess weld metal removal is checked

REPAIR OF WELD DEFECTS* FOUND DURING NDT(*Prohibited Discontinuity)

AWS NDT Specs (Section 6, Part C)Notice: NDE shall be clearly defined (as stated in this Attachment or as agreed upon).

NDT SHALL BE SPECIFED (Noted in WPS) - SUBMITTED TO SA INSPECTOR FOR APPROVAL.

UT, MT, PT, RT shall be performed per detailed requirements & Acceptance Criteria Tables of this section.

BEAM & COLUMN SPLICING WELD REPAIRS (NOTICE TO THE CONTRACTOR)1. Contractor shall have approved WPS & Repair Procedure. Cut edges shall be examined* for discontinuities.

2. Contractor shall specify 100% CJP (complete joint penetration) RT Quality welds as detailed in Procedure.

3. RT OR UT SHALL BE SPECIFIED BY ENGINEER AT 100% on butt-welded load bearing* members.

*Main frames and any extensions that are part of the lateral load carrying system such as splice welds for horizontal

piperack beams or vertical columns supporting piping loads in SA Plants. Other shapes (angles, etc) in non-load

bearing secondary applications are spliced with 100% CJP (10% RT Optional). Visual Exam = OK With Hold Points.

4. Contractor shall specify flush, smooth surface after welding per 5.24.4.1 "as required" for service application.

5. Contractor Inspection (NDE HOLD POINTS): Perform 100% VISUAL ON FIT-UP, ROOT PASS, FINAL

6. Contractor shall notify Authorized SA Inspector of ANY repair or splice weld BEFORE welding.

7. Contractor shall perform supplemental NDT based on Visual Exam (suspect areas, laminations, discontinuities).

QA/QC MGRs & ENGINEER ARE RESPONSIBLE TO IMPLEMENT ABOVE REQUIREMENTS ON PROJECTS.

Page 26 of 29


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12-SAMMS-007 WELDING INSPECTION REQMTS

Page 28 of 29

12-SAMMS-008 CORRECTION OF ERRORS (REPAIR PROCEDURE SHALL COPY & PASTE ELEMENTS)

PIP STS05130 CORRECTION OF ERRORS (REPAIR PROCEDURE TO INCLUDE)

Page 29 of 29



Review WPS & Process Control Procedure (Plant Piping) SAIC-W-2001 11-Dec-13 WELD-







A Instructions for Approval (Responsibilities) ... Quality Managers see Notes 1 & 2 at end of this checklist

A1

COMPANY previously approved WPS(s) & any new or proposed WPS(s)

intended for project use are compiled into a Welding Master Set (WMS)

for Projects.

Follow S-PM-G000-1520-0006, Appendix 1 instruction. See

Attachment 1.

Allow adequate time (in weeks) for COMPANY review & approval stage.

S-PM-G000-1520-

0011,

Para. 9.1.1 & S-

PM-G000-1520-

0006

Appendix 1

A2

Individual WPS & PQR are prepared using correct COMPANY Forms:

A) Attachment A - S-PM-G000-1520-0011/SAES-W-012 Welding

Procedure Spec (See attachment A, PAGES A1, A2, A3, A4, A5)

B) Attachment B - S-PM-G000-1520-0011/SAES-W-012, Weld & Line

Description Table (See ATTACHMENT B).

Note:COMPANY performs technical approval of all WPS & indicates such

approval on each and every page of the WPS (requirement).

COMPANY Assigned Inspector performs approval based on the intended

WPS application. See Section C for specific checks relative to the WPS

application.

S-PM-G000-1520-

0011,

Para. 9.1.1 & S-

PM-G000-1520-

0006

Appendix 1

S-PM-G000-1520-

0011, Para.

9.1.3

A3

All WPSs & PQRs conform to the latest edition of ASME IX.

Procedures that comply with a previous edition but not the current

edition of the relevant Code are not acceptable. Procedures no

longer conforming to the latest Code edition shall be revised,

requalified and resubmitted for COMPANY approval.

S-PM-G000-1520-

0011, Para.

9.1.2 &

Para. 9.2.1

A5

Each Weld Table shall be completed & show all line designations,

Material, Joints & Welding procedure to be used for the entire complete

job or contract. Note : Line

Service designation ("sour", non-sour, Internal FBE Coated, Impact

tested CS, Severe Cycle or Category M service, & other special service

considerations such as Hardness Testing & PWHT shall be so

designated in the Attachment B . Utilize the Remarks Section as needed.

S-PM-G000-1520-

0011, Para.

9.1.4

A4

Weld & Line Description Table (Attach. B) lists:

A) Matls, thickness, & weld joint type for individual line designations.

B) A welding procedure shall be listed for each different weld type and

line designation.

C) All base materials (by spec, grade, P-No, Piping Diameter range) and

wall thicknesses to be used shall be included in the Weld Table.

D) Weld Table shall only be reviewed with WPSs and PQRs and and vice-

versa.

A6

Welding shall not commence until the welding package has been

approved for application by COMPANY Inspector & returned to

the fabricator. Any welding prior to the approval of the welding

package is subject to rejection at the sole option of COMPANY

Inspector. Any rework required as a result of this rejection shall be at the

fabricator's expense.

S-PM-G000-1520-

0011, Para.

9.1.5

A7

After approval by COMPANY Inspector, fabricator shall issue copies of

the approved Welding Procedures & Weld Table to COMPANY and PMT

prior to the start of fabrication.

S-PM-G000-1520-

0011, Para.

9.1.6

Approval of welding procedures shall not be construed as authority for

deviation from listed specifications or requirements of relevant

codes and standards and shall not relieve the contractor, fabricator, or

vendor from correcting any deviations.

S-PM-G000-1520-

0011, Para.

9.1.7

REFERENCEITEM

No.ACCEPTANCE CRITERIA PASS FAIL N/A RE-INSP DATE

A8

Page 1 of 21

Attachment 1 - S-PM-G000-1520-0006 Welding Master Set Preparation & Approval (Instructions)




Page 3 of 21

Page 4 of 21

Page 5 of 21

SAES-W-011/012 WELDING PROCEDURE SPECIFICATION (ATTACHMENT A, PAGES A1, A2, A3, A4, A5)




Page 7 of 21

Page 8 of 21

Page 9 of 21

Page 10 of 21

Page 11 of 21




SAES-W-011/012 WELD & LINE DESCRIPTION TABLE (ATTACHMENT B)

Page 12 of 21

Attachment 2 - WPS PROCEDURE VARIABLES (S-PM-G000-1520-0011, Section 9.4, 9.5 & 9.6)




Page 13 of 21


Page 14 of 21


Page 15 of 21


Page 16 of 21


Page 17 of 21


Page 18 of 21

SEE ASME B31.3 PWHT TABLE 331.1.1 … P-No 4 / 5 Code Exemptions do not apply

Page 20 of 21




Attachment 3 - NACE SP-0472 Table 2:

Process/Filler Material Combinations Exempt from Weld Deposit Hardness Testing

ASME SEC II C (SFA 5.18) & ER70S-6 "Description" below.

A7. Description and Intended Use of Electrodes and RodsA7.4 ER70S-6: Electrodes and rods of the ER70S-6 classification are intended for both single and multiple-pass

welding. They are especially suited for sheet metal applications, where smooth weld beads are desired,

and structural and plate steels that have moderate amounts of rust or mill scale.

A7.1 ER70S-2: Electrodes and rods of the ER70S-2 classification are primarily used for single-pass welding of killed,

semi-killed, and rimmed steels, but may be used for some multipass applications.

ER70S-2 Filler metals are used extensively to produce high quality, high toughness welds with the GTAW

process. These filler metals are also well suited for use in single side, melt through welding without a

protective root shielding gas on the backside of the joint. (GTAW, for sure = ER-70S-2)

A7.2 ER70S-3: Electrodes and rods of the ER70S-3 classification are intended for welding single-pass & multi-pass

welds. Typical base metal specifications are often the same as those for the ER70S-2 classification. Electrodes of

that conforms to ASME SEC II C. Don't allow hardness values to fall above minimum reqmts causing PWHT repair.

ASME SEC II C & NACE SP0472

SAES-W-11 : 14 Production Weld Hardness Testing

14.1 Testing shall be in accordance with NACE SP0472 and the requirements listed below. Exemptions with respect to welding process and

consumables are not allowed.

ER70S-3 classification are the most widely used of GMAW electrodes classified under this specification.

SAES-W-012, Section 6 (Welding Consumables)

Para. 6.1 Electrodes, filler wires, and fluxes shall conform to ASME SEC IIC. What does "conform" mean?

WELDING APPLICATIONSSimply, ER70S-6 runs smooth (it's great for sheet metal per ASME/AWS), but clearly we don't have many

sheet metal pipelines in Saudi Aramco. So choose an application ER70S-2 (GTAW) or ER70S-3 (GMAW)

Page 21 of 21

ITEM

No.ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE

A9Repair procedure states that repair welds are performed by welders

qualified in accordance with ASME SEC. IX. (Valid JCCs).

S-PM-G000-1520-

0011,

Para. 10.1

S-PM-G000-1520-

0011,

Para. 20.4

A8

Damage or deformation to the base metal or welds, including dimensional

changes, caused by external forces (intentional or accidental), requires

special repair and inspection procedures to be submitted to ID, and if

necessary forwarded to COMPANY for review and approval, prior to

undertaking the repairs.

S-PM-G000-1520-

0011,

Para. 20.6

A7

The repair procedure may utilize a welding procedure previously

approved by COMPANY in conjunction with a separate method statement

or it may be a separate detailed welding procedure.

A6

All repaired welds shall be inspected using the original testing method.

Additional test methods may also be required, if deemed necessary by

the authorized COMPANY inspector. Replacement weld (cut-out) shall be

examined as a repair.

S-PM-G000-1520-

0011,

Para. 20.5,

A5

Repair Procedure contains a disposition for weld repair as follows:

A) Welds may be repaired twice.

b) If the repair weld is still not acceptable after the second repair, then

COMPANY has the sole authority for the decision to permit additional

repair attempts or to require the entire weld be cut out.

Note: The limitation on the number of repairs does not include adjacent

sequential repairs where the length of the area to be repaired is limited

by structural strength or other considerations.

S-PM-G000-1520-

0011,

Para. 20.1

S-PM-G000-1520-

0006, Section 8

S-PM-G000-1520-

0011, Para.20

A4

Specific Repair requirements for cracks is stated as follows:

A) Cracked welds (except for crater cracks) are cut-out unless a

repair is approved by COMPANY.

B) Crack repairs require COMPANY special review & approval. Inspection

procedures are submitted to COMPANY prior to undertaking any repairs,

including excavation of the defect.

c) Crater cracks are ground out and NDT performed as necessary.

S-PM-G000-1520-

0011,

Para. 20.2

A2

Repair procedure shall include the following Provisions:

1) A step-by-step detail of the repair, from weld ID change thru the

excavation process, NDT, special cleaning & other considerations,

rewelding of the excavation, final acceptance/clearance (includes Final

NDE, PWHT, PMI, HT, visual acceptance, etc per S-PM-G000-1520-

0006)

2) NDT* reqmts (MT/PT to verify defect removal & RT/UT)

3) Welding requirements (ie: WPS, Pre-heating, PWHT)

A General Requirements … Welding Process Control Procedure shall utilize SAIC-W-2013 along with this Checklist.

A1

Repairs are identified, controlled, tracked and reported per the database

requirements of S-PM-G000-1520-0006 (See Attachment 1):

A) ID is per unique numbering system (Para. 8.2)

B) Control is per the Contractor's Written & approved procedure & use of

Saudi Aramco Checklist SAIC-W-2013 & NDE SATIPs & Process Control

Checklists (Radiography, MT, PT, etc)

C) Tracking & reporting (Backlogs, etc) are per Para. 8.3

S-PM-G000-1520-

0006, Section 8



TRAVEL TIME

SCHEDULED INSPECTION DATE & TIME ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT


PLANT NO.EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID.


Review of Procedure for Weld Repair (Plant Piping) SAIC-W-2002 11-Dec-13 WELD-



Page 1 of 7

N/A RE-INSP DATEITEM

No.



Initials and Date:

ACCEPTANCE CRITERIA REFERENCE PASS FAIL



T&I Witnessed QC Record Reviewed Work Verified

Work Verified

Contractor QC Supervisor Proponent and Others

Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed




3. AWS D1.2, Structural Welding Code-Aluminum, 2004 Edition


Attachment 2 - S-PM-G000-1520-0011 REQUIREMENTS (REPAIRS)


1. S-PM-G000-1520-0011, Welding Requirements for On-Plot Piping

2. ASME B31.3, Process Piping, Latest Edition

1. USE SAIC-W-2013 & the applicable NDE SATIP for all repairs.

2. Utilize SAIC-M-2012 & Structural Steel & NDE SATIPs that define AWS D1.1 repair reqmts & NDE.

ATTACHMENTS:

Attachment 1 - S-PM-G000-1520-0006 DATABASE, PROCESS CONTROL TRACKING (By Weld)

REMARKS:

NOTES:


Review of Procedure for Weld Repair (Plant Piping) SAIC-W-2002


11-Dec-13 WELD-


Page 2 of 7





Page 3 of 7

Page 4 of 7

Page 5 of 7

Page 6 of 7

Attachment 2 - S-PM-G000-1520-0011 REQUIREMENTS (REPAIRS)




Page 7 of 7

ITEM

No.ACCEPTANCE CRITERIA PASS FAIL N/A RE-INSP DATEREFERENCE

A6

Table shall include the following info. for each joint or component:

a) location

b) drawing number

c) diameter

d) wall thickness e)

material f)

heating rate g)

cooling rate h)

soak temperature i)

soak time

S-PM-G000-1520-

0011,

Para. 15.2

A5

Prior to start of WORK, Contractor shall prepare a Table listing (see A6 )

for each joint or component requiring heat treatment, & submit for

COMPANY review.

See Attachment 3 for a sample PWHT Table, SATR-W-2004.

A) This provides field direction for PWHT Field Crew / Personnel.

B) PWHT work / results are controlled & entered daily into the

COMPANY approved S-PM-G000-1520-0006 Production Weld

Database. C)

Data specified in the PWHT Table shall meet ASME B31.3 PWHT Table

331.1.1 & Specific SA PWHT Requirements. Check accuracy.

S-PM-G000-1520-

0011,

Para. 15.2

A4

PWHT procedure shall include descriptions of the equipment,

method of heating, location and type of heating elements, temperature

measurement method, and thermocouple locations

S-PM-G000-1520-

0011,

Para. 15.1

A3

A written procedure describing the general PWHT requirements of

ASME B31.3, shall be submitted for review and approval of COMPANY

Note : review and approval process is the same as described for

welding procedures (Per Paragraph 9.1 of S-PM-G000-1520-0011 ).

S-PM-G000-1520-

0011,

Para. 15.1

A2

PWHT Procedure shall include a step-by-step detail of the PWHT

specified, from initial weld ID & entry of PWHT into the S-PM-G000-1520-

0006 Database through final visual acceptance, including reporting per S-

PM-G000-1520-0006 requirements. Activities shall be tied into the

Project welding Database. PWHT shall be properly sequenced relative to

any NDT performed and Control over activities shall be documented.

See Attachment 2 . Production work, Reporting & Status (Backlogs,

etc) are controlled & documented.

S-PM-G000-1520-

0006, Section 8 &

Procedure

A General Requirements (Pre-Work)

A1

Contractor shall complete 100% Pressure Piping Design & submit a

Project Specific Design Specification for Welding containing:

A) Summary of Piping Line Classes & Design Information

B) Proposed Project PWHT Specification (details, notes, reqmts) that are

based on ASME Code & COMPANY Stds within workscope.

C) Proposed Project NDE Specification (Refer to the NDE SATIPs)

D) Proposed Project Specifications for other Special Processes such as

PMI, Pressure Testing, Coatings & Insulation

PWHT Specifications by Line Class are reviewed & approved by

COMPANY , this includes COMPANY Authorized Inspector . Follow

checklist & the applicable SATIPs.

Utilize Attachment 1 for review. PWHT Spec meets reqmts.

S-PM-G000-,

1360-0001

Section 7






Review Post Weld Heat Treatment (PWHT) Specification,

Procedure, & Table for On-Plot PipingSAIC-W-2003 11-Dec-13 WELD-




Page 1 of 15


No.ACCEPTANCE CRITERIA

B2Additional TCs are required if multiple heat control zones are used, in

which a control zone is not monitored by any of the primary T/Cs.

S-PM-G000-1520-

0011,

Para. 15.13

B Thermocouple Requirements

B1

If localized PWHT is used, the following minimum number of equally

spaced recording thermocouples (T/C) shall be used:

a) Pipe diameter of 305 mm or less: 1 T/C.

b) Pipe diameter above 305 mm up to and including 610 mm: 2 T/C.

c) Pipe diameter above 610 mm: 4 T/C.

S-PM-G000-1520-

0011,

Para. 15.13

A16

PWHT shall be carried out using one or more of the following types:

a) Permanent or semi-permanent furnaces (gas/oil/electric heaters)

b) Electrical resistance heaters.

c) Induction heaters.

S-PM-G000-1520-

0011,

Para. 15.12

A15

Welding or heating to joints already PWHT'd requires re-PWHT. PWHT

shall follow all welding and repairs, but shall precede any hydrotest. Note

: S-PM-G000-1520-0006 requires Weld ID change on repair.

S-PM-G000-1520-

0011,

Para. 15.11

A14The actual temperature range for the soak period, as recorded by TC's,

shall not have a spread of more than 40°C.

S-PM-G000-1520-

0011,

Para. 15.10

A13All temperatures within the heated zone for furnace or localized PWHT

shall exceed the specified minimum holding temperature.

S-PM-G000-1520-

0011,

Para. 15.10

A12

Ends of open lines shall be closed off in order to eliminate drafts or

air circulation that could lower temperatures on inside surface of joints

unless the internal surface is also insulated.

S-PM-G000-1520-

0011,

Para. 15.6

A11

For PWHT not performed in a furnace, insulation shall be applied a

minimum of 300 mm on either side of the weld to be PWHT'd. Insulation

shall not be removed before temp. has cooled to < 300°C.

S-PM-G000-1520-

0011,

Para. 15.6

A10

The specified PWHT shall be applied over an area extending at least 3 x

thickness of the material being welded from each weld toe, but not less

than 25 mm from each weld toe, whichever is greater.

S-PM-G000-1520-

0011,

Para. 15.5

A9The PWHT heating and cooling rates > 316°C shall not exceed 222°C/hr

÷ weld thickness in inches, but in no case > 222°C/hr.

S-PM-G000-1520-

0011,

Para. 15.4

A8

For applications where PWHT is required by service fluid (Item A7

above) " OR " where hardness limits are specified:

a) Reductions in PWHT temperature or alternative temperatures

below normal holding temps listed in ASME B31.3 are not permitted.

b) Minimum PWHT soak time shall be 1 hour.

c) If hardness limits are specified, production weld soak time shall not be

less than 80% of PQR soak time unless approved by COMPANY.

Note : A copy of the COMPANY approved WPS shall be cross checked

S-PM-G000-1520-

0011,

Para. 15.9

A7

Carbon & low alloy steel butt welds requiring PWHT for Process

Conditions & Services are as listed in Attachment 1.

A) PWHT requirement of Carbon steel for Caustic service shall be

decided by temperature and density and it shall be consult to the

COMPANY.

B) All monoethanolamine (MEA) solutions (all temperatures).

C) All diglycol amine (DGA) solutions above 138°C design temp.

D) Rich amino diisoprop (ADIP) solutions above 90°C design temp.

E) All lean ADIP solutions above 60°C design temperature.

F) Boiler Deaerator serv (ambient temp vacuum deaerator = exempt)

G) Hydrogen service for P-No. 3, 4, and 5A/B/C base materials.

H) All diethanolamine (DEA) solutions.

These reqmts also apply to external welds to attach non-pressure

containing component to piping (e.g., reinforcement pad or sleeve

attached to the pipe) and to seal welds. Seal welds on threaded valves

may be exempt if PWHT will damage valve internals.

S-PM-G000-1520-

0011,

Para. 15.3

DATE APPROVED QR NUMBER



REFERENCE



SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER

Page 2 of 15






REFERENCE




B3Thermocouples and a calibrated temperature chart recorder shall be used

to provide an accurate and legible record of all PWHTs.

S-PM-G000-1520-

0011,

Para. 15.14

Page 3 of 15






REFERENCE




C6

After completion of the PWHT all thermocouples shall be removed and

the attachment areas ground smooth to clean and sound metal. If

specified by PID, the areas shall be MT'd or PT'd after grinding.

S-PM-G000-1520-

0011,

Para. 15.20

C5

All PWHT chart records shall be submitted to COMPANY for review and

approval. All records shall be submitted as part of the equipment file for

permanent record.

S-PM-G000-1520-

0011,

Para. 15.19

C4

All machined surfaces, such as flange faces, threaded bolt holes,

threads, etc., shall be protected from oxidation during the heat treatment

by coating with deoxaluminite or other suitable material.

S-PM-G000-1520-

0011,

Para. 15.18

C3In addition, the PWHT chart should be marked, prior to PWHT, with

identification number of the weld(s).

S-PM-G000-1520-

0011,

Para. 15.17

C2

Prior to the start of the PWHT, components shall be checked to ensure

that all restraints are removed and the component is free to expand and

contract, and suitable and sufficient supports are used.

S-PM-G000-1520-

0011,

Para. 15.17

C Preparation for PWHT

C1Thermocouples shall not be in direct contact with electrical heating

elements or subjected to flame impingement by gas or oil burners.

S-PM-G000-1520-

0011,

Para. 15.16.3

B12Thermocouples shall be attached to the component by capacitive

discharge welding only.

S-PM-G000-1520-

0011,

Para. 15.16.3

B11

Procedure shall also include a listing of the insulation coloring of each

core wire & the overall sheath for both the compensating cable & TC.

Site inspectors to verify that the proper wires have been used and

are connected in the proper polarity.

S-PM-G000-1520-

0011,

Para. 15.16.2

B10The national standard that the thermocouple conforms to shall be

indicated in the PWHT procedure.

S-PM-G000-1520-

0011,

Para. 15.16.2

B9

For Type K TCs, copper- Constantan (Type T) compensating cables may

be used with the following conditions:

a) Junction between the copper-Constantan compensating cable

and the Type K thermocouple lead shall be a minimum of 0.5 m*

outside the insulated area. (*Inspection to verify each weld)

b) Acceptable temperature range of the junction between the

compensating cable & thermocouple lead is from 0 to +80°C.

S-PM-G000-1520-

0011,

Para. 15.16.1

B8

Only Type K (Chromel-Alumel) or Type J (iron-Constantan) TCs are

permitted. All extension, compensating, and jumper cables in the

measurement or control circuits shall be the specified TC wire or

matching extension wire, i.e., KX or JX, as appropriate.

S-PM-G000-1520-

0011,

Para. 15.16.1

B7

Calibration frequency may be extended to 6* months with PID approval

if documented calibration checks for recorder demonstrate acceptable

accuracy for a suitable period. *Sch Q M&TE limit.

S-PM-G000-1520-

0011,

Para. 15.15 &

Sch Q, M&TE

B6Temperature recorders shall be calibrated every three months & a current

calibration sticker shall be maintained on the recorder.

S-PM-G000-1520-

0011,

Para. 15.15

B5Multipoint chart recorders clearly differentiate/identify each channel /point

by use of different colored inks or automatic # stamping.

S-PM-G000-1520-

0011,

Para. 15.14

B4All charts shall be marked with the date and sufficient information to

uniquely identify the joint/component being heat treated.

S-PM-G000-1520-

0011,

Para. 15.14

Page 4 of 15






REFERENCE




REMARKS:

Page 5 of 15






REFERENCE






Initials and Date:

Contractor QC Supervisor Proponent and OthersT&I Witnessed QC Record Reviewed



Work Verified

Contractor QC Inspector COMPANY InspectorPerformed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified



1. S-PM-G000-1520-0011, Welding Requirements for On-Plot Piping,

2. ASME B31.3, Process Piping (Latest Edition)



2. Condition of PWHT Insulation blankets shall be monitored for deterioration & burn damage. Deteriorated blankets and those without wire

mesh coverings release Ceramic fibers into the immediate work area and are a great health hazard (Safety & Quality Concern).

3. Strict controls for work sequence and work segregation are required.

4. For Recording of Results & Final Acceptance, utilize checklist SAIC-W-2004 R3 to cover any points in the Procedure deemed necessary.

ATTACHMENTS:

Attachment 1 - Requirements for Heat Treatment (ASME B31.3, Table 331.1.1) & S-PM-G000-1520-0011


Attachment 3 - SATR-W-2004 - SAMPLE PWHT TABLE (PROCESS CONTROL TRACKING BY WELD)


NOTES: 1. Code exemptions for PWHT for P-No. 4 & P-No. 5 materials are not allowed at COMPANY. PWHT all P-No. 4 & P-No. 5 mat'l

welds & pressure boundary attachments when Sour Service exists or nominal chrome content is above 1.5%. (S-PM-G000-1520-0011,

Para. 15.8)

Page 6 of 15

SAIC-W-2003 11-Dec-13 WELD-

Attachment 1 - Requirements for Heat Treatment (ASME B31.3, Table 331.1.1) & S-PM-G000-1520-0011, Section

15




Procedure, & Table for On-Plot Piping

Page 7 of 15


Page 8 of 15



Page 9 of 15

Page 10 of 15






Page 11 of 15

Page 12 of 15

Page 13 of 15

Page 14 of 15



7. Those responsible for work and data entry have been approved by Saudi Aramco to perform work on IK Projects.

8. Rework shall require a new Weld ID Number (suffix added = R 1, etc) per SAEp-1160 Requirements.




Instructions for PWHT Table (Line List) Use: 1. Perform Heat Treatment in conjunction with SAIC-W-2012 and

SAIC-W-2014 for Brinnell Hardness Testing and the applicable NDE SATIP & Project NDE Specification.

2. Localized PWHT = 100% Brinnell Hardness Testing. Furnace Batch PWHT = 10% Brinnell Hardness Testing.

3. PWHT Crew & QC Responsible utilize this Work Sheet to perform field work under close supervison/Witness.

4. Results are entered into the S-PM-G000-1520-0006 Database for Welds on Projects. Verify Weld ID numbers

carefully.5. Such Databases are not needed when 500 welds or less are in the Project Work Scope (S-PM-G000-1520-0006

Reqmt).

6. PWHT shall be performed per approved Project Welding & PWHT Specification including all notes.

Page 15 of 15



Post Weld Heat Treatment (PWHT) for On-Plot Piping SAIC-W-2004 11-Dec-13 WELD-




WORK PERMIT REQUIRED?



SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER

A General Requirements (Pre-Work)

A1

Company has approved the Project Specification for Welding and the

PWHT Specification (all details, notes, reqmts) that are based on ASME

Code & Saudi Aramco Stds within workscope.

PWHT Specifications by Line Class are reviewed & approved by

COMPANY , this includes Authorized COMPANY Inspector. Follow

checklist & the applicable SATIPs. Requirements are clear.

See Attachment 1 for PWHT requirements & general note 1.

S-PM-G000-1360-

0001,

Section 7

A2

PWHT Procedure has been approved & includes a step-by-step detail of

the PWHT specified, from initial weld ID & entry of PWHT into the S-PM-

G000-1520-0006 Database through final visual acceptance, including

reporting per S-PM-G000-1520-0006 requirements. Activities shall be tied

into the Project welding Database. PWHT is properly sequenced relative

to NDT performed and Control over activities is documented.

Production work, Reporting & Status (Backlogs, etc) shall be

carefully controlled & documented. See Attachment 2.

S-PM-G000-1520-

0006, Section 8 &

Procedure

S-PM-G000-1520-

0011,

Para. 15.2

A3

A written procedure describing the general PWHT requirements of ASME

B31.3, has been reviewed and approved by COMPANY and the

application has been verified and accepted by COMPANY Assigned

Inspector. Approval Process is the same for welding Procedures &

PWHT procedure shall include descriptions of the:

a) equipment

b) method of heating

c) location and type of heating elements

d) temperature measurement

e) thermocouple locations

Perform initial Set-up Inspection to verify that the set-up is performed per

Procedure (safety check) for elements above

S-PM-G000-1520-

0011,

Para. 15.1

A5

Table shall include the following info. for each joint or component:

a) location

b) drawing number

c) diameter

d) wall thickness

e) material

f) heating rate

g) cooling rate

h) soak temperature

i) soak time

Verify that code and COMPANY requirements have been met.

S-PM-G000-1520-

0011,

Para. 15.2

A4

Prior to start of WORK, Contractor shall prepare a Table listing points at

(A5) for each joint or component requiring heat treatment , & submit for

PID review.

Note :See Attachment 3 for a sample PWHT Table,SATR-W2004. a. This

provides field direction for PWHT Field Crew / Personnel.

b) PWHT work / results are controlled & entered daily into the COMPANY

approved S-PM-G000-1520-0006 Production Weld Database.

c) Data specified in the PWHT Table shall meet ASME B31.3 PWHT

Table 331.1.1 & Specific SA PWHT Requirements. Check accuracy.

ITEM


Page 1 of 15




A6

Carbon & low alloy steel butt welds requiring PWHT for Process

Conditions & Services are as listed in Attachment 1.

A) PWHT requirement of Carbon steel for Caustic service shall be

decided by temperature and density and it shall be consult to the

COMPANY.

B) All monoethanolamine (MEA) solutions (all temperatures).

C) All diglycol amine (DGA) solutions above 138°C design temp.

D) Rich amino diisoprop (ADIP) solutions above 90°C design temp.

E) All lean ADIP solutions above 60°C design temperature.

F) Boiler Deaerator serv (ambient temp vacuum deaerator = exempt)

G) Hydrogen service for P-No. 3, 4, and 5A/B/C base materials.

H) All diethanolamine (DEA) solutions.

These reqmts also apply to external welds to attach non-pressure

containing component to piping (e.g., reinforcement pad or sleeve

attached to the pipe) and to seal welds. Seal welds on threaded valves

may be exempt if PWHT will damage valve internals.

S-PM-G000-1520-

0011,

Para. 15.3

S-PM-G000-1520-

0011,

Para. 15.4

A7

For applications where PWHT is required by service fluid (Item A6

above) " OR " where hardness limits are specified:

a) Reductions in PWHT temperature or alternative temperatures

below normal holding temps listed in ASME B31.3 are not permitted.

b) Minimum PWHT soak time shall be 1 hour.

c) If hardness limits are specified, production weld soak time shall not be

less than 80% of PQR soak time unless approved by COMPANY.

A copy of the COMPANY approved WPS shall be cross checked

S-PM-G000-1520-

0011,

Para. 15.9

A9

The specified PWHT shall be applied over an area extending at least 3 x

thickness of the material being welded from each weld toe, but not less

than 25 mm from each weld toe, whichever is greater.

S-PM-G000-1520-

0011,

Para. 15.5

A8The PWHT heating and cooling rates > 316°C shall not exceed 222°C/hr

÷ weld thickness in inches, but in no case > 222°C/hr.

A10

For PWHT not performed in a furnace, insulation shall be applied a

minimum of 300 mm on either side of the weld to be PWHT'd. Insulation

shall not be removed before temp. has cooled to < 300°C.

S-PM-G000-1520-

0011,

Para. 15.6

S-PM-G000-1520-

0011,

Para. 15.10

A11

Ends of open lines shall be closed off in order to eliminate drafts or

air circulation that could lower temperatures on inside surface of joints

unless the internal surface is also insulated.

S-PM-G000-1520-

0011,

Para. 15.6

A13The actual temperature range for the soak period, as recorded by TC's,

shall not have a spread of more than 40°C.

S-PM-G000-1520-

0011,

Para. 15.10

A12All temperatures within the heated zone for furnace or localized PWHT

shall exceed the specified minimum holding temperature.

A14

Welding or heating to joints already PWHT'd requires re-PWHT. PWHT

shall follow all welding and repairs, but shall precede any hydrotest. S-

PM-G000-1520-0006 requires Weld ID change on repair.

S-PM-G000-1520-

0011,

Para. 15.11

A15

PWHT shall be carried out using one or more of the following types:

a) Permanent or semi-permanent furnaces (gas/oil/electric heaters)

b) Electrical resistance heaters.

c) Induction heaters.

S-PM-G000-1520-

0011,

Para. 15.12

S-PM-G000-1520-

0011,

Para. 15.13

B Thermocouple Requirements

B1

If localized PWHT is used, the following minimum number of equally

spaced recording thermocouples (T/C) shall be used:

a) Pipe diameter of 305 mm or less: 1 T/C.

b) Pipe diameter above 305 mm up to and including 610 mm: 2 T/C.

c) Pipe diameter above 610 mm: 4 T/C.

S-PM-G000-1520-

0011,

Para. 15.13

B2Additional TCs are required if multiple heat control zones are used, in

which a control zone is not monitored by any of the primary T/Cs.



Page 2 of 15






B3Thermocouples and a calibrated temperature chart recorder shall be used

to provide an accurate and legible record of all PWHTs.

S-PM-G000-1520-

0011,

Para. 15.14

B4All charts shall be marked with the date and sufficient information to

uniquely identify the joint/component being heat treated.

S-PM-G000-1520-

0011,

Para. 15.14

Page 3 of 15






S-PM-G000-1520-

0011,

Para. 15.15

B5Multipoint chart recorders clearly differentiate/identify each channel /point

by use of different colored inks or automatic # stamping.

S-PM-G000-1520-

0011,

Para. 15.14

B7

Calibration frequency may be extended to 12* months with COMPANY

approval if documented calibration checks for recorder demonstrate

acceptable accuracy for a suitable period. *Sch Q M&TE limit.

S-PM-G000-1520-

0011,

Para. 15.15 &

Sch Q, M&TE

B6Temperature recorders shall be calibrated every three months & a current

calibration sticker shall be maintained on the recorder.

B8

Only Type K (Chromel-Alumel) or Type J (iron-Constantan) TCs are

permitted. All extension, compensating, and jumper cables in the

measurement or control circuits shall be the specified TC wire or

matching extension wire, i.e., KX or JX, as appropriate.

S-PM-G000-1520-

0011,

Para. 13.16.1

S-PM-G000-1520-

0011,

Para. 13.16.2

B9

For Type K TCs, copper- Constantan (Type T) compensating cables may

be used with the following conditions:

a) Junction between the copper-Constantan compensating cable

and the Type K thermocouple lead shall be a minimum of 0.5 m*

outside the insulated area. (*Inspection to verify each weld)

b) Acceptable temperature range of the junction between the

compensating cable & thermocouple lead is from 0 to +80°C.

S-PM-G000-1520-

0011,

Para. 13.16.1

B11

Procedure shall also include a listing of the insulation coloring of each

core wire & the overall sheath for both the compensating cable & TC.

Site inspectors to verify that the proper wires have been used and

are connected in the proper polarity.

S-PM-G000-1520-

0011,

Para. 13.16.2

B10The national standard that the thermocouple conforms to shall be

indicated in the PWHT procedure.

B12Thermocouples shall be attached to the component by capacitive

discharge welding only.

S-PM-G000-1520-

0011,

Para. 13.16.3

C Preparation & Execution of PWHT:

C1Thermocouples shall not be in direct contact with electrical heating

elements or subjected to flame impingement by gas or oil burners.

S-PM-G000-1520-

0011,

Para. 13.16.3

C2

Prior to the start of the PWHT, components shall be checked to ensure

that all restraints are removed and the component is free to expand and

contract, and suitable and sufficient supports are used.

S-PM-G000-1520-

0011,

Para. 15.17

S-PM-G000-1520-

0011,

Para. 15.18

C3In addition, the PWHT chart should be marked, prior to PWHT, with

identification number of the weld(s). Matches Database Weld ID

S-PM-G000-1520-

0011,

Para. 15.17

C5

All PWHT chart records shall be submitted to Saudi Aramco Inspection

for review and approval. All records shall be submitted as part of the

equipment file for permanent record.

S-PM-G000-1520-

0011,

Para. 15.19

C4

All machined surfaces, such as flange faces, threaded bolt holes,

threads, etc., shall be protected from oxidation during PWHT by

coating with deoxaluminite or other suitable material.

D Post Work Examination & Recording of Results:

D1

After completion of the PWHT all thermocouples shall be removed and

the attachment areas ground smooth to clean and sound metal. If/when

specified by COMPANY, areas shall be MT'd or PT'd after grinding.

Determine if MT or PT is required based on visual exam.

Visual exam shall cover entire surface of heated areas and shall verify

that no heat damage exists. Check all machined surfaces, threaded bolt

holes, threads, etc. for heat damage and oxidation See Notes.

S-PM-G000-1520-

0011,

Para. 15.20

Page 4 of 15






D2

Utilize SAIC-W-2012 (Procedure) & SAIC-W-2014 (Inspection) &

perform 100% Brinnell Hardness Testing on all PWHT'd welds where the

localized PWHT method was employed. For smaller sections, 10% BHT

is allowed for Furnace Batch method.

S-PM-G000-1520-

0011,

Para. 16

Page 5 of 15






D3

All PWHT chart records shall be reviewed and submitted to Saudi

Aramco Inspection for review and approval. All records shall be submitted

as part of the equipment file for permanent record.

Complete Reports. SATR-W-2004 & SATR-W-2005. Enter results in

Weld Database.

S-PM-G000-1520-

0011,

Para. 15.19

REMARKS:

NOTES: 1. Code exemptions for PWHT for P-No. 4 & P-No. 5 materials are not allowed at COMPANY. PWHT all P-No. 4 & P-No. 5 mat'l

welds & pressure boundary attachments when Sour Service exists or nominal chrome content is above 1.5%. (S-PM-G000-1520-0011, Para. 13.8)

D4

Welding or heating to joints that have been PWHTed, shall require

re-PWHT. PWHT shall follow all welding and repairs, but shall be

performed prior to any hydrotest.

S-PM-G000-1520-

0011,

Para. 15.11

2. Condition of PWHT Insulation blankets shall be monitored for deterioration & burn damage. Deteriorated blankets and those without wire

mesh coverings release Ceramic fibers into the immediate work area and are a serious health hazard (Safety & Quality Concern).

3. Heat damage & oxidation shall not be visible after PWHT operations.

ATTACHMENTS:



QC Record Reviewed Work Verified



REFERENCE DOCUMENTS: 1. S-PM-G000-1520-0011, Welding Requirements for On-Plot Piping

2. ASME B31.3, Process Piping (Latest Edition)


Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified


Subcontractor QC Inspector COMPANY PMT Representative Performed Inspection Work / Rework May Proceed T&I Witnessed


Contractor QC Inspector COMPANY InspectorPerformed Inspection



Initials and Date:



Page 6 of 15




Attachment 1 - Requirements for Heat Treatment (ASME B31.3, Table 331.1.1) & S-PM-G000-1520-0011, Section

15

Post Weld Heat Treatment (PWHT) for On-Plot Piping

Page 7 of 15



Page 8 of 15


Page 9 of 15

Page 10 of 15





Page 12 of 15

Page 13 of 15

Page 14 of 15

Page 15 of 15



EQUIPMENT ID NUMBER(S)


Pre-Welding Inspection (Shop & Field) of Plant Piping SAIC-W-2005 11-Dec-13 WELD-

PURCHASE ORDER NUMBER EC / PMCC / MCC NO.

PLANT NO.


EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID.

LAYOUT DRAWING NUMBER REV. NO.

TRAVEL TIMESCHEDULED INSPECTION DATE & TIME ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT


A General Requirements (Pre-Welding)

SAUDI ARAMCO INSPECTION LEVEL

S-PM-G000-1520-

0011,

Para. 9.1.8

CONTRACTOR INSPECTION LEVEL

A2Welder(s) have been issued Job Clearance Card, and that range of

qualification shown matches the application of WPS being used.

SAEP-324,

Sec. 5

A1

Approved Welding Procedure(s) or WPS are available/posted at the weld

site.

Note: All attachments (A, B) and cover pages to WPS are posted. Page

A1 (WPS Approval Request) is signed by Company welding

Representative .WPS & Special Process Control Procedures are

approved.

A3

Inspectors highlight any special features or precautions listed in the spec

concerning Welding & other special processes such as NDE criteria (Line

Class, Service Category or SA reqmts.)

*Best Practice: Tool-Box Meeting or Pre-Job Conference covers

approved Welding Specs & any special requirements

SAES-L-310,

Section 7,

Last Bullet Item

(Welding Specs)

& Special

Process Control

(Pre-Welding)

S-PM-G000-1520-

0011,

Para. 18.1

S-PM-G000-1520-

0006,

Section 8.1

A4

All weld joints shall be marked for identification as follows:S-PM-G000-

1520-0006 & SAIC-W-2008.

a) by weld number and by welder symbol.

b) with suitable weather-proof marking material.

c) easy visibility location, and durable for a time suitable to authorized

COMPANY inspector.

S-PM-G000-1520-

0006 Section 8 &

S-PM-G000-1520-

0011,

Section 18

A6

Isometric Piping Dwgs for work have been reviewed & approved:

A) Process Control Procedure for Welding is followed relative to checks

on mat'ls (Traceability, marking, dimensional) using latest approved*

drawing revisions. *Document Control system exists.

B) Fab Shops have been approved per SAIC-L-2031. Shops follow

strict mat'l & consumable controls as outlined in Procedure

C) Equipment checks for welders (checks are established)

SAIC-L-2031 was utilized prior to Kickoff of Construction .

SAES-L-310,

Section 7,

Bullet Item

& Special

Process Control

(Pre-Welding)

A5

Weld number & Welder symbol are to be marked adjacent to welds.

Note: Use suitable weather-proof permanent markers & materials, such

as certified low-chloride (50ppm) markers for Stainless steel

Note: This is an assigned unique weld ID number to be tracked by

database & shall remain intact during the construction process

A7

Welding power supplies are calibrated

Note: Sch Q requires a 6 month interval (max). Process control

procedures shall detail intervals. BS

7570 is used for validation when Charpy Impacts are specified.

Note : See SAIC-W-2011 checklist.

S-PM-G000-1520-

0011,

Section 21 &

Sch Q, Attch-IV

Para-6



Page 1 of 29





B WELD JOINT EDGE PREP (Includes Cutting & Arc Gouging Method, Joint Edge Buttering, & Cleaning Method)

B1

Stainless steel and nonferrous materials shall be cleaned with grinding

wheels or stainless steel brushes not previously used on other materials..

Use Attachment 1 . Lessons Learned (CuNi - SS segregation)

S-PM-G000-1520-

0011, Para.

13.3.3

B2Thermal cut surfaces of stainless steel and non-ferrous materials shall be

ground to bright (unoxidized) material prior to welding.

S-PM-G000-1520-

0011,

Para. 11.2.2.4

B3

A minimum of 1.5 mm depth shall be removed by grinding/machining from

thermally cut or gouged surfaces of air-hardenable materials (e.g.,

Chrome-Moly steels or P-No 3 / 4 / 5). Additional NDE required on cut

surfaces is at the option of the authorized COMPANY inspector.

S-PM-G000-1520-

0011,

Para. 11.2.2.3

S-PM-G000-1520-

0011,

Para. 13.2.2.1

B4

Ragged and irregular edges shall be ground or machined to bright metal.

Thermally cut or gouged surfaces for all materials, including carbon

steels, shall be power brushed or ground prior to welding.

S-PM-G000-1520-

0011,

Para 13.2.2.1 &

Para 13.2.2.2

B6Re-cut or re-beveled Fittings shall have cut surfaces examined for

laminations before welding. Perform MT or PT.

S-PM-G000-1520-

0011,

Para. 13.2.3

B5

All holes cut for set-on nozzles, bosses, or branch connections shall be

ground smooth and the diameter of the hole shall be ± 1.6 mm of the

inside diameter of the set-on member.

B7

Oil, moisture, scale, rust, paint (except approved weldable primers),

metallic coatings (e.g. zinc) or other foreign matter, has been removed

from weld surfaces at least 25mm adjacent to weld joint.

S-PM-G000-1520-

0011,

Para. 13.2.1

S-PM-G000-1520-

0011, Para.

13.2.5 &

SATIP-W-011-01

Item 3.5

B8

Butt joint Internal misalignment shall not exceed 1.5 mm.

NOTE: Internal tapering (ASME B31.3) by machining, backwelding, or a

combination may be used to correct any misalignment.

If external surfaces of the components are not aligned, the weld shall be

tapered between them. [ASME B31.3, Para. 328.4.3 (2).

S-PM-G000-1520-

0011,

Para. 11.3

B10

Note: Inspect Piping ends for Cleanliness int/ext FBE Coating:

A) Solvent Clean oil residues.

B) Chloride Content Testing (ID & OD) for External & Internal FBE

C) Feathering of Internal FBE Coating & Surface Preparation

Applicable SATIP

FBE COATING

B9

Buttering or weld build-up on the prepared surfaces shall not exceed the

lesser of ⅓ of the base metal thickness or 10mm without the approval of

COMPANY. If the buttering or buildup exceeds this, then the following

requirements shall apply. a) The buttering

operation shall be witnessed by COMPANY. b) The buttering shall

be inspected by RT, and PT or MT after completion of the build-up but

before final welding of the joint. Note.repairs shall be performed per SAIC-

W-2033

B11

Coated & clad or overlayed surfaces are protected from welding arc,

associated weld spatter, and damage from ground clamps or other

associated equipment. Take appropriate action for protection to provide

cover & ensure proper selection of grounding locations is inspected.

S-PM-G000-1520-

0011,

Para. 13.11

C WELD JOINT DETAIL

C1

All pressure-containing welds shall be made with multiple passes.

Socket welds shall be welded in two passes S-PM-G000-1520-0011

Para 11.1 (SAIC-W-2037)

S-PM-G000-1520-

0011,

Para. 11.1 & Para

13.18.1

C2All nozzles, branch, and tee connections shall be made with full

penetration groove welds only.

S-PM-G000-1520-

0011,

Para. 11.2



Page 2 of 29







S-PM-G000-1520-

0011,

Para. 11.4

C3

Internal misalignment of butt joints shall not exceed 1.5 mm. Internal

tapering in accordance with ASME B31.3 (Par 328.4.3 ) by machining,

backwelding, or a combination may be used to correct the misalignment.

S-PM-G000-1520-

0011,

Para. 11.3

C5Full penetration groove joint included angles < 30 degrees, except

portions of compound bevels, shall not be used without approval.

S-PM-G000-1520-

0011,

Para. 11.7

C4Permanent backing rings or strips shall not be used unless approved by

the COMPANY.

C6

For nozzles with re-pads, the nozzle attachment weld shall be

completed & inspected (SAIC-L-2010 PMI & See Para 19.5 ) prior to

installing the re-pad.

S-PM-G000-1520-

0011,

Para. 11.7

S-PM-G000-1520-

0011,

Para. 13.15.2

C7

Every Weld joint conforms with an approved WPS (Joint Detail):

a. Base material & b. Thickness & c. Bevel type & d. Root Gap

e) Special surface preparation instructions (Low-Alloys, etc)

Adequate field instruction (detail or written notes) exist.

S-PM-G000-1520-

0011,

Para. 9.1.1

C9

Pressure containing welds (e.g., nozzles and other attachments) shall be

separated from other pressure containing welds by no less than 20 mm or

three times the joint thickness, whichever is greater.

NOTE: RT of the butt welds is required when minimum separation is not

achieved. Inspection approval is required For joints other than butt welds,

other appropriate inspection methods shall be used, depending on the

geometry and material.

S-PM-G000-1520-

0011,

Para. 11.15.2

C8Minimum distance between parallel butt welds shall be 20 mm or

three times the wall thickness of the joint, whichever is greater.

D Welding Environment (Planning & Weather Checks)

D1

Wind shields or tents shall be required when wind is strong enough to

affect arc stability or shielding gas coverage or when deemed necessary

by COMPANY. GTAW, GMAW, or gas-shielded FCAW shall not be used

for field or yard fabrication unless adequate windshield is used. Wind

velocity in the weld area for GTAW, GMAW, or gas shielded FCAW shall

not exceed 8 kph (2.2 m/s)

keep other side pipe ends closed when working with any weld process.

S-PM-G000-1520-

0011,

Section 13.1.1

D2

Welding is not done if surfaces are wet, damp, exposed to rain, or when

welders are exposed to inclement conditions such as wind blown sand,

dust, rain.

S-PM-G000-1520-

0011,

Para. 13.1.2

D3

For field welding, remote Current controls shall be used if welding is more

than 30 m from welding power source or when welders are working in

"remote" locations (e.g., on an elevated piperack).

S-PM-G000-1520-

0011, Para. 21.1

As Referenced

SAIC-W-2032

E Welding Consumables … Use also SAIC-W-2032

E1

Check WPS application & consumable Filler metal size, type & class

conform with the WPS. Note.Change

in filler metal or deposit chemistry from A-No. 1 (based on ASME SEC IX)

to A-No. 2 and vice-versa is not permitted without approval obtained

through welding procedure review process. Change from A-No. 1 to A-

No. 2 is not permitted for sour service without requalification.

S-PM-G000-1520-

0011,

Para. 9.4.5

E2

Filler Metal and other weld consumables at weld site are controlled as per

SAIC-W-2032 (4 & 8 hr rules, reconditioned rod use, etc).

Welders have issue slips at site. Check these to SATR-W-2010.

Page 3 of 29







E3

Welding consumables shall be the same brand, type, maximum size as

indicated on WPS & PQR for welding processes as follows:

A) GMAW electrode specified on WPS with impact toughness reqmt

B) SAW flux specified

C) FCAW electrode specified

S-PM-G000-1520-

0011,

Para. 9.4.4

F Workmanship, Technique & Preheating (Pre-Job Awareness)

Page 4 of 29







F1

Welders & Fitters know the requirements for Preheating & Tack Welding

before the first tack weld is made. See

Attachment 2.

S-PM-G000-1520-

0011,

Section 13 & 14

G Preheat

F2GTAW Practices (Consumable Control, Technique, Purging) are

acceptable and in place before work & follow Attachment 3.

S-PM-G000-1520-

0011,

Section 13

G1

If a weld joint is wet or has surface moisture or condensation, it shall be

dried by heating for a distance of 100 mm from the weld joint and shall be

warm to the hand before welding unless a greater preheat temperature is

required.

S-PM-G000-1520-

0011,

Para. 14.3

S-PM-G000-1520-

0011,

Para. 14.5

G2

Preheat temperature selected/used is sufficient to prevent cracking &

achieve req'd hardness value OR at least the greater as follows:

A) 10°C (50 F).

B) Required/recommended preheat listed in ASME B31.3 Tables.

C) Pre-heat temps from SASD AE-036451 (8 pgs) for ASME P-No. 1

materials, including API grades up to and including X60.

D) Preheat value listed in Tables 3A and 3B for SMAW process.

E) Temperature determined by COMPANY for steels with SMYS above

60 ksi, (incl API grades X65 or greater) or for matl without ASME P-No.

F) Temperature as specified in the approved welding procedure.

Note: Preheat is clearly specified in the WPS or Process Control

Procedure to give clear & available field instruction for WORK

Flanges, fittings and piping often require different preheat temps due to

differing Carbon Equivalent Values. Know these reqmts.

S-PM-G000-1520-

0011,

Para. 14.1

G4

Temperature-indicating crayons, thermocouples, or contact pyrometers

shall be used to measure preheat & interpass temps.

Temperature indicating crayons are prohibited for any weld joint to be

coated, or that will have a heat-shrink sleeve installed on it.

S-PM-G000-1520-

0011,

Para. 14.4

G3

Preheat temperatures shall be established over a minimum distance of 75

mm on each side of the weld. Preheat temperature specified (WPS, etc)

is obtained prior to & maintained during welding.

G5

On wall thickness exceeding 25mm, preheat is done from the same side

as the welding. Heat source is removed for 1 minute prior to measuring

the temperature. (allow temperature equalization).

Perform frequent checks to maintain preheat temps during welding

S-PM-G000-1520-

0011,

Para. 14.6

3. 12-SAMSS-007, Fabrication of Structural and Miscellaneous Steel (3 September 2006)

4. SAEP-324, Certification Review and Registration of Project Welders and Brazers, 1 July 2008

5. SAES-W-011, Welding Requirements for On-Plot Piping, (30 March 2005)

REMARKS:

ATTACHMENTS:

Attachment 1 - Stainless Steel Practices (PFI-ES-43, From SAIC-L-2031, Section F)

Attachment 2 - S-PM-G000-1520-0011 TECHNIQUE, WORKMANSHIP & PREHEATING

Attachment 3 - GTAW PRACTICES (CONSUMABLE CONTROL, TECHNIQUE, PURGING)

Attachment 4 - HEAT INPUT MEASUREMENT REQUIREMENTS


Work VerifiedPerformed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed

REFERENCE DOCUMENTS: 1. S-PM-G000-1520-0011, Welding Requirements for On-Plot Piping.

2. SAES-W-016, Welding of Special Corrosion-Resistant Materials, (30 March 2005)


Page 5 of 29










Work Verified


Performed Inspection Work / Rework May Proceed T&I Witnessed


QC Record Reviewed

Name, Initials and Date:Name, Organization,

Initials and Date:



Quality Record Approved:

Page 6 of 29




FAustenitic Stainless Steel & Nickel Alloy Shop (Per SAIC-L-2031)

Cross-Contamination Measures (Shop & Field)

Check

any Fail

APPLY 100% IN WELD SHOPS,

FIELD APPLICATION IS AS SHOWN


F2Stainless Steel & Nickel Alloy Shops are safely & properly ventillated (ANSI Z49.1).

Adequate air movers lift toxic fumes. Check for Confined spaces in the field*. PFI-ES-43, Sec 1 *Check in field

Check in field

F4Conduct a visual exam of both internal & external surfaces to detect existing

contamination or gouges caused by contact with contaminating material. PFI-ES-43, Sec 2.2 Check in field

F3Handle Austenitic stainless steel & nickel alloys with nylon slings or equipment protected

with a non-contaminating buffer mat'l. PFI-ES-43, Sec 2.1

N/A field

F6 Storage areas for these matls are separate from areas where CS material is stored. PFI-ES-43, Sec 2.4 N/A field

F5 Fittings are stored on pallets or shelving constructed of non-contaminating material PFI-ES-43, Sec 2.3

Check in field

F8

CS strapping is used if a durable, non-contaminating mat'l (clean wood, cardboard, cloth,

paper & SS buffer) isolates the strapping from contact with the stainless steel or nickel

alloy. Gray duct tape (high chlorides) is absolutely prohibited

PFI-ES-43, Sec 2.6 Check in field

F7 SS material stored outdoors was covered (water repellent sheet, etc). PFI-ES-43, Sec 2.5

Check in field

F10Contact surfaces of tools & equipment* containing CS, zinc, copper or their alloys are

covered in noncontaminating matl. (Shall be adequate to prevent cross-contamination)PFI-ES-43, Sec 3.1

Check in field

*scaffold, etc

F9 Walking on austenitic SS or nickel alloy material is not allowed. PFI-ES-43, Sec 2.7

Check in field

F12Grinding discs, abrasive discs & belts are "labelled for SS" and made of resin-bonded

alumina, silicon carbide or zirconium carbide. (No Sulphurized items) PFI-ES-43, Sec 3.3 Check in field

F11Tools (grinding wheel, wire brush, etc) are color coded and used ONLY for each

specific metal. Hawiyeh Lessons Learned (copper contamination / SS)PFI-ES-43, Sec 3.2

Check in field

F14

All material removal & cleaning tools are marked to identify that they are to be used on

specific austenitic & nickel alloy materials only. Marking is visible while a tool is in use.

(Purple & other color codes). Different grades of alloys use new/ different tools.


F13 Only 300 series SS brushes are used on austenitic & nickel alloys. PFI-ES-43, Sec 3.4

Field avoids

contamination

F16

Suitable methods prevent cross contamination by CS shavings, grinding dust, and zinc dust

from coating operations by Enclosure, separation & location of work areas OR Engineering

controls & ventillation assure cleanliness & safety

PFI-ES-43, Sec 3.6

Check in field

Field shielding

as suitable

F15Austenitic & nickel alloy material fabrication areas are separated from CS areas (upwind to

prevent cross contamination). PFI-ES-43, Sec 3.6

Check in field

F18Pressure-sensitive & adhesive-backed tape is removed (along with any adhesive residue)

using a suitable solvent or abrasive.PFI-ES-43, Sec 3.8 Check in field

F17Where tape is used for back purging, the tape uses an adhesive with a water soluble

chloride content not exceeding 50 ppm. Gray duct tape is prohibited (chlorides)PFI-ES-43, Sec 3.7

Check in field

F20Shipping of materials uses new packing matls & shipping protectors such as PVC caps,

plugs, & new adhesive tapes. No harmful substances are used in shipping.PFI-ES-43, Sec 4.1

Check in field

staging areas

F19Cutting fluids or oils are low halogen, low sulphur & are completely removed from all

surfaces prior to any welding or forming.PFI-ES-43, Sec 3.9

Check in field

F22 ID tags & Attachment devices used are made of noncontaminating materials. PFI-ES-43, Sec 4.3 Check in field

F21Certified chloride-free marking or color coding has a water soluble chloride content

below 50 ppm (measured after drying). Weld ID is marked per SAIC-W-2008PFI-ES-43, Sec 4.2

Check in field

F24 Alloys on same load as CS matl are segregated by wood bracing or other suited matl. PFI-ES-43, Sec 4.4 Check in field

F23Austenitic stainless steel & nickel alloys are handled in a manner that will minimize the risk

of material becoming contaminated. Small segments use caution (controls) PFI-ES-43, Sec 4.4

NOTES: 1) Prevent costly cross contamination repairs* (*Cleaning/passivation per ASTM A380 methods shall be COMPANY approved). 2)

Where cross contamination occurs, do not allow welding. If rust is not yet visible, Water-wet with pure Demin/distilled water to form rust using clean

soaked rag on suspect areas. Wet-dry cycles allows test areas to remain dry for a total of 8 hrs in a 24-hr test period. (Pass) shows no evidence of

rust stains or corrosion product. Fact: Once cross-contamination occurs, rust will remain until repaired. 3) Copper Contamination in SS (From

CuNi electrodes, grinders, etc) exists when PMI Cu values exceed 0.7% - See Hawiyah LL).

Page 7 of 29

Attachment 1 - Stainless Steel Practices (Photo Examples for Inspector Awareness)

F-11 & F12 … Color Coding of cutter & grinders (yellow tape = 316L mat'l only) & discs used for SS works

F-10 … Examples of Approved Shop with acceptable "buffer material" to prevent Cross contamination

Page 8 of 29

Page 9 of 29

Creative yet simple Jigs & Restraints with buffer mat'l prevent welding distortion and cross contamination


Tungsten Sharpeners are required to prevent Tungsten Tip Contamination (Piranha Model shown)

Page 10 of 29


Item F-10 … Inspector Caution: Prevent Copper Contamination of Stainless Steel at grounding points … Ground

Clamps must be similar metallurgy or as shown here, quality 316L SS overlay welds were made.

Page 11 of 29


Adjustable Non-metallic pipe roller supports designed specifically for Stainless Steel

Typical GTAW (Tig) rig with portable pallet making a weld. Note the taped ends using an approved tape low in

chlorides (Never allow gray duct tape in SS Shop). Lastly, 316L electrodes without color code ends

Page 12 of 29

Attachment 1 - Stainless Steel Practices (Photo Example of Approved SS Shop)

Page 13 of 29

Attachment 1 - Stainless Steel Practices (Photo Examples of CS Contamination of SS piping)

Note 1: Passivation Cleaning per ASTM A380 is now required (or COMPANY approved other method)

Note 2: Examples are from Vendor supplied skid-mounted Pumps (Associated piping)

Page 14 of 29

Attachment 1 - Stainless Steel Practices (Hawiyeh Lessons Learned CuNi - SS Contamination)

Lessons Learned Summary: Always make sure everything in a SS & Non-Ferrous Material Shop & in the field is

field is color coded / segregated, especially CuNi electrodes (coat them green on the ends). Take steps

early to completely segregate and color code all materials, electrodes, and especially Tools such as

cutting wheels, grinders, brushes FOR EACH SPECIFIC MATERIAL USED ON THE JOB. Note the unusual

discoloration of the Copper Contaminated 316L SS welds in the COMPANY photos below. In the final analysis,

PMI results showing Copper Content greater than 0.7% indicate unacceptable "cross contamination".

Page 15 of 29


Page 16 of 29


Photo below shows both ERCuNi & ER316L Electrodes - Highlighting need for color coding electrode ends

Page 17 of 29


Summary Notes: Following #6 Recommedation, Simulation Samples (info only) were taken at Khurais. Samples

showed PMI results for 316L SS greater than 0.7% Copper indicated a Copper Contamination. As Certain fittings

have up to 0.7% Copper content, this is above the 0.4% noted in the COMPANY report. CuNi tacks in a 316L joint

are very easily picked up by PMI due to dilution. Also, the use of a grinder previously used on CuNi, then

afterwards used on 316L SS showed a PMI test failure. Prevent cracking and failures!

Page 18 of 29


WELD-


ATTACHMENT 2 - SAES-W-011 TECHNIQUE, WORKMANSHIP & PREHEATING

Pre-Welding Inspection (Shop & Field) of Plant Piping SAIC-W-2005 11-Dec-13

Page 19 of 29


Page 20 of 29


Page 21 of 29


Page 22 of 29


Page 23 of 29



ATT. 3 - GTAW PRACTICES (CONSUMABLE CONTROL, TECHNIQUE, PURGING)GTAW CONSUMABLES (CONTROL & SURVEILLANCE)


repair/replace the electrode by means listed below in Tungsten Repair section. If weld is to be of RT quality then the tungsten inclusion shall

be ground out (repair). Power source & current used shall be specified on the WPS & shall be that used in the field.

Tungsten electrode & Consumable Preparation & Redressing/Repair: Tungsten electrode preparation (before welding) and repair

or redressing of contaminated and/or oxidized tips is an area frequently overlooked by organizations unfamiliar with proper shop practices.

Contaminated electrodes produce an erratic arc & dirty, contaminated welds of inconsistent quality. Cutting and grinding contaminated and

or oxidized tungsten electrode tips using the common unacceptable practice of silicon carbide grinding wheels spreads contamination and

does not produce quality GTAW welds because of a tendency for tip fracturing & splintering & thus the need for frequent redressing. Use

of silicon carbide type* grinding wheels results in contamination of tungsten & inconsistent tip quality. *Prohibited per COMPANY.

Quality Step (COMPANY approved, Required for shop approval): Procedures & surveillance shall ensure proper shop & field practices:

1. Properly prepare new tungsten electrodes by using diamond type cutting equipment specifically designed for Tungsten (Piranha, etc)

These commercially available and inexpensive tungsten cutters/grinders utilize diamond technology to provide clean, contamination free,

separation and grinding finish that prevents splintering/shattering of tips, prevents cross contamination, provides precise tip geometry for

desired weld shape, size, and penetration for consistency in welding (Cost savings in time, fewer repairs, extended electrode life).

2. QC surveillance shall ensure that the following GTAW practices regarding Tungsten consumables are carried out on SA Projects

A) Issue of properly prepared Tungsten electrodes (AWS A5.12 specification) is included in Consumable control measures. Use Issue slips

B) Prohibited are: 1) The unacceptable practice of field grinding tungsten. 2) The improper methods of removing contaminated or oxidized

tungsten tips such as breaking with wire cutters, breaking by hand with a hammer, or grinding off with silicon carbide wheel.

C) Early identification of welders using improper techniques (retrain and monitor welders until they produce quality results).

D) Redressing of contaminated or oxidized tips is done at a specified location using proper tip geometry.

Filler metal contamination: See Section 5 below for detailed In-Process GTAW Surveillance

IN-PROCESS MANUAL GTAW TECHNIQUE SURVEILLANCE

FOR MANUAL GTAW TECHNIQUE, there are SIX (6) basic areas for In-Process Surveillance (Page 3 covers purging practice):

Poor Practice shall be identified and corrected ASAP as part of an ongoing effort toward Continuing Process Improvement on IK Projects.

(1) ARC INITIATION & EFFECTS (5 types GTAW equipment are listed below): GTAW equipment for specific P-No is listed below.

High Frequency (HF) Start: Use for all P-No GTAW manual welds, mandatory* for P-No 5 & above, including dissimilar welds.

Use high frequency start & post-purge gas flow for the torch. SAES-W-011, Para 5.2.1 & SAES-W-016 Para 6.2 Also, a remote contactor

and current level control (pedal or torch mounted) is required. Pre-set power source current start/rise and decay/stop controls triggered by

a foot switch (remote foot pedal rheostat) or torch mounted control (finger control rheostat) is an acceptable alternative for remote control.

Note: GTAW for P-No 1, P-No 3 & P-No 4 materials shall utilize HF Start (above) or equipment below Except Touch or Scratch start.

Pulse Start/Capacitor Discharge: Used for machine or automatic welding (DC), not for manual GTAW

Automatic Pulsed (GTAW-P): When used for root pass welding of single-sided joints, welding shall be performed with the same make

and model of welding system using same equipment and/or program settings as those used in procedure quals. Comment: The need to

specify make & model, program, equipment settings & pulse waveform is based upon the effects these variables have on welding arc

performance, especially sidewall fusion and out-of-position welding. Studies verify considerable variation in arc characteristics when one

make or model of welding system is compared to another. Variation can lead to welding defects difficult to detect by RT (API 582 Par 5.2.1)

Touch or scratch start (Prohibited by COMPANY): With power source energized, contactor closed, & shielding gas flowing from cup,

torch is lowered toward the work piece until the tungsten electrode contacts with work piece. The torch is quickly withdrawn a short distance

to establish the arc. Depending on the instantaneous short circuit current capability of the welding power source, the current through the

welding electrode upon arc initiation may cause damage to the weld or the electrode. This is corrected by limiting the current upon arc start.

Touch starting has a tendency for electrodes to stick to the work causing electrode contamination & tungsten transfer.

Touch & Retract Starters: Touch and retract starters are similar to contact starting in that the tip of the electrode is lowered to make

contact with the work piece. However, the controls in this starter do not allow current to flow until the electrode begins to be withdrawn,

thus striking the arc. This eliminates the tendency for electrode contamination. Another variation involves a low current to be passed thru

the electrode, which heats the electrode tip and allows the arc to more easily be initiated upon retraction. Acceptable method per COMPANY

(2) CURRENT SELECTION (WPS ESSENTIAL VARIABLE) & CURRENT CONTROLS

Selection: Direct current electrode negative (DCEN*) & Direct current electrode positive (DCEP**) are two types of direct current used in

Page 24 of 29




GTAW. WPS terminology using DCSP* or straight polarity and DCRP** or reverse polarity is no longer standard terminology. *DCEN = DCSP

A) DCEN produces the greatest heat, deep joint penetration & faster welding. This is the most common configuration in SA, almost all WPS.

B) DCEP (DCEP = DCRP or reverse polarity) is extremely limited in use (3mm & less extremely thin aluminum & magnesium alloys)

C) AC is used in GTAW process at Saudi Aramco in similar applications to DCEP such as for P- No 23 Aluminum materials (ER4043 filler)

D) PROGRAMMED CURRENT - Combines AC & DC. Variable Polarity or VP is a type of programmed current. Not used in SA applications.

Programmable controllers: Programmable controllers control weld sequence, pulse, arc voltage, arc length, and other parameters)

Current Controls (See also HF Start): Current Control Mechanisms are listed below for GTAW process:

Remote foot pedal type & Finger control type rheostats - Arc control in DC welding machines uses a rheostat in welding circuit.

Contactor - A device that opens and closes an electrical circuit (Used in Touch Start Methods)

VERIFY that current type, current controls, electrode type, & shielding gas match a COMPANY approved WPS. - See Table below

Page 25 of 29




(3) TORCH MANIPULATION (TECHNIQUE & APPLICATION): Notes for inspector awareness are identified with an asterisk *

Walking the Cup*: A technique for manipulating the torch when manually welding groove & fillet welds. With this technique, the electrode

extension is adjusted* to allow the proper arc length* while the edge of the cup* rests on the side of the joint. The torch is manipulated in a

manner to swing the tip of the tungsten back & forth across the side of the joint by “walking-the-cup” on each edge of the joint. The left or

right edge of the gas nozzle/cup is in constant contact with the members giving the cup a walking motion on the weld joint. One limitation of

this technique is that it is very difficult* to walk-the-cup when welding pipe less than 2 in. [50 mm] in diameter*.

Dragging the Finger: A technique used in manual welding of all types of joint configurations. It can be used when welding all diameters

of pipe & tubing. A fingerstall is made by overlapping a “sleeve” of fiberglass mat’l approx 8 in. [200 mm] long. Fingerstall is placed over the

middle finger & should extend about 1 in. [25 mm] beyond the end of the finger. A Fingerstall stabilizes the hand holding the torch as it is slid

along during welding and provides added insulation and protection for the welder.

Brace Technique: Used in manual welding of vessels, very large pipe diameters and structures. In this technique, the welder stabilizes

the torch by resting his wrist, arm or elbow as far away from the weld zone as possible & sliding the wrist in the direction of welding.

Freehand Technique: This technique should be used only when no other technique is feasible. Very few welders create quality welds

without technique to stabilize the torch. Uncontrolled torch motion can lead to tungsten contact with work or filler. Ensure only the best

welders make joints in difficult field locations where freehand technique is used. Also increase surveillance and NDE as needed.

(4) WORK PIECE MANIPULATION

Planning for production: During the planning of welding operation sequence & qualifying welding procedures & welders, the welding

engineer must establish in which welding position the joint will be welded in production. Shop handling practices are found in SAIC-L-2031.

Manual Manipulation: For small pipe welds that can be rotated, it may be economical to make the welds using pipe rollers. Weld the top

quarter, then manually rotating the pipe & completing the weld in quarters. Other ways the weld joint can be manually positioned are by

physically moving the component or using lifting devices such as overhead cranes or universal balance positioners (manually operated).

(5) FILLER METAL ADDITION (For manual GTAW, only cut length Filler Wire is covered. Wire feed or autogenous welding is not allowed)

Filler Metal Addition: When retracting weld filler rod from the pool, care shall be exercised to ensure the hot end of the rod is not

removed from within the welding torch’s protective gas envelope. If the end of the filler wire should become oxidized, then the oxidized end

shall be cut prior to using the remaining wire. Typically a pair of cutting pliers* is used in this process. (*Prohibited for cutting tungsten).

When welding a root pass, filler metal is normally held in one position and not manipulated. When welding filler and cover passes, filler metal

may be manipulated a slight amount based on joint opening. During welding, the welder must be careful not to touch the filler wire to the

tungsten electrode, since the electrode would become contaminated (Repair or replace).Prior to using filler wire, verify that the type of the

filler wire matches the filler material specified on the welding procedure. Additionally, assure cleanliness of filler material (no visible rust,

discoloration, or evidence of atmospheric contamination such as dust or residues. GTAW Filler metals shall be issued & stored in a portable

container such as a capped PVC tube. Welder training assures that approved consumable id and storage procedures are followed.

(6) EXTINGUISHING THE ARC: Care is taken to avoid forming crater cracks, porosity & start/stop weld defects. Perform close visual check

Welders can achieve this in several ways. After the arc has been extinguished, it is good practice to flow the shielding gas from the torch

over the end of the weld to permit this area to cool* under the protective gas. At the same time, this allows the tungsten electrode to cool

under the shielding gas and prevents its oxidation. Filler material ends are maintained under shielding gas to prevent their oxidation OR

any oxidized filler metal ends shall be cut (cutting tool pliers) each time arc is extinguished & filler becomes oxidized (every tack, stop, etc).

*Inert gas flow time over an extinguishing arc follows the "15 second rule" = Zero Contamination ... QC surveillance point*

Note: 15* seconds cooling under gas flow will result in zero oxidation. Time is dependent on application & can be less to achieve quality.

Decreasing the Current (Down Slope, Down Ramp): Decreasing current is one of the most effective methods for extinguishing the

arc. In this method, the size of the weld pool is decreased by decreasing the current with a foot or hand controlled rheostat.

Weld Tie-In: Moving the arc up and over to the side of the joint (while remaining in the joint) or over the previous pass or back stepping is

effective in minimizing disturbance of the final weld pool. A gradual breaking of the arc will reduce the possibility of porosity & crater crack.

Filling the Crater: A small quantity of filler can be added just as the electrode is withdrawn (& cools under gas) to compensate for weld

pool solidification shrinkage & provide a little extra filler material to help prevent a shrinkage cavity.

Inspect completed welds for undercut, underfill, excess penetration or reinforcement, crater cracks, & porosity

Page 26 of 29




GTAW PURGING PRACTICESAcceptance Criteria (Oxidation)

The purge shall achieve actual oxygen levels inside or exiting the joint (via the vent) never greater than 50 ppm O2 (maximum 0.005%) prior

to and during welding, as measured with an O2 analyzer with low-level read-out capability. The actual oxygen levels achieved in

production shall be measured periodically (i.e., at the start of production work for each welder, and thereafter, on a random basis for the

number of joints to be performed). Analyzers shall be used for all joints if excessive internal oxidation is observed on any joints based on

the visual appearance of the oxide tint. Use the AWS C5.5 Figure 40 Oxidation Table for guidance, comparison & reporting.

Treat or Passivate using an approved method such ASTM A380 practice or other COMPANY approved method.

1. 12 ppm O2 = No oxide tint ... ACCEPTABLE

2. 60-70 ppm O2 = Slight oxide tint visible ... Unacceptable

3. 70-90 ppm O2 = Slightly more visible oxide tint ... Unacceptable

4. 200 ppm O2 = Dark oxide tint ... Unacceptable

5. 250 ppm O2 = Almost Black oxide tint ... Unacceptable

6. 500 ppm O2 = (0.05%) = Black or “sugared” ... Unacceptable ... Likely will be a "Cut out" or weld metal repair

PURGE DAM DETAILSPurge Dams shall follow the detailed practices of AWS D10.11, Recommended Practices for Root Pass Welding. Due to a common problem

of leakage with proprietary dissolvable water-soluble dams, these shall be avoided whenever possible. If purge dams are to be used but

cannot be retrieved after welding, then proprietary dissolvable (water soluble paper such as rice paper, etc) dams shall be used and the

dams “stay put”. Dams using rice paper often allow a high rate of gas escape & require multiple layers “glued” together to maintain purge.

Comment: Discoloration (oxide tint) is dark at 200 parts per million or ppm O2, with a discernible tint at 60-70 ppm .

Welding procedure shall cover “additional testing” or disposition of those welds found with “oxide tint” or discoloration.

If no such procedure exists: See Disposition Below

Disposition of Oxidized Root Pass & Welds“Welds with internal oxidation, based on visual appearance of oxide tint as Inspected, shall be repaired or treated by COMPANY approved method

B) Before decreasing purge gas pressure and closing the weld joint, a “visual inspection window” shall be left open for Inspection to

verify acceptable root pass condition. This is an extremely quick inspection with a mini-light that determines any root oxidation.

Inspector specifies a 25 mm visual "window" & identifies visible oxide tint. Pass/Fail.COMMENTARY: Currently, tape is being used in many instances on large bore pipe to hold these dams in place ... This is the only way the

following stringent conditions for their application shall apply:

A) In addition, water-soluble approved “low chloride” glues* shall be used to hold the dams in place (Elmer’s glue is accepted in our Industry

for this exact purpose) or proprietary water soluble adhesive tape shall be applied to purge dams. Dams shall be located far enough from

the joint to prevent their failure during the welding process, usually 150-300 mm.

Page 27 of 29




USE SATR-W-20111. Use a calibrated Volt/amp meter. Check readings adjacent to source & Work (without disturbing welder)


2. Welding Machines are calibrated per SAIC-W-2011 Checklist. SA Witness Point.

3. Have a Test Form to list values against welds made. Determine Acceptable Limits before Testing

4. Take valid readings. (10 Degree, 90 Degree Rule). Travel speed (& SMAW bead width) is critical.

5. Procedure shall have a disposition for retraining & disposition for unacceptable results.

TAKE H.I. MEASUREMENTS (Use the 10 degree - 90 degree rule)Measurements in either 90 degree quadrant is used to validate H.I. Results (Pass/Fail)

Notes for H.I. Measurements

1. Take measurements for the

voltage & amperage when the

welder is welding in those two

quadrants shown in the sketch.

2. Travel speed measurements

4. Testing may be reduced to a

random check once the Saudi

are also taken in the same two


3. 100% checks of Heat Input is

required for all welders until

they establish their ability to

meet WPS Heat Input Values.

Page 28 of 29

during qualification and before

any production work to assure

sound welds within H.I. Limits

Aramco authorized inspector

has accepted initial results.

5. Highly recommended is the

practice & testing of welders

Page 29 of 29

PASS FAIL N/A

C Back Purging & Shielding Gas

ITEM


C1

Inert gas is used for GTAW or GMAW root passes on single-sided

groove welds, on ASME P-No. 5 matls & above* & maintained until 2

layers of the weld deposit thickness is completed.

Note: Nitrogen as a backing gas for Austenitic SS is prohibited.

See Att. 3, Page 3 for GTAW Purging Practices

S-PM-G000-1520-

0011,

Para. 13.13.1 to

13.13.3

B6

Bridge tacks (located above the root area) are acceptable but such tacks

must be made completely within the weld groove and shall be

completely removed prior to completion of the weld.

Note: Tacks made outside the groove require MT/PT examination.

S-PM-G000-1520-

0011,

Para. 13.4.6

S-PM-G000-1520-

0011,

Para. 13.4.4

B5

If the tack welds are to be incorporated into the final root pass weld

and are made with a different process or electrode than the root pass,

then the tack weld process and electrode shall have been used as the

root pass for an appropriate procedure qualification.

S-PM-G000-1520-

0011,

Para. 13.4.5

B4

Tack welds to be incorporated into the final weld are thoroughly cleaned,

prepared (feathered) at each end, & inspected for cracks.

NOTE: Any cracked tacks shall be removed before welding joints.

B3

The minimum number of tack welds are:

a) Pipe diameter of 101.6mm or less: three equally spaced tacks.

b) Pipe dia. > 101.6mm: minimum of four equally spaced tacks.

S-PM-G000-1520-

0011,

Para. 13.4.3

B2Tack welds are sufficient size to maintain joint alignment. The tack

thickness is 3.2 to 4.8 mm and tack length is 12.5 to 25.4 mm.

S-PM-G000-1520-

0011,

Para. 13.4.3

B SAIC-W-2005 has been followed (Every weld)

B1

All tacks or temporary welds are performed with the same care,

materials, electrodes, minimum preheat, & procedures that are used

for permanent welds. This includes back purging with gas.

S-PM-G000-1520-

0011,

Para. 13.4.2

A3

GTAW follows acceptable practice per Attachment 3:

A) Tungsten preparation, issue & repair using proper equipment

B) Welder Technique prevents oxidation of tungsten tips

C) Purging Practices & Purge Dams are adequate

S-PM-G000-1520-

0011, Section 13

&

Section 14

A2

Technique, Workmanship & Preheat is per Attachment 2:

A) Electrode type & Size limits

B) Minimum distance between Welds & Weld Encroachment

C) Preheat Requirements

S-PM-G000-1520-

0011, Section 13

&

Section 14

A General Requirements … Use this checklist in conjunction with SAIC-W-2005

A1

Stainless Steel & Corrosion-Resistant Piping Practices meet strict

Attachment 1 criteria (inspector must know):

A) Cross-contamination prevention practice is adequate

B) Welding Environment was acceptable

C) Joint Prep & Cleaning was acceptable

S-PM-G000-1520-

0011, Section 12

&

Section 13


RE-INSP DATE


TRAVEL TIME





In-Process Welding Inspection SAIC-W-2006 11-Dec-13 WELD-


SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff -June 2008) Rev 3 30-Jun-08

Page 1 of 24

RE-INSP DATEITEM

No.ACCEPTANCE CRITERIA REFERENCE PASS

D10Adjacent beads of a weld shall be staggered and not started in the same

location.

S-PM-G000-1520-

0011,

Para. 13.12

S-PM-G000-1520-

0011,

Para. 21.1

D9

Heat input (HI) of each* production weld is calculated (using formula

below) if Charpy impact is specified on the WPS, and then confirmed not

to exceed the heat input limits listed in the WPS's.

HI (kj/cm) = Volt X Amp X 60/Travel Speed (cm/min)

See Attachment 4.

Note: ensure above HI values as per WPS are maintained by each

welder, perform random monitoring of welders

S-PM-G000-1520-

0011,

Para. 21.3

D8

Remote Current controls are used if welding is more than 30 m from

welding a power source or when welders work in "remote" areas

Note: Welding in elevated pipe racks shall meet this requirement.

D7

Maximum SMAW electrode size to be used are:

A) Low hydrogen electrode - 5 mm in 1G/1F position, 4 mm all other

B) Non-low hydrogen electrodes - 5 mm for all positions.

SAES-W-011,

Para. 11.1

D6SAW Flux fused during welding shall not be reused (i.e., fluxes that use

recrushed slag are not acceptable).

S-PM-G000-1520-

0011,

Para. 8.5.2

S-PM-G000-1520-

0011,

Para. 7.2.3

D5

The back purge for stainless steel and nickel alloys shall done to reduce

the oxygen level below 0.05%.(refer WPS for same). Recommended

Where no oxygen analyzer was used, a visual insp (25 mm window) was

performed. See Att 3, Page 3 Purge shall be maintained until deposition

reaches 10 mm*

S-PM-G000-1520-

0011,

Para. 13.14.4

D4GTAW process shall* be used for root pass of all piping single side

groove welds and set in nozzles.

D3Root pass is deposited without backing for WPS qualified for single-sided

groove welds without backing.

S-PM-G000-1520-

0011,

Para. 9.4.10

D2

Each weld pass is thoroughly cleaned and all slag or other foreign matter

removed before the next pass is deposited. NOTE: See WPS remarks for

cleaning method, e.g. mechanical brush.

S-PM-G000-1520-

0011,

Para. 13.3.1

D Root , Hot & Final Pass

D1

The direction of welding conforms with the WPS.

(NOTE: If the WPS is not qualified in the vertical position, then the

direction of welding shall be vertical-up. )

S-PM-G000-1520-

0011,

Para. 9.4.7.1

C3Forced or accelerated cooling of welds is prohibited without the specific

approval of COMPANY.

S-PM-G000-1520-

0011,

Para. 13.17

C2

The back purge for stainless steel and nickel alloys shall reduce the

oxygen level below 0.05%. An oxygen analyzer should be used to

determine the oxygen content inside the pipe during purging. If more

than 20 joints are to be welded at the same time then minimum of 10% of

the total joints shall be analyzed. The below formula is used to achieve

the required purging time: See Att. 1 & Photo

GTAW Practices shall follow AWS C5.5 & AWS D10.11 with regard to

purge dams and purge gas containment.

S-PM-G000-1520-

0011,

Para. 13.13.5

FAIL N/A





Page 2 of 24

RE-INSP DATEITEM

No.ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A







Contractor QC Inspector





Initials and Date:Name, Initials and Date:


Work Verified



COMPANY Inspector


6. ASME B31.3, Process Piping, (2007 Edition). ASME SEC II Part C – Specs for Welding Rods, Electrodes & Filler Metals, (2005 Edition)

8. ASME SEC IX - Qual. Standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators, (2005)



3. 12-SAMSS-007, Fabrication of Structural and Miscellaneous Steel (30 April 2005)

4. American Welding Society (AWS) D1.1 Structural Steel Welding Code (2004 Edition)

5. American Welding Society (AWS) C5.5 Recommended Practices for Gas Tungsten Arc Welding (2003 Edition)

Attachment 2 - S-PM-G000-1520-0011 TECHNIQUE, WORKMANSHIP & PREHEATING

Attachment 3 - GTAW PRACTICES (CONSUMABLE CONTROL, TECHNIQUE, PURGING)



REMARKS:

ATTACHMENTS:


D15All slag, flux, weld spatter, and undercuts are removed from the

completed weld and surrounding areas.

S-PM-G000-1520-

0011,

Para. 13.3.2

D14Forced or accelerated cooling of welds is prohibited without the specific

approval of COMPANY.

S-PM-G000-1520-

0011,

Para. 13.17

S-PM-G000-1520-

0011,

Para. 14.7

D13Unless specified in the WPS, back welding is done using the same

process, consumables and preheat as the fill passes.

S-PM-G000-1520-

0011,

Para. 13.16

D12

Unless specified otherwise, maximum interpass temperatures are:

A) 177°C for P-No. 8 and P-No. 4x materials

B) 315°C for P-1,P3, P-4 and P-5 steels.

D11

All full penetration joints requiring double sided welding shall be ground or

gouged to sound metal & inspected by penetrant test (PT) or magnetic

particle testing (MT) prior to welding the reverse side, unless exempted

by S-PM-G000-1520-0011, Para. 9.4.10 as follows: For the exempt

applications, production results shall demonstrate that acceptable

penetration can be reliably achieved. If periodic lack-of-penetration

defects are found, then backgouging will be mandatory for joint

geometries other than butt welds and either backgouging or 100%

radiography will be required for butt welds.

S-PM-G000-1520-

0011,

Para. 13.2.4

Page 3 of 24



NOTES: 1) Prevent costly cross contamination repairs* (*Cleaning/passivation per ASTM A380 methods shall be COMPANY approved).

2) Where cross contamination occurs, do not allow welding. If rust is not yet visible, Water-wet with pure Demin/distilled water to form rust using

clean soaked rag on suspect areas. Wet-dry cycles allows test areas to remain dry for a total of 8 hrs in a 24-hr test period. (Pass) shows no

evidence of rust stains or corrosion product. Fact: Once cross-contamination occurs, rust will remain until repaired. 3)

Copper Contamination in SS (From CuNi electrodes, grinders, etc) exists when PMI Cu values exceed 0.7% - See Hawiyah LL).

Check in field

F24 Alloys on same load as CS matl are segregated by wood bracing or other suited matl.

PFI-ES-43, Sec 4.1Check in field

staging areas

F23Austenitic stainless steel & nickel alloys are handled in a manner that will minimize the risk

of material becoming contaminated. Small segments use caution (controls) PFI-ES-43, Sec 4.4

Check in field

F22 ID tags & Attachment devices used are made of noncontaminating materials.


F21Certified chloride-free marking or color coding has a water soluble chloride content

below 50 ppm (measured after drying). Weld ID is marked per SAIC-W-2008PFI-ES-43, Sec 4.2

Check in field

F20Shipping of materials uses new packing matls & shipping protectors such as PVC caps,

plugs, & new adhesive tapes. No harmful substances are used in shipping.

PFI-ES-43, Sec 3.6

Check in field

Field shielding

as suitable

F19Cutting fluids or oils are low halogen, low sulphur & are completely removed from all

surfaces prior to any welding or forming.PFI-ES-43, Sec 3.9

Check in field

F18Pressure-sensitive & adhesive-backed tape is removed (along with any adhesive residue)

using a suitable solvent or abrasive.


F17Where tape is used for back purging, the tape uses an adhesive with a water soluble

chloride content not exceeding 50 ppm. Gray duct tape is prohibited (chlorides)PFI-ES-43, Sec 3.7

Field avoids

contamination

F16

Suitable methods prevent cross contamination by CS shavings, grinding dust, and zinc dust

from coating operations by Enclosure, separation & location of work areas OR Engineering

controls & ventillation assure cleanliness & safety


F15Austenitic & nickel alloy material fabrication areas are separated from CS areas (upwind to

prevent cross contamination). PFI-ES-43, Sec 3.6

Check in field

F14

All material removal & cleaning tools are marked to identify that they are to be used on

specific austenitic & nickel alloy materials only. Marking is visible while a tool is in use.

(Purple & other color codes). Different grades of alloys use new/ differ

PFI-ES-43, Sec 3.1Check in field

*scaffold, etc

F13 Only 300 series SS brushes are used on austenitic & nickel alloys. PFI-ES-43, Sec 3.4

Check in field

F12Grinding discs, abrasive discs & belts are "labelled for SS" and made of resin-bonded

alumina, silicon carbide or zirconium carbide. (No Sulphurized items)


F11Tools (grinding wheel, wire brush, etc) are color coded and used ONLY for each

specific metal. Hawiyeh Lessons Learned (copper contamination / SS)PFI-ES-43, Sec 3.2

Check in field

F10Contact surfaces of tools & equipment* containing CS, zinc, copper or their alloys are

covered in noncontaminating matl. (Shall be adequate to prevent cross-contamination)

PFI-ES-43, Sec 2.4 N/A field

F9 Walking on austenitic SS or nickel alloy material is not allowed. PFI-ES-43, Sec 2.7

Check in field

F8

CS strapping is used if a durable, non-contaminating mat'l (clean wood, cardboard, cloth,

paper & SS buffer) isolates the strapping from contact with the stainless steel or nickel

alloy. Gray duct tape (high chlorides) is absolutely prohibited


F7 SS material stored outdoors was covered (water repellent sheet, etc). PFI-ES-43, Sec 2.5

N/A field

F6 Storage areas for these matls are separate from areas where CS material is stored.

PFI-ES-43, Sec 1 *Check in field

F5 Fittings are stored on pallets or shelving constructed of non-contaminating material PFI-ES-43, Sec 2.3

Check in field

F4Conduct a visual exam of both internal & external surfaces to detect existing

contamination or gouges caused by contact with contaminating material.

Check

any Fail

APPLY 100% IN WELD SHOPS,

FIELD APPLICATION IS AS SHOWN

F3Handle Austenitic stainless steel & nickel alloys with nylon slings or equipment protected

with a non-contaminating buffer mat'l. PFI-ES-43, Sec 2.1

Field use as

applicable

F2Stainless Steel & Nickel Alloy Shops are safely & properly ventillated (ANSI Z49.1).

Adequate air movers lift toxic fumes. Check for Confined spaces in the field*.


F1Stainless Steel & Nickel Alloy Weld Shops address material Handling & Storage,

Fabrication & Shipping per Piping Fabrication Institute (PFI) Standard ES-43. PFI-ES-43, Sec 1


FAustenitic Stainless Steel & Nickel Alloy Shop (Per SAIC-L-2031)

Cross-Contamination Measures (Shop & Field)



SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER

Page 4 of 24


F-11 & F12 … Color Coding of cutter & grinders (yellow tape = 316L mat'l only) & discs used for SS works

F-10 … Examples of Approved Shop with acceptable "buffer material" to prevent Cross contamination

Page 5 of 24


Creative yet simple Jigs & Restraints with buffer mat'l prevent welding distortion and cross contamination

Page 6 of 24


Item F-10 … Inspector Caution: Prevent Copper Contamination of Stainless Steel at grounding points … Ground

Clamps must be similar metallurgy or as shown here, quality 316L SS overlay welds were made.

Page 7 of 24

Typical GTAW (Tig) rig with portable pallet making a weld. Note the taped ends using an approved tape low in

chlorides (Never allow gray duct tape in SS Shop). Lastly, 316L electrodes without color code ends


Page 8 of 24

Attachment 1 - Stainless Steel Practices (Photo Example of Approved SS Shop)

Attachment 1 - Stainless Steel Practices (Photo Examples of CS Contamination of SS piping)

Note 1: Passivation Cleaning per ASTM A380 is now required (or COMPANY approved other method)

Note 2: Examples are from Vendor supplied skid-mounted Pumps (Associated piping)

Page 9 of 24

Page 10 of 24

cutting wheels, grinders, brushes FOR EACH SPECIFIC MATERIAL USED ON THE JOB. Note the unusual

discoloration of the Copper Contaminated 316L SS welds in the COMPANY photos below. In the final analysis,

PMI results showing Copper Content greater than 0.7% indicate unacceptable "cross contamination".

Lessons Learned Summary: Always make sure everything in a SS & Non-Ferrous Material Shop & in the field is

field is color coded / segregated, especially CuNi electrodes (coat them green on the ends). Take steps

early to completely segregate and color code all materials, electrodes, and especially Tools such as


Page 11 of 24


Page 12 of 24

Photo below shows both ERCuNi & ER316L Electrodes - Highlighting need for color coding electrode ends


COMPANY

COMPANY

COMPANY

Page 13 of 24

ATTACHMENT 2 -S-PM-G000-1520-0011 TECHNIQUE, WORKMANSHIP & PREHEATING




Page 14 of 24

ATTACHMENT 2 - S-PM-G000-1520-0011 TECHNIQUE, WORKMANSHIP & PREHEATING

Page 15 of 24


Page 16 of 24


Page 17 of 24


Page 18 of 24


Page 19 of 24


Page 20 of 24

Current Controls (See also HF Start): Current Control Mechanisms are listed below for GTAW process:

Remote foot pedal type & Finger control type rheostats - Arc control in DC welding machines uses a rheostat in welding circuit.

Contactor - A device that opens and closes an electrical circuit (Used in Touch Start Methods)

VERIFY that current type, current controls, electrode type, & shielding gas match a COMPANY approved WPS. - See Table below

B) DCEP (DCEP = DCRP or reverse polarity) is extremely limited in use (3mm & less extremely thin aluminum & magnesium alloys)

C) AC is used in GTAW process at Saudi Aramco in similar applications to DCEP such as for P- No 23 Aluminum materials (ER4043 filler)

D) PROGRAMMED CURRENT - Combines AC & DC. Variable Polarity or VP is a type of programmed current. Not used in SA applications.

Programmable controllers: Programmable controllers control weld sequence, pulse, arc voltage, arc length, and other parameters)

(2) CURRENT SELECTION (WPS ESSENTIAL VARIABLE) & CURRENT CONTROLS

Selection: Direct current electrode negative (DCEN*) & Direct current electrode positive (DCEP**) are two types of direct current used in

GTAW. WPS terminology using DCSP* or straight polarity and DCRP** or reverse polarity is no longer standard terminology. *DCEN = DCSP

A) DCEN produces the greatest heat, deep joint penetration & faster welding. This is the most common configuration in SA, almost all WPS.

Touch & Retract Starters: Touch and retract starters are similar to contact starting in that the tip of the electrode is lowered to make

contact with the work piece. However, the controls in this starter do not allow current to flow until the electrode begins to be withdrawn,

thus striking the arc. This eliminates the tendency for electrode contamination. Another variation involves a low current to be passed thru

the electrode, which heats the electrode tip and allows the arc to more easily be initiated upon retraction. Acceptable method per CSD

torch is lowered toward the work piece until the tungsten electrode contacts with work piece. The torch is quickly withdrawn a short distance

to establish the arc. Depending on the instantaneous short circuit current capability of the welding power source, the current through the

welding electrode upon arc initiation may cause damage to the weld or the electrode. This is corrected by limiting the current upon arc start.

Touch starting has a tendency for electrodes to stick to the work causing electrode contamination & tungsten transfer.

specify make & model, program, equipment settings & pulse waveform is based upon the effects these variables have on welding arc

performance, especially sidewall fusion and out-of-position welding. Studies verify considerable variation in arc characteristics when one

make or model of welding system is compared to another. Variation can lead to welding defects difficult to detect by RT (API 582 Par 5.2.1)

Touch or scratch start (Prohibited by COMPANY): With power source energized, contactor closed, & shielding gas flowing from cup,

Note: GTAW for P-No 1, P-No 3 & P-No 4 materials shall utilize HF Start (above) or equipment below Except Touch or Scratch start.

Pulse Start/Capacitor Discharge: Used for machine or automatic welding (DC), not for manual GTAW

Automatic Pulsed (GTAW-P): When used for root pass welding of single-sided joints, welding shall be performed with the same make

and model of welding system using same equipment and/or program settings as those used in procedure quals. Comment: The need to

High Frequency (HF) Start: Use for all P-No GTAW manual welds, mandatory* for P-No 5 & above, including dissimilar welds.

Use high frequency start & post-purge gas flow for the torch. SAES-W-011, Para 5.2.1 & SAES-W-016 Para 6.2 Also, a remote contactor

and current level control (pedal or torch mounted) is required. Pre-set power source current start/rise and decay/stop controls triggered by

a foot switch (remote foot pedal rheostat) or torch mounted control (finger control rheostat) is an acceptable alternative for remote control.

IN-PROCESS MANUAL GTAW TECHNIQUE SURVEILLANCE

FOR MANUAL GTAW TECHNIQUE, there are SIX (6) basic areas for In-Process Surveillance (Page 3 covers purging practice):

Poor Practice shall be identified and corrected ASAP as part of an ongoing effort toward Continuing Process Improvement on IK Projects.

(1) ARC INITIATION & EFFECTS (5 types GTAW equipment are listed below): GTAW equipment for specific P-No is listed below.

tungsten tips such as breaking with wire cutters, breaking by hand with a hammer, or grinding off with silicon carbide wheel.

C) Early identification of welders using improper techniques (retrain and monitor welders until they produce quality results).

D) Redressing of contaminated or oxidized tips is done at a specified location using proper tip geometry.

Filler metal contamination: See Section 5 below for detailed In-Process GTAW Surveillance

desired weld shape, size, and penetration for consistency in welding (Cost savings in time, fewer repairs, extended electrode life).

2. QC surveillance shall ensure that the following GTAW practices regarding Tungsten consumables are carried out on SA Projects

A) Issue of properly prepared Tungsten electrodes (AWS A5.12 specification) is included in Consumable control measures. Use Issue slips

B) Prohibited are: 1) The unacceptable practice of field grinding tungsten. 2) The improper methods of removing contaminated or oxidized

Quality Step (CSD approved, Required for shop approval): Procedures & surveillance shall ensure proper shop & field practices:

1. Properly prepare new tungsten electrodes by using diamond type cutting equipment specifically designed for Tungsten (Piranha, etc)

These commercially available and inexpensive tungsten cutters/grinders utilize diamond technology to provide clean, contamination free,

separation and grinding finish that prevents splintering/shattering of tips, prevents cross contamination, provides precise tip geometry for




of silicon carbide type* grinding wheels results in contamination of tungsten & inconsistent tip quality. *Prohibited per CSD.





ATT. 3 - GTAW PRACTICES (CONSUMABLE CONTROL, TECHNIQUE, PURGING)GTAW CONSUMABLES (CONTROL & SURVEILLANCE)

Welders shall prevent tungsten electrode contact with work (including molten pool). If this happens, welders shall extinguish the arc &

In-Process Welding Inspection SAIC-W-2006


11-Dec-13 WELD-


Page 21 of 24



11-Dec-13 WELD-


Inspect completed welds for undercut, underfill, excess penetration or reinforcement, crater cracks, & porosity

Weld Tie-In: Moving the arc up and over to the side of the joint (while remaining in the joint) or over the previous pass or back stepping is

effective in minimizing disturbance of the final weld pool. A gradual breaking of the arc will reduce the possibility of porosity & crater crack.

Filling the Crater: A small quantity of filler can be added just as the electrode is withdrawn (& cools under gas) to compensate for weld

pool solidification shrinkage & provide a little extra filler material to help prevent a shrinkage cavity.

*Inert gas flow time over an extinguishing arc follows the "15 second rule" = Zero Contamination ... QC surveillance point*

Note: 15* seconds cooling under gas flow will result in zero oxidation. Time is dependent on application & can be less to achieve quality.

Decreasing the Current (Down Slope, Down Ramp): Decreasing current is one of the most effective methods for extinguishing the

arc. In this method, the size of the weld pool is decreased by decreasing the current with a foot or hand controlled rheostat.

Welders can achieve this in several ways. After the arc has been extinguished, it is good practice to flow the shielding gas from the torch

over the end of the weld to permit this area to cool* under the protective gas. At the same time, this allows the tungsten electrode to cool

under the shielding gas and prevents its oxidation. Filler material ends are maintained under shielding gas to prevent their oxidation OR

any oxidized filler metal ends shall be cut (cutting tool pliers) each time arc is extinguished & filler becomes oxidized (every tack, stop, etc).

filler wire matches the filler material specified on the welding procedure. Additionally, assure cleanliness of filler material (no visible rust,

discoloration, or evidence of atmospheric contamination such as dust or residues. GTAW Filler metals shall be issued & stored in a portable

container such as a capped PVC tube. Welder training assures that approved consumable id and storage procedures are followed.

(6) EXTINGUISHING THE ARC: Care is taken to avoid forming crater cracks, porosity & start/stop weld defects. Perform close visual check





physically moving the component or using lifting devices such as overhead cranes or universal balance positioners (manually operated).

(5) FILLER METAL ADDITION (For manual GTAW, only cut length Filler Wire is covered. Wire feed or autogenous welding is not allowed)

Filler Metal Addition: When retracting weld filler rod from the pool, care shall be exercised to ensure the hot end of the rod is not


Planning for production: During the planning of welding operation sequence & qualifying welding procedures & welders, the welding

engineer must establish in which welding position the joint will be welded in production. Shop handling practices are found in SAIC-L-2031.

Manual Manipulation: For small pipe welds that can be rotated, it may be economical to make the welds using pipe rollers. Weld the top

quarter, then manually rotating the pipe & completing the weld in quarters. Other ways the weld joint can be manually positioned are by

Freehand Technique: This technique should be used only when no other technique is feasible. Very few welders create quality welds

without technique to stabilize the torch. Uncontrolled torch motion can lead to tungsten contact with work or filler. Ensure only the best

welders make joints in difficult field locations where freehand technique is used. Also increase surveillance and NDE as needed.

(4) WORK PIECE MANIPULATION

middle finger & should extend about 1 in. [25 mm] beyond the end of the finger. A Fingerstall stabilizes the hand holding the torch as it is slid

along during welding and provides added insulation and protection for the welder.

Brace Technique: Used in manual welding of vessels, very large pipe diameters and structures. In this technique, the welder stabilizes

the torch by resting his wrist, arm or elbow as far away from the weld zone as possible & sliding the wrist in the direction of welding.

right edge of the gas nozzle/cup is in constant contact with the members giving the cup a walking motion on the weld joint. One limitation of

this technique is that it is very difficult* to walk-the-cup when welding pipe less than 2 in. [50 mm] in diameter*.

Dragging the Finger: A technique used in manual welding of all types of joint configurations. It can be used when welding all diameters

of pipe & tubing. A fingerstall is made by overlapping a “sleeve” of fiberglass mat’l approx 8 in. [200 mm] long. Fingerstall is placed over the

(3) TORCH MANIPULATION (TECHNIQUE & APPLICATION): Notes for inspector awareness are identified with an asterisk *

Walking the Cup*: A technique for manipulating the torch when manually welding groove & fillet welds. With this technique, the electrode

extension is adjusted* to allow the proper arc length* while the edge of the cup* rests on the side of the joint. The torch is manipulated in a

manner to swing the tip of the tungsten back & forth across the side of the joint by “walking-the-cup” on each edge of the joint. The left or

Page 22 of 24



11-Dec-13 WELD-


dams “stay put”. Dams using rice paper often allow a high rate of gas escape & require multiple layers “glued” together to maintain purge.

B) Before decreasing purge gas pressure and closing the weld joint, a “visual inspection window” shall be left open for Inspection to

verify acceptable root pass condition. This is an extremely quick inspection with a mini-light that determines any root oxidation.

Inspector specifies a 25 mm visual "window" & identifies visible oxide tint. Pass/Fail.COMMENTARY: Currently, tape is being used in many instances on large bore pipe to hold these dams in place ... This is the only way the

following stringent conditions for their application shall apply:



the joint to prevent their failure during the welding process, usually 150-300 mm.

PURGE DAM DETAILSPurge Dams shall follow the detailed practices of AWS D10.11, Recommended Practices for Root Pass Welding. Due to a common problem

of leakage with proprietary dissolvable water-soluble dams, these shall be avoided whenever possible. If purge dams are to be used but

cannot be retrieved after welding, then proprietary dissolvable (water soluble paper such as rice paper, etc) dams shall be used and the

If no such procedure exists: See Disposition Below

Disposition of Oxidized Root Pass & Welds“Welds with internal oxidation, based on visual appearance of oxide tint as Inspected, shall be repaired or treated by CSD approved method

Treat or Passivate using an approved method such ASTM A380 practice or other CSD approved method.

5. 250 ppm O2 = Almost Black oxide tint ... Unacceptable

6. 500 ppm O2 = (0.05%) = Black or “sugared” ... Unacceptable ... Likely will be a "Cut out" or weld metal repair

Comment: Discoloration (oxide tint) is dark at 200 parts per million or ppm O2, with a discernible tint at 60-70 ppm .

Welding procedure shall cover “additional testing” or disposition of those welds found with “oxide tint” or discoloration.

1. 12 ppm O2 = No oxide tint ... ACCEPTABLE

2. 60-70 ppm O2 = Slight oxide tint visible ... Unacceptable

3. 70-90 ppm O2 = Slightly more visible oxide tint ... Unacceptable

4. 200 ppm O2 = Dark oxide tint ... Unacceptable

to and during welding, as measured with an O2 analyzer with low-level read-out capability. The actual oxygen levels achieved in

production shall be measured periodically (i.e., at the start of production work for each welder, and thereafter, on a random basis for the

number of joints to be performed). Analyzers shall be used for all joints if excessive internal oxidation is observed on any joints based on

the visual appearance of the oxide tint. Use the AWS C5.5 Figure 40 Oxidation Table for guidance, comparison & reporting.

GTAW PURGING PRACTICESAcceptance Criteria (Oxidation)

The purge shall achieve actual oxygen levels inside or exiting the joint (via the vent) never greater than 50 ppm O2 (maximum 0.005%) prior

Page 23 of 24

during qualification and before

any production work to assure

sound welds within H.I. Limits

Aramco authorized inspector

has accepted initial results.

5. Highly recommended is the

practice & testing of welders

they establish their ability to

meet WPS Heat Input Values.

4. Testing may be reduced to a

random check once the Saudi

are also taken in the same two


3. 100% checks of Heat Input is

required for all welders until

In-Process Welding Inspection

voltage & amperage when the

welder is welding in those two


2. Travel speed measurements

TAKE H.I. MEASUREMENTS (Use the 10 degree - 90 degree rule)Measurements in either 90 degree quadrant is used to validate H.I. Results (Pass/Fail)

Notes for H.I. Measurements

1. Take measurements for the

QR NUMBER

2. Welding Machines are calibrated per SAIC-W-2011 Checklist. SA Witness Point.

3. Have a Test Form to list values against welds made. Determine Acceptable Limits before Testing

4. Take valid readings. (10 Degree, 90 Degree Rule). Travel speed (& SMAW bead width) is critical.

5. Procedure shall have a disposition for retraining & disposition for unacceptable results.


USE SATR-W-20111. Use a calibrated Volt/amp meter. Check readings adjacent to source & Work (without disturbing welder)



SAUDI ARAMCO INSPECTION CHECKLISTSAIC NUMBER DATE APPROVED

Page 24 of 24



Post-Welding Visual Inspection (Plant Piping) SAIC-W-2007 12/11/2013 WELD-PROJECT TITLE CONTRACT NUMBER CONTRACTOR






S-PM-G000-1520-

0011,

Para. 13.5

A General Requirements

A1All slag, flux and spatter is removed from the completed weld and

surrounding area.

S-PM-G000-1520-

0011,

Para. 11.3.2

A3Temporary attachments have been cut off no closer than 3mm to the base

metal, then ground flush.

S-PM-G000-1520-

0011,

Para. 13.6

A2All arc strikes, gouges & other surface imperfections are removed by

grinding.

A4Grinding does not reduce the base metal thickness to less than the

design thickness. Inspectors know their specs & mill tolerances.

S-PM-G000-1520-

0011,

Para. 13.7

S-PM-G000-1520-

0011,

Para. 18.1

A5

Where temporary welds were removed, base metal repairs made, or arc

strikes repaired by grinding, examination by MT or LT has been carried

out.

S-PM-G000-1520-

0011,

Para. 13.8

A8

Surface irregularities, including weld reinforcement, which inhibit accurate

interpretation of specified method of NDT (including VT) are ground

smooth.

S-PM-G000-1520-

0011,

Para. 19.1.7

A6

Weld numbering & welder symbols are placed in a location so that they

will remain visible for a time suitable to the authorized COMPANY

inspector. (Thru successful pressure test until coating).

A9Inspection of all welds includes a band of base metal at least 25mm wide

on each side of the weld. (Includes 100% HAZ as needed)

S-PM-G000-1520-

0011,

Para. 19.1.8

As referenced

A10

Visual defects found in completed welds & at least 25mm wide on each

side of the weld are within the allowable weld imperfections listed in

ASME B31.3, Table 341.3.2. See Attachment 1.

S-PM-G000-1520-

0011,

Para. 19.1.7 &

19.1.8

A12

All weld to be FBE coated either Internal or External shall be ground

smooth and free from burrs, weld spatter,sharp edges. Weld toes shall be

merged smoothly and rounded with no sharp undercuts. The weld cap or

internal root protrusion shall not be more than 1.5 mm.

SAES-H-201

Para.7.2.2

A11

SOCKET WELDS & SEAL WELDED THREADED JOINTS MEET THE

REQUIREMENTS OF SAIC-L-2015 & SAIC-W-2037.

COMPANY Requirements for these welds supercede ASME code.

B

ASME B31.3 Code Table 341.3.2 Use (Visual & NDE Acceptance Criteria) ... See Attachment 1 Acceptance Criteria for Welds and

Examination Methods for Evaluating Weld Imperfections & Fig. 341.3.2 Typical Weld Imperfections

NOTE: FBE COATED LINES MUST RECEIVE FINAL INTERNAL VISUAL INSPECTION OF ROOT PASS

B1

Visually inspect finished welds (including root profile) to confirm the height

& width of reinforcement, technique of cap (multi-pass or weave), comply

with WPS. {ASME B31.3, Para. 341.4.1, (a) (1)}, See Attachment-I for

correct profile & acceptance limits

S-PM-G000-1520-

0011,

Para. 19.5.1.1

B2

Where accessible, welds shall be visually examined from

the root side to ensure that proper penetration and fusion

have been achieved.

S-PM-G000-1520-

0011, Para.

19.5.1.2

REFERENCE

B3

Zero Cracks are accepted (Refer ASME B31.3, Para. 341.4.2 ) & any

repair of cracks that are fabrication related shall require the approval of

Saudi Aramco assigned inspector.

S-PM-G000-1520-

0011, Para. 20.2

ITEM


Page 1 of 12



Post-Welding Visual Inspection (Plant Piping) SAIC-W-2007 11-Dec-13 WELD-PROJECT TITLE CONTRACT NUMBER CONTRACTOR

B4LOP & LOF shall be carefully examined against acceptance limit by visual

examination (refer ASME B31.3, Para. 341.4.2 )

S-PM-G000-1520-

0011,

Para. 19.5.1.1

C Welding of special corrosion-resistant piping Materials

C1

Back purging for stainless steels and nickel alloys has reduced O2 levels

to prevent root pass oxidation/tint. See SAIC-W-2006.

Where accessible, Visual inspection verifies this quality.

Note: Observance of any oxide tint shall be evaluated & properly

dispositioned per SAIC-W-2006 measures .

S-PM-G000-1520-

0011,

Para. 11.13.5

Weld of corrosion-resistant material shall have weld surfaces and heat

affected zones free of dark colored and heavy 'sugary' oxidization,

pinholes, cracks, crevices, undercut, lack of penetration and incomplete

fusion

SAES-W-016,

Para. 6.9.1

C3

If the root ID surface can be visually inspected, the stop/starts shall be

examined. No crater defects, such as cracks, "suck-back," or

shrinkage,are permitted.

SAES-W-016,

Para. 6.9.1

C2

D HEAT INPUT RECORDS (EACH WELD)

D1

Heat input (HI) of each production weld is calculated (using formula

below) if notch-toughness tests are specified, and then confirmed not to

exceed the heat input limits listed in the WPS's.

HI (kj/cm) = Volt X Amp X 60/Travel Speed (cm/min)

S-PM-G000-1520-

0011,

Para. 21.3

Attachment 3 - Structural Steel In-Process Welding Requirements & Repairs (AWS D1.1)




4. American Welding Society (AWS) D1.1 Structural Steel Welding Code (Applicable Edition)

D2

Welds failing Heat Input Requirements (outside acceptable ranges) are

dispositioned (repairs/welder retraining/etc) per an approved procedure

(Welding Process Control Procedure Element).

S-PM-G000-1520-

0011,

Para. 21.3

5. American Welding Society (AWS) C5.5 Recommended Practices for Gas Tungsten Arc Welding (2003 Edition)

6. ASME B31.3, Process Piping, (2008)


Work Verified


Proponent and OthersT&I Witnessed QC Record Reviewed Work Verified

Contractor QC Inspector COMPANY InspectorPerformed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed




ITEM






Initials and Date:

Contractor QC Supervisor

Page 2 of 12



Post-Welding Visual Inspection (Plant Piping) SAIC-W-2007 11-Dec-13 WELD-

Attachment 1 - Process Piping Welding Acceptance Criteria

ASME B31.3 EQUAL LEG FILLET WELD (Fig 328.5.2A) - Acceptable Fillet Weld Shape & Contour

Note: Leg Size shall be determined by Fillet Gage* (Properly Used Depending upon the weld contour)

Page 3 of 12


Page 4 of 12


Page 5 of 12

Note 3: Internal root reinforcement is directly proportional to root gap opening on fit-up.

Rule # 1: Never allow fit-ups to exceed 2.5mm root openings (GTAW process)

Reason: Larger gaps result in greater penetration unacceptable per COMPANY specs.

Rule # 2: GMAW/STT process is highly dependent upon consistent, even fit-ups with gaps

kept to about 1.5 mm. Bigger gaps are not advised and may result in rejected roots.

Rule # 3: Do not allow SMAW process! E60 (Cellulosic) and E70 Series low hydrogen

electrodes deposit spatter and require 100% access for POWER GRINDING.

Note 4: GTAW Process is mandatory for all lines that will be less than 24" in diameter.

Reason: Internal access to remove spatter (GMAW/STT Process) is impossible as a general

rule. This diameter limitation (24") is determined by the ability to SAFELY go inside piping

spools and manually clean / inspect welds.

Attachment 1 - Process Piping Welding Acceptance Criteria (FBE COATED LINES)

Note 5: When liquid coating systems will be employed, internal pressure blasting at 90 psi or

greater will remove any GMAW/STT spatter … for any piping diameter.

Note 2: Excess internal & external reinforcement for FBE Coated Lines shall be Welding

Inspector's TOP PRIORITY at start of WORK. Welders must be able to deposit maximum root

/ cap of 2.5mm or less. Excess root or cap reinforcement is unacceptable. Utilize the "window

technique" and maintain an Inspection "Hold Point" on initial production, until the welder's

ability to deposit small consistent root passes is "unquestionable".

Note 1: Root pass Conditions "c", "d", "e", & "f" (Refer to ASME B31.3 sketch above) is not

acceptable when evaluating internal weld root pass profiles for FBE Coated Lines. Porosity /

spatter / sharp edged discontinuities are considered unacceptable defects that require repair

or grinding per Company SAES-H-201 Specification, Para. 7.2.2

Warning: SMAW & GMAW/STT process produce spatter that sticks to internal surfaces and

these processes must be limited to welds where internal grinding / cleaning is accessible.

Spatter & other sharp imperfections must be ground smooth. Welders initial root passes on

FBE Lines are an Inspection HOLD POINT (Window Technique). Retrain or remove from

duties any welder who is unable to consistently meet root reinforcement requirements per

COMPANY specifications. Reject any irregular root pass profile ASAP.

Page 6 of 12





AWS D1.1 --- 5.24 Weld Profiles - All welds, except as otherwise allowed below, shall be free from cracks, overlap,

and the unacceptable profile discontinuities exhibited in Figure 5.4. FILLET SIZE SHALL BE MEASURED (GAGE).

5.24.1 Fillet Welds: The faces of fillet welds may be slightly convex, flat, or slightly concave as shown in Figure 5.4

Figure 5.4(C) shows UNACCEPTABLE FILLET WELD PROFILES. THESE ARE NEVER* ALLOWED AT SA.

* Inspectors accepting such welds are subject to retraining & rating of "Unsatisfactory Field Performance".

* INSPECTORS FINDING POOR WORKMANSHIP SHALL NOTIFY THEIR QA/QC MGR & THE SA INSPECTOR.

5.24.3 Convexity:. Except at outside welds in corner joints, the convexity C of a weld or individual surface bead

shall not exceed the values given in Figure 5.4.(1/16" to 3/16" per Table) --> FILLET SIZES SHALL BE SPECIFIED

IF FILLET SIZE IS UNKNOWN, INSPECTOR ENSURES ENGINEERING DIRECTION IS PROVIDED AS NEEDED.

5.14 Minimum Fillet Weld Sizes - The minimum fillet weld size, except for fillet welds used to reinforce groove

welds, shall be as shown in Table 5.8. The minimum fillet weld size shall apply in all cases, unless the design

drawings specify welds of a larger size. AGAIN, DESIGN DRAWINGS SHALL SPECIFY A FILLET SIZE!

CAUTION: MANDATORY HOLD POINT FOR DWG & SPECIFICATION CHECK FOR CORRECT FILLET SIZE

Page 7 of 12


AWS D1.1 - Section 6.9 (Visual Inspection)

All welds shall be visually inspected and shall be acceptable if the criteria of Table 6.1 are satisfied.

LOAD TYPE CONNECTIONS SHALL BE SPECIFIED (PROVIDE ADEQUATE EVALUATION CRITERIA)

Page 8 of 12


See Section 5.23 for applications other than Columns & Trusses (Beams)

5.24.4 Groove or Butt Welds: Groove welds shall be made with minimum face reinforcement unless otherwise

specified. In the case of butt and corner joints, face reinforcement shall not exceed 1/8 in. [3 mm] in height.

All welds shall have a gradual transition to the plane of base-metal surfaces with transition areas free from undercut

except as allowed by this code. Figure 5.4(D) shows typically acceptable groove weld profiles in butt joints.

Figure 5.4(E) shows typically unacceptable weld profiles for groove weld butt joints. *NEVER ALLOWED.

Butt Joint Misalignment (5.22.3)

5.23.8 - FLANGE WARPAGE & TILT (WELDING DISTORTION)

1% of total flg width or 1/4" (6mm) whichever is greater & "Exception"

OH, NO! THEY WELDED IT

& NOW IT LOOKS LIKE A GIANT BANANA** Splice welds and welding of gusset plates and other members shall require proper use of "strongbacks" and

other means to prevent distortion during welding. This is critical when welding will be concentrated in one

side or area of a member. WELD PASS SEQUENCE CANNOT BE OVERLOOKED IN THESE CASES.

Page 9 of 12





Joint preparation & cleanliness meets the detailed requirements of Section 5.15 below:

INSPECTION POINTS (VERIFY)

1. Observance of smoke with objectionable fumes may indicate welding is being done on fouled surfaces.

2. Joint Prep method, i.e., thermal cutting, gouging, and grinding results in a workmanlike profile & finish.

5.15.4.4 Gouge or Notch Limitation: Roughness exceeding these values & notches or gouges not more than 3/16

in. [5 mm] deep on other wise satisfactory surfaces shall be removed by machining or grinding. Notches or gouges

exceeding 3/16 in. [5 mm] deep may be repaired by grinding if the nominal cross-sectional area is not reduced by

more than 2%. Ground or machined surfaces shall be fared to the original surface with a slope not exceeding one in

ten. Cut surfaces & adjacent edges shall be left free of slag. In thermal-cut surfaces, occasional notches or gouges

may, with approval of the Engineer, be repaired by welding.

3. Any Mill Discontinuities are resolved per AWS D1.1, dispositioned & repaired as per Table 5.4 below.

POINT 1: Welding Joint preparation & cleanliness meets AWS D1.1 requirements ........... PASS or FAIL

Page 10 of 12


Welding Environment & Preheat is acceptable per requirements of Section 5.12 below:

INSPECTION POINTS TO WATCH

A quick look at this and you can see where the 8 Km / hour wind rule in SAES-W-011/012/etc comes from.

BIG POINT OF DIFFERENCE (OMISSION): NO MENTION IS MADE OF THE SMAW PROCESS.

SO ... WELDERS CAN WELD SMAW (AWS D1.1 APPLICATIONS ONLY) IN WINDS ABOVE 8 KM/Hr ... RIGHT?

ANSWER: AS LONG AS WELD QUALITY MEETS ATTACHMENT 2 FOR FILLET & GROOVE WELDS AND THE

WELDING PROCESS CONTROL PROCEDURE DOES NOT SPECIFY A MAXIMUM LIMIT FOR WIND SPEED.

REQUIREMENT: With SMAW, unshielded work shall not be subject to excessive* arc fluctuations.

* This varies from welder to welder depending on skill level in wind & how wide his butt is to keep wind off the work.

WINDBORNE DUST/SAND (ELEMENT OF HIGH WINDS) SHALL ALSO REQUIRE PROTECTIVE MEASURES.

5.6 Preheat and Interpass Temperatures

Base metal shall be preheated, if required, to temperature not less than minimum value listed on WPS (see 3.5 for

prequalified WPS limitations & Table 4.5 for qualified WPS essential variable limitations). For combinations of base

metals, the minimum preheat shall be based on the highest minimum preheat. This preheat and all subsequent

minimum interpass temperatures shall be maintained during the welding operation for a distance at least equal to the

thickness of thickest welded part but not less than 75 mm all directions from point of welding. Minimum interpass

temperature requirements shall considered equal to the preheat requirements, unless otherwise indicated on WPS.

PREHEAT & INTERPASS TEMPS SHALL BE CHECKED JUST PRIOR TO INITIATING ARC FOR EACH PASS.

THIS MEANS EACH WELDER KNOWS THE PREHEAT REQMTS & HAS THE CORRECT TEMP CRAYON (ETC)

POINT 2: Welding Environment & Preheat meets AWS D1.1 requirements ........... PASS or FAIL

Page 11 of 12


Welding Consumables (Section 5.3):

5.3.2 SMAW Electrodes. Electrodes for SMAW shall conform to the requirements of the latest edition of AWS A5.1,

Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding, or to the requirements of AWS A5.5,

Specification for Low-Alloy Steel Electrodes for Shielded Metal Arc Welding.

NO SIGNIFICANT CHANGES EXIST FOR CONSUMABLE CONTROL & CONSUMABLES USED FOR PIPING

Utilize the applicable checklists for Consumable Control & an approved Procedure detailing controls.

POINT 3: Welding Consumables & Controls followed an approved procedure ........... PASS or FAIL

Welding Execution (Procedure):Welding Activities shall follow an approved or pre-approved WPS that has been submitted to SA PID & approved

per the requirements of SAEP-352.

Where details of welding are unknown (unspecified), ENGINEER & QUALITY MANAGER shall make these KNOWN

This shall be done to provide adequate Field Instructions to Inspectors & Welders. Quality Mgr. Action.

NDT Specs (Section 6, Part C & See Repairs Below):SECTION 6 Part C Acceptance Criteria (Visual & NDT)

6.7 Scope - Acceptance criteria for visual and NDT inspection of tubular connections and statically and cyclically

loaded nontubular connections are described in Part C. The extent of examination & acceptance criteria shall

be specified in the contract documents on information furnished to the bidder. Quality Mgr. Action!

Allowable Repairs (Summary)

Page 12 of 12




Review Procedure - Weld ID & Traceability, Process Control

Tracking (S-PM-G000-1520-0006 Database)SAIC-W-2008 11-Dec-13 WELD-

EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID.


PLANT NO.

ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT


TRAVEL TIME

SCHEDULED INSPECTION DATE & TIME


RE-INSP DATEITEM

No.

A2

SAEP-1160 Database EXCEPTION:

For limited scopes with fewer than 500 groove/butt welds:

Contractor may elect to use a hardcopy tracking system with the approval

of COMPANY. Reporting for these projects shall use applicable SATRs

such as:

A) Weekly Welder Repair Rate Report (SATR-W-2013).

B) Weekly Welder Repair Assessment & Tracer Welds Report (SATR-W-

2018).

C) Weekly & Cumulative Weld Status Report (SATR-W-2019).

D) Weld Summary Report (SATR-W-2008) to document special process

control on a per weld basis through Pressure Testing

S-PM-G000-1520-

0006,

Section 8.1

A General Requirements (S-PM-G000-1520-0006 Database) ... Applies to Plant Piping. Pipelines, Tanks & Vessels

A1

Procedure Scope:

Production Welding, Welder Performance, Reporting, NDE Tracking,

Pressure Test Verification (Process Completion):

A) Contractor Data Mgmt & Tracking System (SAEP-1160 Database)

must be approved by COMPANY prior to start of work on Projects

Exception: S-PM-G000-1520-0006 Database Reqmt (See Item A2

below)

S-PM-G000-1520-

0006,

Section 8.1

A3

Procedure Purpose (Goals):

Establishes requirements & responsibilities for tracking & reporting

production welds, welder performance, NDE and other special processes

and pressure testing of completed systems associated with In-Kingdom

construction activities at COMPANY facilities.

S-PM-G000-1520-

0006,

Section 1

A4

S-PM-G000-1520-0006 Database Data Availability:

Data tracking system(s) shall be maintained, kept current & available for

COMPANY review at all times. Data shall be available on daily basis for

both current & cumulative data. Data shall be retrievable by date for any

given day from commencement of the work through project completion. At

the end of the project the archived records shall be submitted in

accordance with contract requirements.

S-PM-G000-1520-

0006,

Section 8

A6

S-PM-G000-1520-0006 Database Data Availability S-PM-G000-1520-

0006 Sect. 8.3):

Welding Production Output for cumulative weld data and welder data

required by this document is to be reported weekly in the weld tracking &

welder performance report. Shop and field weld and welder data may be

included on the same report.

Refer to Att. 1 (Section 8.3) for Data & Reporting Details.

S-PM-G000-1520-

0006,

Section 8.3*

A5

S-PM-G000-1520-0006 Database Data Reporting (S-PM-G000-1520-

0006, Section 8):

Contractor shall track welding activities on a daily basis and submit to

COMPANY each week a weld tracking & welder performance report for

that week's work. Cut-off date for submitting weekly performance report

shall be agreed to by Contractor & COMPANY PQM.

Refer to Att. 1 (Section 8) for Details.

S-PM-G000-1520-

0006,

Section 8

ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A

Page 1 of 9


11-Dec-13 WELD-




Tracking (S-PM-G000-1520-0006 Database)SAIC-W-2008

B Detailed Requirements (S-PM-G000-1520-0006 Database) ... Quality Manager Checklist

B1

S-PM-G000-1520-0006 Database Minimum Data Requirements:

The following* minimum data items associated with full penetration

groove and butt welds and associated special processes for pressure

piping or field-erected pressure vessels and API storage tanks are

required to be collected, linked, and maintained for each weld to the

extent it is applicable. The acceptance or rejection of groove and butt

weld special processes shall be indicated as applicable. When UT is

used in lieu of RT the tracking and reporting requirements shall remain

the same. Contractor shall record and track production, inspection &

testing of socket and fillet welds in a separate database and submit to

Saudi Aramco on a weekly basis.

Attachment 1 lists Section 8 in it's entirety.

S-PM-G000-1520-0006 Database Key Elements are listed below

S-PM-G000-1520-

0006,

Section 8

B3 Weld Fit-up Inspection ... Attachment 1

S-PM-G000-1520-

0006,

Section 8

B2 Weld Identification – Basic Information ... Attachment 1

S-PM-G000-1520-

0006,

Section 8

S-PM-G000-1520-

0006,

Section 8

B5 Completed Weld Visual Inspection ... Attachment 1

S-PM-G000-1520-

0006,

Section 8

B4 In-Process Weld Inspection ... Attachment 1

B7 Weld Selection for HT ... Attachment 1 (SAIC-W-2012)

S-PM-G000-1520-

0006,

Section 8.1

B6

Weld Selection for NDT ... Attachment 1

A) Sequence of Process & NDT is critical. (NDT of PWHT welds for P-

Nos 3, 4 & 5 materials prior to PWHT should be considered for

information only & not final acceptance. The intent is to evaluate the weld

quality prior to PWHT so any unacceptable discontinuities can

be repaired prior to PWHT.

B) NDT Process Control Procedure is used (SAIC-NDT-2010 Series)

C) Design Information & Code Criteria ... Ex: Severe Cycle Service

S-PM-G000-1520-

0006,

Section 8.1

S-PM-G000-1520-

0006,

Section 8.1

B9

NDT Control and Identification ... Attachment 1

This number, once assigned to a weld, shall remain with weld until final

acceptance. Repeated NDT on a weld shall be indicated by adding or

modifying the NDT Report Number suffix similar to that used for weld

repair as stated below.

This is further detailed in NDT Process Control Procedure.

S-PM-G000-1520-

0006,

Section 8

B8 NDT Required ... Attachment 1

B10

Selection of Tracer Welds ... Attachment 1

A) Two tracer welds must be selected for each rejected weld in a 10% RT

system. The two welds must have been welded by the same welder using

the same welding process and use the NDT method as the initial weld for

evaluation.

B) Progressive sampling of welds (tracer welds) shall follow the

progressive sampling method as stated in governing SAES. Tracer welds

are not to be counted in the 10% sampling process.

S-PM-G000-1520-

0006,

Section 8

REFERENCEACCEPTANCE CRITERIAITEM

No.PASS FAIL N/A RE-INSP DATE

Page 2 of 9


11-Dec-13 WELD-







B11

Results of RT Film Evaluation by Saudi Aramco

A) Welds rejected for weld quality requiring repair have their original

weld id numbers modified by suffix & progression

(R1, R2, T1, T2, T1R1, T1R2, T2R1, T2R2, etc)

B) Welds rejected for film quality (error exists in S-PM-G000-1520-

0006) require reshoot as follows:

W-01 (Reshoot) using lead letter ID

See also SAIC-RT-2010 Checklist

S-PM-G000-1520-

0006,

Section 8

S-PM-G000-1520-

0006,

Section 8.1

B13

Retests for HT

A) If any reading exceeds the specified limit by no more than 10 BHN,

then a minimum of three (3) additional indentations shall be made near

the original high reading B)

Indicate acceptance or rejection of the required 3 additional HT test on

the same weld. If all three (3) retests are below specified limits, then the

joint is acceptable. If any of the retest readings are found to exceed the

specified limits, then the weld shall be

considered unacceptable.

C) If any welds are found to be unacceptable, then two additional welds

from the same lot shall be tested. If more than one weld in a lot is found

to be unacceptable, then all welds in that lot are tested.

S-PM-G000-1520-

0006,

Section 8

B12

Evaluation of other completed Special Processes

A) PMI Required ... Attachment 1

B) PWHT Required ... Attachment 1

C) Hardness Testing (HT) ... Attachment 1

C PHYSICAL MARKING OF WELD ID NUMBERS BY SYSTEM (SEE ATTACHMENT 1, S-PM-G000-1520-0006, SECTION 8.2)

C1

Weld Identification Numbering System - The following weld

identification numbering system shall be used to identify and track piping

groove & butt welds as a minimum. Weld numbering shall be consecutive

in the direction of flow per line. Each weld shall be identified by joint

number, line number, and spool number.

S-PM-G000-1520-

0006,

Section 8.2

C3Welds fabricated in field shall be prefixed with letter "F"

Welds fabricated in approved weld shops with letter "S"

S-PM-G000-1520-

0006,

Section 8.2

C2

In addition to the spool number & line number identification, each weld (W-

01) shall be identified as per Attachment 1, Section 6.2.

Suffixes shall be R1, R2, T1, T2, & RW (RW for "cut out" joint)

Note 1: Tracers can have repairs (W-01T1R1, R2)

Note 2: Cut out joints can have repairs (W-01RWR1, R2)

S-PM-G000-1520-

0006,

Section 8.2.1

S-PM-G000-1520-

0006,

Section 8.2

C5

Contractors/fabricators may propose alternative numbering systems for

approval by COMPANY. The identification system shall be used to

identify all examinations, surveys, inspections, etc.

S-PM-G000-1520-

0006,

Section 8.2.2

C4

Weld numbering id system for pressure vessels, tanks,and other pressure-

retaining non-pipe welds shall be approved by the Insp Dept

Representative prior to the start of work.

D WELD MODIFICATIONS AFTER FINAL ACCEPTANCE SEE SAIC-W-2036, SAIC-W-2013 & SAIC-W-2015)

C6

All weld joints shall be marked for identification by weld number & welder

symbol. Identifications shall be made with a suitable weather-proof

marking material. Markings shall be placed in a location so they will be

easily observed & remain visible for a time suitable* to authorized SA

inspector.

* Until Coating system has been approved to cover up completed /

accepted* (Visual, NDT, Tested, etc) welds.

Note 1: Markings shall be compatible with subsequent coating or heat-

shrink sleeve applications.

Note 2: Markers shall be low chloride type for SS.

S-PM-G000-1520-

0011,

Section 18.

S-PM-G000-1520-

0010, Section 16,

SAES-W-012,

Section 15,

SAES-W-017,

Section 15,

Page 3 of 9


11-Dec-13 WELD-







D1

Engineering Change Notice Procedure* covers such work.

SAIC-W-2036 is followed relative to Rework/Repairs

SAIC-W-2013 is followed relative to Repairs.

ID, Numbering, NDE & Special Processes are controlled.

Page 4 of 9


11-Dec-13 WELD-







REMARKS:

4. SAES-W-012, Welding Requirements for Pipelines (31 December 2002)

5. SAES-W-017, Welding Requirements for API Tanks (7 December 2005)


ATTACHMENTS: Attachment 1 - S-PM-G000-1520-0006 DATABASE, PROCESS CONTROL TRACKING (By Weld)

REFERENCE DOCUMENTS: 1. S-PM-G000-1520-0006, SPECIFICATION FOR WELDING PROCEDURE APPROVAL AND WELD STATUS WITH

NDT TRACKING

2. S-PM-G000-1520-0010, Welding Requirements for Pressure Vessels





Work Verified

Work Verified






T&I Witnessed QC Record Reviewed



Initials and Date:



Page 5 of 9

WELD-





Tracking (S-PM-G000-1520-0006 Database)SAIC-W-2008 11-Dec-13

Page 6 of 9

Page 7 of 9

Page 8 of 9

Page 9 of 9

ITEM


A8

Procedure contains applicable elements (Notes, etc) S-PM-G000-1520-

0011/SAES-W-011, Conditioning, Storage & Exposure of SMAW Electrode

as per Manufacture recommendation & SAW Consumables.

See Attachment 2. Copy & paste in procedure as applicable.

S-PM-G000-1520-

0011 Para

8.2 &

SAES-W-011,

Para. 6.2

A7

GTAW filler metals (*including those cut or partially used) have either

the AWS/ASME identification or manufacturer's unique ID code marked on

each individual rod, by manufacturer, with flags, stencils or stamps. *This

has been a big problem on large projects

SAES-W-016

Para 3 & S-PM-

G000-1520-0011

Para. 8.3

A6

Quality Mgr. takes action on items in Attachment 1 for:

A) GTAW consumables & Proper Practices for the Field

B) Purging Consumables & Controls (as applicable to scope)

S-PM-G000-1520-

0011,

Section 8

A5

Procedure lists Instruments & Equipment that will be used for storing,

handling and conditioning of welding consumables. Humidity & temperature

control requires use of calibrated hygrometers, temp gauges, ovens and

cabinets for Dry Environment. Condition of

existing electrodes shall be evaluated per the detailed requirements of

Manufacture .

S-PM-G000-1520-

0011,

Para. 8.2

A4Electrodes, filler wires, and fluxes shall conform to ASME SEC IIC.

Other consumables may be used only with the approval of COMPANY

S-PM-G000-1520-

0011, Para.

8.1

Special Process

(Welding)

A3

Procedure contains these relevant QC Report Forms (Records) for

documenting & monitoring control of welding consumables:

A) SATR-W-2009 - Rod Oven Calibration (Storage, Bake, Portable)

B) SATR-W-2010 - Welding Consumable Issuance Record

C) SATR-W-2020 - Recv Insp Detail Form & QC log (Consumables)

Special Process

(Welding)

A2

Procedure has provided details on how welding consumables are controlled

by the following but not limited to:

A) Receipt & Storage requirements - prior to issuance

B) Material controller- Stock control (First in, First out) & issuance

C) Requestor/User - Receiving of consumables (Daily Basis)

D) Return of un-used consumables, ID system & reconditioning

E) Disposal Authorization (Rejected Consumables, etc)

SAIC-W-2010, SAIC-W-2009 & SAIC-W-2032 are utilized in

development & revision of Procedures

A General Requirements (Quality Manager Action as Indicated)

A1

Personnel involved in handling, storage, conditioning, issuance & controls

for use of welding consumables are identified with detailed responsibilities

& are trained in the procedure as follows:

A) Material Controller (Receipt, Control, Storage, Handling, Issue, etc)

B) Welding Foreman/Supervisor (Issue, Distribution, Control, Return)

C) QC Inspector (Monitors approved procedure and all activities)

D) Welders (Follows approved procedures and controls)

Note: Clearly detail all consumable control responsibilities, ensure

procedure is available & understood by all responsible for controls.

Special Process

(Welding)



TRAVEL TIME





Review Procedure - Control of Welding Consumables

(Storage, Handling, Issuance, Conditioning) - Plant PipingSAIC-W-2009


11-Dec-13 WELD-


Page 1 of 8



E4 Re-Conditioning: As per the Manufacture Recommendation.

S-PM-G000-1520-

0011,

Para. 8.2

S-PM-G000-1520-

0011,

Para. 8.2

E3 Exposure: As per the Manufacture Recommendation.

S-PM-G000-1520-

0011,

Para. 8.2

E2Storage: After drying, the electrodes shall be stored as per Manufacture

recommendation.

E Table 1 – Conditioning, Storage, and Exposure of Low Hydrogen Electrodes to A5.1 (Notes 1, 2, 3, 4):

E1Drying & Re-Drying: Prior to use all electrodes shall be dried & Re-

drying as per Manufacture recommendation.

S-PM-G000-1520-

0011,

Para. 8.2

D3

Maximum allowable SMAW electrode sizes that can be used are:

A) Low hydrogen: 5 mm = 1G/1F position; 4 mm = all other positions.

B) Non-low hydrogen electrodes: 5 mm = all positions.

Sizes larger than those listed are acceptable only if approved by

COMPANY and only if the PQR was performed using the electrode size

and positions to be used in production. The approval shall be obtained

through the welding procedure review process.

SAES-W-011

Para. 11.1

D2

F-Nos. 1 and F-Nos. 2 SMAW electrodes are prohibited on:

A) Mat'ls requiring impact* tests (Per Code or spec).

B) For Pressure-Retaining welds.

S-PM-G000-1520-

0011

Para. 8.6

D SMAW ELECTRODES

D1All consumables shall be stored and dried, per the requirements

Manufacture.

S-PM-G000-1520-

0011,

Para. 8.2

C SAW FLUX

C1

Submerged Arc Welding Fluxes

A) Active type Submerged Arc Welding fluxes shall not be used without

approval (obtained prior to welding procedure qualification)

B) Fabricator shall clearly identify the proposed use of active fluxes in

their welding procedure submissions.

C) Flux fused during welding is not reused (recrushed slag, etc)

D) SAW fluxes that the flux manufacturer recommends for single pass

welding shall not be used for multiple pass welding.

S-PM-G000-1520-

0011

Para. 8.5


(Storage, Handling, Issuance, Conditioning) Plant Piping

B SHIELDING GASES

B1

Shielding gases shall conform to the following requirements:

A) AWS A5.32 Specification for Welding Shielding Gases

1. Carbon dioxide (CO2): Federal Specification BC-C-101, Type B or

Compressed Gas Association CGA G-6.2, Type F.

2. Argon (Ar): Compressed Gas Association CGA G-11.1, Grade A.

3. Use of other gases and gas mixtures shall require COMPANY

approval.

B) The requirements for other gases and gas mixtures shall be submitted

to COMPANY for approval.

S-PM-G000-1520-

0011

Para. 8.7

QR NUMBER



SAIC-W-2009 12/11/2013 WELD-

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED

Page 2 of 8





QR NUMBER



SAIC-W-2009 12/11/2013 WELD-


G3

A detailed list of checkpoints are added to this checklist after approval of

the procedure for control of electrode issuance, receiving & return is

approved. Add best practices.

Sch Q, CPI

Clause

G2

Procedure contains SATR-W-2010 - Welding Consumable Issuance

Record or an approved equivalent. Take Note of Improvements:

A) List of all Consumables to be used on the Project. (Important)

B) Issue & Expiry Times (Critical) & Atmospheric Exposure Time

C) Batch/Lot/Heat Numbers (Critical)

D) QC Comments Area (Allows Surveillance)

E) GTAW & Tungsten (SEE ATTACHMENT 1)

F) Stub End Returns Daily (Stub Buckets) Stop Poor Practices*.

G) Color-Code & Segregation of 1-Time Reconditioned SMAW rods

Sch Q, Att. IV

Table

(WELDING)

G1

QA/QC Mgrs are tasked with CPI in the Critical Area of Consumable

Control. Please ensure that procedure contains BEST PRACTICES.

Several are identified below & in Attachments & SATR-W-2010

Sch Q, CPI

Clause

G Control of Electrode Issuance and Return ... See Note 2

F6

Filler metal or deposit chemistries conforming to A-number 2 (ASME

SEC IX), i.e., carbon-0.5% Mo, shall not be used for sour service

applications without PWHT unless specifically approved by COMPANY.

S-PM-G000-1520-

0011

Para. 8.4.5

F5

Procedure addresses Dissimilar Metal Welds (as defined):

A) Any weld joint (excluding weld overlays or strip lining) between

ferritic steel and either austenitic stainless steel, duplex stainless

steel, or nickel-based alloys, or

B) Use of SS or nickel-based filler metals on ferritic steels.

S-PM-G000-1520-

0011

Para. 8.4.2

F4

Root pass of single-sided groove welds without backing in P-No. 1 carbon

steels may be made with an Exx10 electrode.

Again, check electrode test values (rated values) closely.

S-PM-G000-1520-

0011

Para. 8.4.1

S-PM-G000-1520-

0011

Para. 8.4

See Note 1

F3

Low hydrogen* consumables, measured per AWS A4.3, are used.

*Verify consumables have less than or equal to 8 ml of hydrogen per 100

g of deposited weld metal, measured per AWS A4.3

S-PM-G000-1520-

0011

Para. 8.4.1

See Note 1

F2

Welding consumables which are being used outside of their rated tensile

or impact ranges listed in the manufacturing specs must be batch tested

or have COMPANY approval. Batch testing must be per the ASME SEC II

C SFA 5.01 to verify they meet base material reqmts.

Check SAIC-W-2010, Section B & Attachment 4

F SPECIAL CONSIDERATIONS FOR CONSUMABLES (APPLICATIONS) ... See Note 2 & also SAIC-W-2010

F1

Welding consumables shall be selected based on their mechanical

properties, compatibility with mat'ls to be joined, their suitability for the

intended service, consideration of polarity, position, & direction of

welding. (Extreme Caution for older electrode lot usage)

Again, this cannot be emphasized enough to QA/QC Mgrs.

S-PM-G000-1520-

0011

Para. 8.4

E5

After any exposure > permitted time period, the electrodes must be Re-

dried* as per Manufacture Recommendation. Wet or moist electrodes are

not used. Break/discard. System exists

to ID any Re-dried electrodes (Coat the ends). These

once re-dried electrodes may be reissued (once).

Redried electrodes returned unused are broken/discarded.

Inspectors know difference between reconditioned & redried

S-PM-G000-1520-

0011,

Para. 8.2

Page 3 of 8





QR NUMBER



SAIC-W-2009 12/11/2013 WELD-




Name, Initials and Date:Name, Initials and Date:


Name, Organization,

Initials and Date:


Work Verified






REFERENCE DOCUMENTS: 1. S-PM-G000-1520-0011, Welding Requirements for On-Plot Piping,

2. ASME SEC IIC Welding Rods, Electrodes and Filler Metals, (Latest Edition)


2) This checklist is to be used with SAIC-W-2010, SATR-W-2010, SATR-W-2020 & SAIC-W-2032 for PLANT PIPING

ATTACHMENTS:

Attachment 1 - Consumable Control Procedural Elements (Tungsten Electrodes & GTAW Filler Metal, Purging Consumables & Control)

Attachment 2 - SAES-W-011 - Conditioning, Storage & Exposure of Consumables (SAW Att. 2)

To those Quality Programs who already practice these points, this has not gone unnoticed by COMPANY. Your proactive practices in

the area of consumable control are saving you cost and rework over time by closely following your consumable manufacturer and those

Best Welding Industry Practices. Where a consumable is used but not mentioned in this checklist, it is the intention that Standard Industry

Practice (AWS C5.5 for GTAW, etc) cover those points necessary to maintain quality consumables and their control on the job.

NOTES: 1) It is the intention of this checklist & Attachments 1 & 2 to address widespread problems existing in Consumable control today on IK Projects. COMPANY states that SAES-W-011 cannot possibly contain all of the quality requirements necessary for Welding Consumable

Controls as it is not the intention of the Standard. COMPANY was consulted in preparation of this checklist & has reviewed its content. COMPANYrecommends that consumables be purchased in such quantities "as they are needed" for IK Projects. The practice of using older,

unused electrodes on projects is not prohibited, but shall be closely monitored with cautions taken for those points addressed

in Attachments 1 & 2.

REMARKS:

H1

PROCEDURE UTILIZES RESOURCES OF:

A) SAIC-W-2010 Receiving Insp of Welding Consumables

B) SATR-W-2020 Welding Consumable Receiving Insp Report

These resources are reviewed and used in the Procedure as they are

applicable to the workscope and this process. Be Prepared for

COMPANY Assessments that check records & details of consumables.

These documents may change the way you do Recv Inspection.

Sch Q, Att. IV

Table

(WELDING)

H CONSUMABLE CONTROL (RECEIVING INSPECTION & CONSUMABLE CERTIFICATION TEST REVIEW)

Page 4 of 8

CSD allows use of ER70S-2, 3 without requalification. *Reason: NACE RP0472 Table 2 restricts base material Composition as

follows: Carbon (C) 0.10 wt% max --- Manganese (Mn) 1.60 wt% max --- Silicon (Si) 1.00 wt% max ** Reason: Frequently,

Brinnell Hardness testing results are well above 200 BHN using this electrode (unfit for sour service) & PWHT is required.

Ensure ONLY water-soluble consumables (dams, tapes, glues) are used. Ensure Low-Chloride content below 50ppm

when consumables are used in Stainless systems. Data sheets shall be available and attest to material composition.

GTAW & GMAW Consumables for P-No. 1 Materials

GMAW Process shall utilize ER70S-2 & ER70S-3 Consumables. ER70S-6 is restricted* & not recommended** for use at SA.

Caution: Currently, tape is being used in many instances on large bore pipe to hold these dams in place. This is the only way the dams

stay in place. Dams using rice paper often allow a high rate of gas escape and require multiple layers “glued” together to maintain an

adequate purge. Many cone-shaped dams now used allow effective sealing and assurance that root pass oxidation will not occur.

C) When first using new materials, the effectiveness of the procedure & water soluble consumables shall be demonstrated. Mock-up!

the joint to prevent their failure during the welding process, usually 300 mm on either side of the weld. (Procedure Point)

B) Before decreasing purge gas pressure and closing the weld joint, a “visual inspection window” shall be left open for Inspection to verify

acceptable root pass condition exists without any evidence of visible oxide tint or discoloration (Inspector shall verify that the consumable

dam is intact prior to closure of root pass. Procedure Hold Point!

to be used but cannot be retrieved after welding, then proprietary dissolvable (water soluble paper such as rice paper, etc) dams shall be

used and the following stringent conditions below for their application (Procedure shall detail these and other similar steps):



Welder training assures that approved consumable id and storage procedures are followed in the field after issuance.

PURGING CONSUMABLES & CONTROLS (GTAW PRACTICES)

Purge Dams & Other Water-Soluble Consumables are listed in AWS D10.11, Recommended Practices for Root Pass Welding. Due to

a common problem of leakage with proprietary dissolvable water-soluble dams, these shall be avoided when possible. If purge dams are

B) Procedure assure cleanliness of filler material (no visible rust, discoloration, or atmospheric contamination such as dust or

residues. GTAW Filler metals shall be issued & stored in portable containers such as a capped PVC tubes (labelled with filler ID)

or other cost effective measures to assure minimum cleanliness and prevent atmospheric contamination.

Note: Similarly, issue Tungsten electrodes in small plastic bags or paper envelopes to assure cleanliness and prevent contamination.




filler wire matches the filler material specified on the welding procedure.

FILLER METAL ADDITION (For manual GTAW, only cut length Filler Wire is covered. Wire feed or autogenous welding is not allowed)

A) Filler Metal Addition: When retracting weld filler rod from the pool, care shall be exercised to ensure the hot end of the rod is not



or oxidized tungsten tips (breaking with wire cutters, breaking by hammer, or grinding off with silicon carbide wheel.

C) Early identification of welders using improper technique (retrain & monitor welders until they produce quality results).

D) Redressing of contaminated or oxidized tips is done at a specified location using proper tip geometry. (Procedure)

3. Filler metal contamination follows Filler Metal Addition Practices (In-Process GTAW Surveillance & Consumable Control)

desired weld shape, size, penetration for consistency (Results are cost savings in time, repairs, extended electrode life).

2. QC surveillance shall monitor GTAW practices and Tungsten consumable control as follows on SA Projects (procedure)

A) Issue properly prepared Tungsten electrodes (Incl Consumable Control Procedure). Issue per SATR-W-2010.

B) Prohibited are: 1) Unacceptable practice of field grinding tungsten. 2) The improper methods of removing contaminated

Quality Step (COMPANY approved, Required for shop approval): Procedure & surveillance ensures proper shop & field practices:

1. Properly prepare new tungsten with diamond type cutting equipment specifically designed for Tungsten (Piranha, etc)

Many available & inexpensive tungsten cutters/grinders utilize diamond technology to provide clean, contamination free,

separation & grinding finish that stops splintering/shattering of tips, cross contamination, & gives precise tip geometry &









Attachment 1 - Consumable Control (Procedural Elements)TUNGSTEN ELECTRODES & GTAW FILLER METAL CONSUMABLES



(Storage, Handling, Issuance, Conditioning) Plant PipingSAIC-W-2009 11-Dec-13 WELD-



Page 5 of 8

Attach. 2 - SAES-W-011 - Conditioning, Storage & Exposure of Consumables (SAW Att. 2)


(Storage, Handling, Issuance, Conditioning) Plant PipingSAIC-W-2009 12/11/2013 WELD-



Page 6 of 8

REFERENCEITEM


B3

Existing consumables were received & stored per S-PM-G000-1520-

0011, SMAW electrodes as per Manufacture recommendation, and for

other Consumables See Attachment 3.

S-PM-G000-1520-

0011 Para

8.2 / SAES-W-

011,Para. 6.2

B2

GTAW filler metal shall have either the AWS/ASME identification or

manufacturer's identification, marked on each individual rod by the

manufacturer with tags ("flags"), stencil, or stamping.

See GTAW consumable controls per Attachment 2.

S-PM-G000-1520-

0011, Para.

8.3

B2

Existing consumables are Reinspected, Test Reports reviewed &

checked per requirements of Attachment 4:

A) Segregate Electrodes by Quality (Test Reqmts) & Lot Number

Note: Electrodes with same designation can be unacceptable for given

applications if they do not meet minimum specified test reqmts.Reports

shall be carefully reviewed & checked against applications

B) Identify missing or unacceptable test report results before use.

C) Evaluate & test electrodes as necessary (COMPANY

recommends).Contact COMPANY regarding queries for supplemental

testing & use of electrodes outside given limits of ASME SEC II C &

Specs.

S-PM-G000-1520-

0011,

Para. 8.1

B

EXISTING* ELECTRODES & SHELF LIFE (THOSE NOT LOGGED INTO COMPANY SYSTEM BY USE OF NEW SATR-W-2020

FORM):Note: Best Practice for Welding Process Control Procedures is to specify purchasing new electrodes specifically for projects and given

applications (especially those with specific or supplemental test requirements). Electrodes with the same designation are not necessarily alike.

Test Reports shall be carefully reviewed to ensure that consumables are not used outside their intended purpose.

B1

Consumable Controls exist (Acceptable to COMPANY) Attachment 1:

A) Program has been set in place to account for electrodes on site &

establish an effective "First In, First Out" Rotation of Stock. Electrodes

unidentified /untraceable (ASME Sec II C) are removed

B) Electrode Shelf Life Questions are resolved and acceptable practices

are in place. Mfg letters & test records are maintained.

C) Electrode cans found opened and stored improperly have been

declared unfit for use & removed from site to prevent inadvertent use on

COMPANY Projects. Check E6010 storage closely.

D) DRY ENVIRONMENT FOR ELECTRODE STORAGE

S-PM-G000-1520-

0011,

Para. 8.1

A3

The relevant QC Report Forms (Records) for documenting & monitoring

control of received welding consumables:

A) SATR-W-2020 - Recv Insp Detail Form & QC log (Consumables)

All electrodes stored are logged & evaluated (acceptance).

Sch. Q,

Attachment IV,

Table 2.1

A2

Welding consumables are received & controlled per procedure:


B) Material controller- Stock control (First in, First out) & Issuance

Sch. Q,

Attachment IV,

Table 2.1

A GENERAL REQUIREMENTS (Procedure per SAIC-W-2009 is approved, Also Use Attachments 1, 2 & 3)

A1

Personnel in receiving inspection, handling, storage, conditioning,

issuance & controlled use of welding consumables are identified with

detailed responsibilities & trained in procedure use as follows:

A) Material Controller (Receipt, Control, Storage, Handling, Issue)

Note: Flow chart clearly details consumable control responsibility

(Available, posted, understood by all responsible for compliance)

Sch. Q,

Attachment IV,

Table 2.1






Receiving Inspection of Welding Consumables SAIC-W-2010 12/11/2013 WELD-PROJECT TITLE CONTRACT NUMBER CONTRACTOR



Page 1 of 15

REFERENCE

C17Non-Low Hydrogen Electrodes to A5.1 or A5.5 are received in a a dry

condition.

C16SAW flux recommended by manufacturer for single pass welding shall

not be used for multiple pass welding.

S-PM-G000-1520-

0011, Para.

8.5.3SAES-W-011,

Attach.-1

C13Opened SAW flux containers are stored continuously in ovens at 65°C

minimum or at mfg's recommendation, whichever is greater.

C15Flux fused during welding shall not be reused (i.e., fluxes that use

recrushed slag are not acceptable).

S-PM-G000-1520-

0011, Para.

8.5.2

C14 Active type SAW fluxes shall not be used without COMPANY approval.

S-PM-G000-1520-

0011, Para.

8.5.1

C12SAW fluxes are stored in sealed containers and kept in a dry

environment. (NOTE: Damp flux are discarded.)

SAES-W-011,

Attach.2

SAES-W-011,

Attach.2

C9

Maximum allowable SMAW electrode sizes that can be used are:

a) Low hydrogen: 5 mm = 1G/1F position; 4 mm = all other positions.

b) Non-low hydrogen electrodes: 5 mm = all positions.

C11Electrodes that have become moist or wet are not used, and are

discarded.

SAES-W-011,

Attach.2

C10

For SAW, GTAW, GMAW, and FCAW electrodes and wires:

All electrodes and wires are stored in sealed containers, kept in a dry

environment. Any wires that have visible rusting or contamination are not

used and are discarded.

SAES-W-011,

Attach.2

C8

SMAW ELECTRODE (LIMITATIONS):

A) F-Nos. 1 & 2 electrodes are not used on materials requiring impact

tests either by Code or job specification.

B) F-Nos. 1 & 2 electrodes are not used (pressure-retaining welds)

S-PM-G000-1520-

0011, Section

8.6

SAES-W-011,

Section 11.1

C5

Low Hydrogen SMAW electrodes are supplied in dried condition in

hermetically sealed metal cans with a positive* indication of seal integrity.

(*Corrosion, improper handling, damage can affect seals)

C7

Following product information (as a minimum) are legibly marked on

outside of each unit package. (ASME Sec IIC, SFA 5.1, Par. 24.1)

(1) AWS specification and classification designations

(2) Supplier’s name and trade designation

(3) Size and net weight

(4) Lot, control, or heat number

S-PM-G000-1520-

0011,

Para. 8.1

C6

SMAW electrodes: At least one imprint of the electrode designation

(classification plus any optional designators) are printed covering within 2-

1⁄2 in. (65 mm) of the grip end of the electrode.

(ASME Sec IIC, SFA's for SMAW Electrodes)

S-PM-G000-1520-

0011,

Para. 8.1

C4

GTAW filler metal shall have either the AWS/ASME identification or

manufacturer's identification, marked on each individual rod by the

manufacturer with tags ("flags"), stencil, or stamping.

Tungsten consumables (ASME SEC II C, SFA 5.12) are received,

controlled/issued.

S-PM-G000-1520-

0011, Para.

8.3

SAES-W-011,

Table 1

C1

Electrodes, filler wires, and fluxes shall conform to ASME SEC IIC.

Review Test Reports & Certificates & Log into SATR-W-2020

See Attachment 4 for Test Review & Receiving Insp Guidelines.

Electrode containers are affixed with the following identification:

a. AWS Specification* and,

b. Classification Designation

* Each AWS Specification shall meet procurement guidelines of ASME

Sec IIC, SFA 5.01 using COMPANY approved vendors.

C3

All consumables were received & stored per S-PM-G000-1520-0011,

SMAW electrodes as per Manufacture recommendation, and for other

Consumables See Attachment 3.

S-PM-G000-1520-

0011 Para

8.2/SAES-W-

011,Para. 6.2

C2

Other welding consumables not listed in ASME SEC IIC shall require

approval from COMPANY. (Check a COMPANY approved WPS for

permission)

S-PM-G000-1520-

0011,

Para. 8.1

C NEW MATERIALS, CONSUMABLE SPECS ARE NEEDED TO CHECK TEST REPORTS/CERTS)

RE-INSP DATEACCEPTANCE CRITERIA N/A

12/11/2013 WELD-

S-PM-G000-1520-

0011, Para.

8.1




ITEM

No.PASS FAIL

Receiving Inspection of Welding Consumables SAIC-W-2010

Page 2 of 15

REFERENCE RE-INSP DATEACCEPTANCE CRITERIA N/A

12/11/2013 WELD-




ITEM

No.PASS FAIL

Receiving Inspection of Welding Consumables SAIC-W-2010



Work / Rework May ProceedPerformed Inspection

T&I Witnessed


Name, Organization,









Attachment 1 - Consumable Control Practices Acceptable to Company

Attachment 2 - Consumable Control (Procedural Elements)

Attachment 3 - SAES-W-011 - Conditioning, Storage & Exposure of Consumables (SAW)


Attachment 4 - ASME SEC II C (SFA-5.01) FILLER METAL PROCUREMENT (RECEIVING INSPECTION) GUIDELINES

Attachment 5 - AWS A5.32 Specification for Welding Shielding Gases


1. SAES-W-011, Welding Requirements for On-Plot Piping, (30 march 2005)

2. ASME Sec II, Part C – Specifications for Welding Rods, Electrodes, and Filler Metals, (Latest Edition)

REMARKS:

Attachments:

C18

1. Carbon dioxide (CO2): Federal Specification BC-C-101, Type B or


2. Argon (Ar): Compressed Gas Association CGA G-11.1, Grade A.

3. Use of other gases and gas mixtures shall require COMPANY

approval.Inspector verifies affixed stickers, Legible Markings clearly ID all

products & existing bottles and valves are in good condition. Check test

certificate for purity, check dew point,moisture content, etc AWS A5.32

Consumable Classes are listed in Attachment 5.

S-PM-G000-1520-

0011, Para.

8.7


Page 3 of 15

C) Electrodes found open and stored outside acceptable Manufacturer & Welding Industry recommended ranges shall be declared unfit for use

and removed from site to prevent their inadvertent use on Saudi Aramco Projects. Check E6010 storage closely.

Dry Environment Note: Air conditioned or climate controlled storage in cabinets within recommended temp ranges and relative humidity values

(verified by hygrometer) shall be demonstrated. In any disagreement, Electrode Mfg recommendations shall be made available and COMPANY shall

resolve all conflicts. Unacceptable is storage of Electrodes in open buildings subject to wide humidity ranges.

Typically, relative humidity can range from 5% to 100% in Saudi Arabia in open areas without climate controls

Note: The Table above applies to AWS A5.1 & AWS A5.5 and is intended for reference only relative to the COMPANY requirement for a DRY

ENVIRONMENT. SAES-W-011 Attachments 1 & 2 shall be affixed to procedures and followed.

4. STORAGE & HOLDING TEMPS AFTER OPENING: 1. Per Lincoln, Electrode cans shall never be placed in ovens as cardboard liners char &

electrode temps are not uniform. COMPANY concurs with this point. 2. Per Lincoln, store non low hydrogen electrodes (6010, 7010, etc) from freshly

opened containers in heated cabinets at 100 to 120 degrees F (40 – 50 degrees C). AWS table above suggests 75 to 125 F.

SAES-W-011 states Dry Environment. COMPANY concurs that AWS & Lincoln temp ranges & a 50-70% relative humidity (typical air

conditioned room) constitute a "dry environment" acceptable for storage of opened non low hydrogen electrodes. COMPANY also concurs

that opened non low hydrogen electrodes (6010, 7010, etc) shall never be stored above 130F or below 50%RH

Best Practice is to operate a small oven (Bench, cabinet or Portable type) set at 100 F to maintain these conditions.

1. All Welding Consumables (electrodes*, filler wires, and fluxes) shall conform to ASME SEC IIC. (SAES-W-011, Para. 6.1) & shall meet an

applicable AWS specification & classification as packaged. Identification labelling shall clearly identify the product & Manufacturer certs (test reports)

shall attest to the correct AWS specification & classification. When "other" Non-ASME electrodes have been specified & are COMPANY approved

(through the WPS process), the same general controls shall apply. A Roster or Log shall be kept for each project(s) with documentation available for

Receiving (SATR-W-2020) and storage. Storage shall conform to the mfg detailed storage requirements as listed and available (attach to records with

Mfg Certs for all consumables). All welding consumables shall have manufacturer data sheets that show detailed storage requirements (temperature &

humidity limits at a minimum), or correspondence to provide adequate instruction in this regard. Shelf life shall be considered. Note: * Electrodes

shall include tungsten electrodes for GTAW process per AWS A5.12

Note: Welding Consumables shall have a SAP ID number to show their purchase from an approved vendor for specific consumable.

Best Practice for Vendor Uninspectable Welding Consumables is close receipt inspection & test report review, and by Inspection visit* to Vendor at

least once (COMPANY recommended). Currently, inspection visits are not required. Best Practice for electrodes* is their purchase specifically for

new projects in quantities based on Workscope using COMPANY-approved WPS as a basis for ordering consumables.

2. New consumables shall be received into Contractor's Quality system by recording pertinent information as listed on SATR-W-2020.

3. Existing consumables (shelf life) intended for use on Saudi Aramco Projects shall be evaluated for their quality and condition as follows & they

shall meet COMPANY, Welding Industry & Manufacturer recommended minimum quality requirements (with disposition) as follows: When meeting

applicable quality conditions, existing consumables shall be recorded into the Contractor's Quality System.

A) Electrodes without proper AWS Spec/Class labelling and/or traceability to manufacturer certs (records shall be kept for all consumables)

shall not be used on Saudi Aramco Projects and shall be removed from site to prevent their inadvertent use on Project work.

B) Electrodes older than 2* years shall not be used to make production welds on Saudi Aramco Projects. Electrodes shall be discarded or removed

from site to prevent their inadvertent use. Contractor shall assure electrode issue control follows a "First In, First Out" Rule.

*Note 1: Three (3) years shelf life is acceptable when demonstrated that mfg storage guidelines were met. (Temp/Humidity Controls)

*Note 2: When storage climate is questionable* (*Dry Environment = Air conditioned/dehumidified with calibrated hygrometer in use) electrodes

shall be limited to a shelf life of 2 years (max). See AWS Table for acceptable "storage before opening" limits.

*Note 3: Lincoln currently recommends a 3-year shelf life in certain brands of SMAW electrodes. When a manufacturer data sheet specifically states

detailed storage conditions (humidity & temperature) and a shelf life beyond three years, and storage requirements have been followed (as verified by

Quality), electrodes may be used for a period per manufacturer's instructions (to a three-year limit).

Receiving Inspection of Welding Consumables SAIC-W-2010 12/11/2013 WELD-

Attachment 1 - Consumable Control Practices Acceptable to Company



Page 4 of 15




















































TUNGSTEN ELECTRODES & GTAW FILLER METAL CONSUMABLES







Attachment 2 - Consumable Control (Procedural Elements)



Page 5 of 15





Page 6 of 15

FOLLOW STEPS 1, 2, 3 ABOVE ... First AWS Filler Metal Spec is Verified ... From the list Below

Receiving Inspection of Welding Consumables SAIC-W-2010 11-Dec-13 WELD-

ATT. 4 - ASME SEC II C (SFA-5.01) FILLER METAL PROCUREMENT (RECEIVING INSPECTION) GUIDELINES



Page 9 of 15

FOLLOW STEPS 1, 2, 3 ABOVE ... Next (Step 2) ... Lot Classification (Section 5, SFA-5.01)

Page 10 of 15

FOLLOW STEPS 1, 2, 3 ... (Step 3) ... Level of Testing Schedule (Sect 6 & Table 1, SFA-5.01)

Page 11 of 15

Page 12 of 15

Let us select ASME SFA 5.1 (Identical with AWS Specification A5.1/A5.1M:2004.)

Section 1 of will state the Scope & Spec - CS (SMAW)

Section 2 covers References (ASTM, etc)

Section 3 covers Classifications of Electrodes & Refers you to Tables (Example Below)

Section 4 is the Acceptance Clause ... Self-explanatory

Section 5 addresses Certifications ... This is one of the elements we seek.

2. Lot Classifications

3. Level of Testing Schedule

These elements have a direct impact on Consumable Quality. The old saying "You get what you pay for" truly

applies to consumables. When "defective" consumables are found, then the extent of the "lot" as related to the

lot classification becomes important. Knowing the elements & Testing required for Consumables is important.

Example Specification Review (Step 4)

STEP 4 - GUIDELINES FOR SPEC REVIEW

OK ... You now know about the required Procurement Elements per ASME II C

1. ASME II C / AWS Material Specifications

Page 13 of 15

5. Electrodes of the same designation ARE NOT THE SAME.

6. Electrodes of the same designation with same specified Tests (Certs verifed) may be used in same applications.

Section 6 addresses Rounding Off Procedure ... Values are rounded to the nearest 1,000 psi (tensiles), etc

Section 7 addresses TESTS, PROCEDURES & REQUIREMENTS ... As shown below

TEST REPORTS SHALL BE CAREFULLY REVIEWED FOR EACH LOT USED FOR A GIVEN

WELDING SPECIFICATION (WPS) TO ASSURE CONSUMABLES MEET THE MIN. REQUIRED

QUALITY (TEST CERTIFICATES ON FILE) & HAVE PASSED THE REQUIRED TESTING BASED

ON THE ASME SEC II C SPECIFICATION REQMTS (SFA 5.1, 5.5, etc)

CONTRACTORS WHO DO NOT FOLLOW CSD ADVICE IN THIS MATTER ARE RISKING GREAT REWORK!

TEST CERTS (REVIEW)

1. Check P.O. against Test Certificates & WPS applications. Were all of the required Tests performed?

2. Missing Certs or consumables without specified Testing are cause for "HOLD" placed on Electrodes.

3. Ensure any existing electrodes to be used meet the req'd Application on a "LOT" basis BEFORE issue.

4. Don't wait until an audit finds welds were made with substandard electrodes (missing req'd tests, etc).

STEP 4 - GUIDELINES FOR SPEC REVIEW

Section 5 addresses Certifications ... This is one of the elements we seek.

After reading Annex A4, the importance of the Consumable Manufacturer's Quality Program becomes clear. It also

becomes clear WHY bad lots of consumables can "pop up at any time". Saudi Aramco has an approved Welding

Consummable Manufacturer's List for this exact reason. Verify consumable is from a SA approved Mfg. (ID #)

CSD recommends early & timely additional tests (composition, weldability, quality) on mat'ls received.

Page 14 of 15

CGAG6.3 Carbon Dioxide Cvlinder Filling and Handling Procedures

CGA-P-9 The Inert Gases Argon, Nitrogen, and Helium

P- 1 Safety Handling of Compressed Gases in Containers

The following example designates the minimum labeling requirement to comply with this specification:

Table A l - Additional Information From Compressed Gas Association (CGA):-

CGA-G4 Oxygen

CGA-G5 Hydrogen

CGA-G6 Carbon Dioxide

Table 4 - AWS Classifications for Typical Gas Mixtures:

All cylinders and containers shall be marked in accordance with DOT regulations plus the following information, legibly

marked on, or attached to, each cylinder: i) AWS specification and classification designation (year of issue may be excluded).

ii) Supplier’s name and product trade designation (name of gas)

iii) Approved DOT warning label

C - Carbon Dioxide

He -Helium

H - Hydrogen

N - Nitrogen

O - Oxygen

Attachment 5 (AWS A5.32 Specification for Welding Shielding Gases)

Individual gas components are identified by the following codes:

A - Argon




Page 15 of 15



Validation of Welding Equipment (Plant Piping) SAIC-W-2011 12/11/2013 WELD-







NOTE

Welding power supplies shall be validated in accordance with BS EN

50504 or an approved equivalent if impact toughness test is reqd by the

applicable company or industry specifications or codes.

S-PM-G000-1520-

0011 , Para.

21.2

ITEM


A

Note : BS EN 50504:2008 ,This British Standard supersedes BS 7570:2000 which is withdrawn. It is technically identical to BS

7570:2000. General

Requirements

A1Welding equipment is validated by an 'expert', using equipment which has

calibration traceable to national standards.

S-PM-G000-1520-

0011 , Para.

21.2

A2Verification of 'expert' is by observation of performance + certifications +

resume, or by approval of the Company. Refer BS EN 50504 Para. 7.

S-PM-G000-1520-

0011 , Para.

21.2

S-PM-G000-1520-

0011 , Para.

21.2

A3Measuring instruments are in good condition. Refer.BS EN 50504

Para. 9.3 (a)

S-PM-G000-1520-

0011 , Para.

21.2

A5Measuring instruments are ≥ 2 x (preferably ≥ 5 x ) more accurate than

the accuracy required for the validation grade. Refer.BS EN 50504 Para.

9.3 (c)

S-PM-G000-1520-

0011 , Para.

21.2

A4

Measuring instruments are calibrated by a recognized calibrator with

standards traceable to a national standard.Refer BS EN 50504

Para. 9.3 (b)

A6

Ambient temperature is measured to ensure it is within the limits specified

for the power source, and the instrument rating been tested. Ambient

temperature is recorded.Refer BS EN 50504 Para. 9.5.1.1

S-PM-G000-1520-

0011 , Para.

21.2

A7

Input voltage is measured to ensure compliance with the specified value

for the power source. This measurement is recorded on the validation

certificate. Correct tappings have been connected within the power

source if relevant. Refer BS EN 50504 Para. 9.5.1.2

S-PM-G000-1520-

0011 , Para.

21.2

A8

For engine driven power sources, check rated load speed and no-load

speed to ensure that the power source meets the rated values Refer BS

EN 50504 Para. 9.5.1.3

S-PM-G000-1520-

0011 , Para.

21.2

A9

The resistive load across the output terminals of the power source, is

connected as far as practical. The instrumentation used for the validation

of the voltage across the resistive load & the transducer in the circuit, is

connected.Refer.BS EN 50504 Para. 9.5.1.4

S-PM-G000-1520-

0011 , Para.

21.2

A10

Power Source for each welding process are subjected to the following

loads, (BS 7570, Para. 9.4):

a. TIG - is loaded with a conventional load of drooping

characteristics{(U2 = (10 + 0,04 I2) V up to I2 = 600 A},

after which it remains constant at 34V.

b. SMAW- is loaded with a conventional load of Drooping

characteristic {U2 = (20 + 0,04 I2) V up to I2 = 600 A}, after

which U2 remains constant at 44 V.

c. MIG/MAG/FCAW/SAW - loaded with Flat characteristic

{U2 = (14 + 0,05 I2) V up to I2 = 600 A}, after which U2

remains constant at 44 V.

d. SAW - loaded with a conventional load U2 = (20 + 0,04 I2) V

up to I2 = 600 A, after which U2 remains constant at 44 V. Refer.BS

EN 50504 Para. 9.4

S-PM-G000-1520-

0011 , Para.

21.2

A11

The wire feed unit being validated, is connected to the source of power

supply normally used during welding.Refer BS EN 50504 Para.

9.5.1.5

S-PM-G000-1520-

0011 , Para.

21.2

PASS FAIL N/A RE-INSP DATEREFERENCE

Page 1 of 4




Validation of Welding Equipment (Plant Piping) SAIC-W-2011 11-Dec-13 WELD-

ITEM

No.

A12The wire feeder is assembled and adjusted according to the

manufacturer's instructions. Refer.BS EN 50504 Para. 9.5.1.6

S-PM-G000-1520-

0011 , Para.

21.2

S-PM-G000-1520-

0011 , Para.

21.2

A13

The wire feeder shall not be driven at speeds or loaded with filler wire

diameters, in excess of that shown on the rating plate. Refer.BS EN

50504.Para. 9.5.1.7

S-PM-G000-1520-

0011 , Para.

21.2

A15

The validation/calibration range of the control or meter fitted to the power

source, is selected from one of the following:

a) the full range of the control or meter;

b) a partial range of the control or meter;

c) selected points over the range of the control or meter.

Either b) or c) is agreed on BEFORE performing validation/calibration

Refer.BS EN 50504.Para. 9.5.1.9

S-PM-G000-1520-

0011 , Para.

21.2

A14

The current rating of validation welding cables used > 2 x maximum

current flowing in the welding circuits. NOTE: Exception is where the

welding system is being validated with specific welding cable, or circuit

assemble characteristics.Refer.BS EN 50504.Para. 9.5.1.9

A16

Measurements are taken at the minimum setting, the maximum setting,

and 3 other points nominally equally spaced between minimum and

maximum, over the full or partial range. Refer.BS EN 50504.Para.

9.5.1.10

S-PM-G000-1520-

0011 , Para.

21.2

S-PM-G000-1520-

0011 , Para.

21.2

B Validation (Calibration) Process ... Company is allowed to witness (Issue RFI)

B1The equipment is switched on 5 minutes before any calibration

requirements. Refer.BS EN 50504.Para. 9.5.2.1

S-PM-G000-1520-

0011 , Para.

21.2

B3

After a further 10 seconds a second reading is taken at the max. setting.

This procedure is repeated for each of the measurement points down to

the minimum,BS EN 50504 .Para. 9.5.2.3

S-PM-G000-1520-

0011 , Para.

21.2

B2

Validation starts at the minimum output setting. The power source output

is energized and stabilized for 10 seconds, and a reading is taken. The

procedure is repeated for each of the measurement points up to the

maximum, BS EN 50504 .Para. 9.5.2.2

B4The power source is loaded in excess of that shown on the rating plate,

BS EN 50504.Para. 9.5.2.4

S-PM-G000-1520-

0011 , Para.

21.2

S-PM-G000-1520-

0011 , Para.

21.2

B5

If validation at a particular current and or voltage is required, but the

nature of the load does not permit that current or voltage at the

corresponding load voltage or current to be achieved, points are taken

above and below the desired values, and the required value calculated,

BS EN 50504 .Para. 9.5.2.5

S-PM-G000-1520-

0011 , Para.

21.2

B7

If the power source has a slope control, the setting is noted. If it is

necessary to validate the power source at different settings of the slope

control, this is agreed prior to the validation.Refer.BS EN 50504. Para.

9.5.2.7

S-PM-G000-1520-

0011 , Para.

21.2

B6

At each validation point selected point, record on to SATR-W-2011:

a) Current and/or voltage control setting

b) Power source meter readings.

c) Two values of the true measurement of current and/or voltage from the

test instrumentation.

d) The mean value of the two measurements.

Results of measurements are systematically recorded and supplied

on, or with validation certificate. (SATR-W-2011). Refer BS EN 50504

.Para. 9.5.2.6

B8

A consistency test is carried out on controls which cannot be calibrated /

validated as they are not graduated in absolute units, or the original

validation is not applicable due to the way the equipment is being used,

e.g. under abnormal load conditions. Refer. BS EN 50504-Section 5

S-PM-G000-1520-

0011 , Para.

21.2

B9

On completion of a validation the results are compared with the Accuracy

set in Table 1 of BS 7570. See Attachment 1. Refer.BS EN 50504.Para.

9.5.2.8

S-PM-G000-1520-

0011 , Para.

21.2

PASS FAIL N/A RE-INSP DATEACCEPTANCE CRITERIA REFERENCE

Page 2 of 4




Validation of Welding Equipment (Plant Piping) SAIC-W-2011 11-Dec-13 WELD-

ITEM

No.PASS FAIL N/A RE-INSP DATEACCEPTANCE CRITERIA REFERENCE

B10

Equipment that meets the accuracy in Attachment 1 (Table 1) are

labeled with the following information:

A) "PASSED"

B) Date the label is valid (Date of Passed);

C) Date of expiry of the validation (6 mos per schedule Q)

D) Name of the authority issuing the label

E) Make, model and serial number of the equipment (Unique ID #) Refer.

BS EN 50504 .Para. 10.1.2

S-PM-G000-1520-

0011 , Para.

21.2

REMARKS:

ATTACHMENTS:

Attachment 1 - BS EN 50504-2008 Table 1 (Validation/Calibration Tolerances)

B11

For Equipment that does not meet accuracy recommended in

Attachment 1 (Table 1), label bearing the following information is

attached, OR, equipment is to be taken off project site:

a) "FAILED"

b) Date the label was issued;

c) Name of the authority issuing the label;

d) Make, model and serial number of the equipment.

All equipment in shops or in the field shall have a label . A tag for

rejected equipment with a reason for rejection is an acceptable

identifier (needs repair, etc). See SAIC-L-2031. Refer.BS EN 50504

.Para. 10.1.3

S-PM-G000-1520-

0011 , Para.

21.2


REFERENCE DOCUMENTS: Attachment 1 - BS EN 50504-2008 Table 1 (Validation/Calibration Tolerances)


2. BS EN 50504-2008, Code of practice for Validation of arc welding equipment

ATTACHMENT:

1. BS EN 50504-2008, Table 1 - Validation accuracies for standard grade power sources.



Saudi AramcoSubcontractor QC Inspector COMPANY PMT Representative

Performed Inspection Work / Rework May Proceed T&I Witnessed

Work Verified




Contractor QC Inspector COMPANY InspectorPerformed Inspection Work / Rework May Proceed



Name, Organization,

Initials and Date:

Contractor / Subcontractor

Contractor QC Supervisor Proponent and OthersT&I Witnessed QC Record Reviewed

Page 3 of 4



Validation of Welding Equipment (Plant Piping) SAIC-W-2011 12/11/2013 WELD-

Attachment 1 - BS EN 50504-2008- Table 1 (Validation/Calibration Tolerances)

Page 4 of 4

WELD-




Review Hardness Testing Procedure - All Applications

(Plant Piping, Pipelines, Vessels & Tanks)SAIC-W-2012 11-Dec-13



TRAVEL TIME



A

GENERAL PROCEDURE REQUIREMENTS (SPECIAL PROCESS CONTROL PROCEDURE PER CONTRACT SCH Q & S-PM-G000-1520-

0006) Note: Applies to Plant Piping (S-PM-G000-1520-0011, W-016), Pipelines (W-012), Vessels (S-PM-G000-1520-0010, W-014) Tanks (W-

017)

A1

Production Hardness Testing Info (Weld reporting/tracking) shall be

gathered, correlated, linked, reported, stored in an e-format (Excel,

Access, PDF or similar). Data Management & Tracking System

(Database) must be COMPANY approved prior to start of work.

S-PM-G000-1520-

0006,

Para. 8.1

A3

Procedure details criteria for weld identification & weld selection of those

welds to be Hardness Tested & responsibilities (per design):

A) HT Random Sampling reqmts for specific production welds.

B) HT of PWHT welds (both Service and thickness considerations)

Design information must reflect actual data and changes can occur

during evolution of the project.

S-PM-G000-1520-

0006,

Para. 8.1,

See also Sect. C

of this checklist

A2

Database for Welding (& Hardness Testing) covers two types of welds for

either pressure piping (Plant, Pipelines) or field-erected pressure vessels

and API storage tanks:

A) Full penetration groove & butt weld hardness tests are tracked

B) Socket & Fillet welds (Includes "other" weld or components specified

for Hardness Testing). These elements shall be tracked.

Note: Reporting follows applicable Welding Database reqmts

A4

Procedure addresses precautions & responsibilities to verify the physical

Identification of materials, parts & components, including partially

fabricated assemblies by approved use of tags, stamps, color coding,

stencils, labels or permanent marking. (Co-ordination)

Note: Welds & items for Hardness Test shall have a unique ID clearly

visible to hardness test personnel & QC documenting test results.

System shall prevent errors in testing & documentation.

Sch. Q,

Attachment IV,

Para. 3.2

& S-PM-G000-

1520-0006,

Para. 8.1

S-PM-G000-1520-

0006,

Para. 8.1

A5

Procedure references this Checklist, all applicable references contained

within this checklist, and is identified/traceable to current Project

Document Control Procedure & Matrix (Project Quality Plan)

Sch. Q,

Attachment IV,

Table 2.1

B2

Procedure specifies primary equipment for hardness test.

Portable Telebrinell Hardness Tester (Method) is mandatory for full

penetration groove and butt welds accessible by equipment.

NACE RP0472,

Appendix A

B

SPECIFIC TECHNIQUE REQUIREMENTS (NACE RP0472, App. A 12-Step Mandatory Guidelines including Equipment)

Note: References are S-PM-G000-1520-0010 (Para 15.1), S-PM-G000-1520-0011, (Para 16.1), SAES-W-012, (Para 13.2) & SAES-W-017,

(Para 13.1)

B1

Procedure addresses: Step by step method for hardness testing using

Portable TeleBrinell Hardness Tester (NACE RP0472, App. A)

Verify Performance step by step per Attachment 2

Note 1: Procedure is available & personnel are trained in its use.

Note 2: Applicable project specs reflect this: NACE HT Exemption based

on welding processes in RP0472 are not applied at SA.

NACE RP0472,

Appendix A

B3

Procedure specifies alternative equipment for performing HT where

weld geometry (fillet welds, small branch connections, etc) prevents the

use of the Portable Telebrinell method.

See Att 2 Notes (Alternative Equip). One of these two COMPANY

approved methods (MIC-10, Minibrinell) is to be selected.

NACE RP0472,

Para 3.4

N/A RE-INSP DATEREFERENCEITEM

No.ACCEPTANCE CRITERIA PASS FAIL


Page 1 of 9





(Plant Piping, Pipelines, Vessels & Tanks)SAIC-W-2012 12/11/2013 WELD-

NACE RP0472,

Appendix A,

(*SAEP-355)

ACCEPTANCE CRITERIA

B5

Procedure cautions: EXTREME CARE shall be taken when grinding

welds flat (Flat-topping) to prevent / minimize base metal removal. Where

base metal removal is deemed excessive by Inspection, additional NDE

(UT, caliper, gauge, etc) shall be performed to verify no minimum wall

violation exists per applicable material specification

NACE RP0472,

Appendix A,

Step # 1

B4

Procedure details Reference Bar requirements (Mat'l, range of

hardness, similarity to tested materials). See Attachment 2 Notes

relative to Reference Bar requirements for all project work

B7

Procedure covers: Test bars shall be saved for test verification by QC &

SA Inspection. Visual verification of test bars & Production welds shall be

performed to verify proper BHT technique is used. Double impressions

and use of more than 2 adjacent sides is not allowed. Technicians make

indentations within .1mm roundness tolerance & follow the 12-step

procedure or they receive retraining, practice & supervision. Reduce

retests & Hold / Witness Points

NACE RP0472,

Appendix A,

Steps #

4, 5, 7, 11

B6

Procedure cautions: Testing with a 1.4 to 2.3-kg (3-5 lb) hammer for

Telebrinell Portable Hardness Testers (BHT) is required. Hammer head

weights shall be visually verified "as stamped" at 3-5 lb, this to assure

reliable results. Caution: Other hammer weights do not provide reliable

results and are prohibited. Any Test performed with incorrect weight

hammer is invalid and must be retested.

NACE RP0472,

Appendix A,

Steps #

4, 5, 7, 11

NACE RP0472,

Appendix A,

Step # 4

B9

Procedure states: Weld deposits shall be hardness tested on the side

contacted by the process whenever possible. If access to

the process side is impractical, such as on piping or small diameter

vessels, hardness testing shall be done on the opposite side.

Sample accessible internal welds "randomly" & safely.

NACE RP0472,

Para 2.2.3

B8

Procedure covers: System for identifying rejected readings (Retest) on

Test bars & Production welds. Indentations found out-of-round, double

impressions, out of 3-4 mm range, etc, requires retesting. Using a

Permanent marker (Sharpy pen, etc), apply an "X" over the invalid

indentation(s) for retest. Welds unmarked with unacceptable indentations

on Production welds shall be investigated and retested to extent

necessary to ensure valid Brinell Hardness test results.

Identify invalid test results & ensure Quality of HT results

C

HARDNESS TESTING (HT) APPLICATIONS Note

1: Checklist Application covers Plant Piping, Pipelines, Vessels & Tanks as referenced. Use as "applicable to workscope".

Note 2: PWHT for Service at COMPANY includes: Caustic, MEA, DGA, ADIP, Boiler Deaerator, Hydrogen, DEA, etc. Review Specs carefully!

B10

Procedure covers sequence of BHT in relation to welding & PWHT. BHT

shall not be performed until AFTER welds are sufficiently cool and an

adequate time period has elapsed to ensure valid HT results.

Follow WPS special requirements for PWHT & BHT as listed, esp. where

potential for delayed Hydrogen cracking exists.

Sch. Q, Att IV,

Table 2.1 &

NACE RP0472,

Para 3.2

C2

P- No 1 Sour Service Production Weld HT Sampling is detailed.

Sour Service Line Classes are sampled at 10% minimum rate:

A) All welders making such welds are monitored by sampling.

B) All weld categories are sampled (groove, butt, fillet, other).

C) All weld repairs "as marked" are sampled.

D) Readings shall be taken at weld center & in the HAZ as close to weld

edge as possible after flat-topping welds.

Note: Review Line Class Summary & specifications for any errors.

*SA does not specify testing at the NACE suggested 5% rate.

PLANT PIPING

NACE RP0472,

Para 3.7,

S-PM-G000-1520-

0006,

Para. 8.1,

S-PM-G000-1520-

0011, Section 16

C1

COMPANY shall specify any PWHT & Production Weld HT (rare at

COMPANY), including sampling extent & test criteria. Procedure reflects

this requirement. Note: When COMPANY specifies HT, follow applicable

equipment requirements & sampling practices within the checklist.

PIPELINES

SAES-W-012,

Para 13.1


No.REFERENCE

Page 2 of 9






ACCEPTANCE CRITERIA PASS FAIL N/A RE-INSP DATEITEM

No.REFERENCE

PLANT PIPING

S-PM-G000-1520-

0011, Para 16.2

&

Para. 16.3 &

ASME B31.3

Para 331.1.7

Attachment 1

C4

P-No 10 " H " Production Welds (DUPLEX SS) shall have specific

detailed requirements listed in Hardness Test procedure as follows:

A) Production Welds are randomly sampled at a 20% rate*.

B) Utilize Telebrinell or COMPANY approved method

C) Reference Bar shall be within +/- 10% of specified Hardness

D) Maximum Hardness = 285 BHN (Non-sour Service), 270 BHN (Sour

Service) or lower specified value per SAES-A-301, Sect. 5.9

E) Test in weld center & in HAZ as close as possible to weld edge.

Note: Review Piping Line Class Tables & SAES-A-301. Verify the

correct application of this critical process requirement.

PLANT PIPING

S-PM-G000-1520-

0011, Section 12,

Para 16.2 & 16.3

*SAES-W-016,

Para. 7.2

ASME B31.3

Para 331.1.7

Attachment 1

C3

P-No 1 & Low-Alloy Production Welds subject to Code PWHT shall

have detailed requirements listed in Hardness Test procedure.

Production Welds PWHT'd for any reason (Service, Thickness, Code,

NACE or SAES-A-301, COMPANY, etc) receive HT as specified:

A) PWHT Furnace Batch method = 10% Hardness Testing

B) Localized PWHT method = 100% Hardness Testing

C) SA specifies: HT criteria = 200 BHN max - ALL P-No 1 weld

D) Hardness Testing applies to groove, butt, fillet, other welds, etc


F) Low-Alloy & Dissimilar Weld HT criteria (See Item C9)

Note: If it gets heat treated for COMPANY , it gets Hardness Tested

to verify satisfactory PWHT as intended by the code.

C6

Procedure covers API TANKS HT extent:

A) Production welds (groove, butt, socket, fillet, etc) subjected to PWHT

(due to Service), test per Checklist Items C6, C7 below

B) Sour Service Production welds (groove, butt, fillet,) for all matls.

"Internal" attachment welds shall be tested when they contact the product

unless specifically exempted from HT by COMPANY.

D) SA specifies: HT criteria = 200 BHN max - ALL P-No 1 weld

E) Low-Alloy Weld HT criteria (if applicable, See Checklist Item C8)

Note: Test on internal side of all welds (Checklist C6 & C7).

"External" attachment welds are exempt from testing.

API TANKS

SAES-W-017,

Para 13.1

C5

Procedure covers PRESSURE VESSEL HT extent:


(due to Service) test as per Checklist Item C6, C7 below.




C) Vessels of P-No 4 or 5 Material

D) SA specifies: HT criteria = 200 BHN max - ALL P-No 1 weld

E) Low-Alloy Weld HT criteria (Checklist Item C8)

Note: Test on process side of all welds (Checklist C6 & C7).


VESSELS &

API TANKS

NACE RP0472,

Para 3.5

PRESSURE

VESSELS

S-PM-G000-1520-

0010, Para 15.1

C8

Procedure states: Vessel or tank fillet welds, a minimum of one location

per each attachment shall be HT'd. In addition, One HT shall be made for

each 3 m (10 ft) of total attachment fillet weld length.

Note 1: Each weld procedure used shall be hardness tested.

Note 2: Each weld is tested at or near middle of weld bead.

Note 3: Tray attachment welds & others with disproportionate thickness

receive additional HT in the HAZ*.

* See Special Precautions (Heat Sinks) in Remarks Section

VESSELS &

API TANKS

NACE RP0472,

Para 3.6,

Para 4.5

C7

Procedure states: Vessel or tank butt welds, a minimum of one location

per weld seam shall be HT'd. One HT shall be made each 3 m (10 ft) of

weld seam. In addition, one hardness test shall be made on each nozzle

flange-to-neck and nozzle neck-to-shell/head weld.



Page 3 of 9







No.REFERENCE

D

EVALUATE TEST RESULTS & PROVIDE DISPOSITION OF UNACCEPTABLE RESULTS (Use SATR-W-012)


(Para 13.1)

C9

Procedure Lists HT Acceptance Criteria (Alloy steel @ P-No) per

ASME B&PV Code Sect IX. P-Nos meet maximum HBW values :

A) 225 for P-3, P-4, P-10 (A, B, C, F), P-11

B) 235 for P-5A, P-5B (exception in C below), P-5C, P-6, P-7

Note: P-5C is listed at 241 in ASME B31.3 Heat Treatment Table

C) 248 for P-5B for 9Cr-1Mo-V grades (F91, P91, T91, WP91, Gr 9, and

C12A)

Note 1: HBW = Brinell Hardness Value taken @ weld

Note 2: SAES-A-301 supercedes ASME PWHT Table HT values for Item

"B" above (235 HBW). Attachment 1 lists a 241 value.

D) All dissimilar welds are HT'd (weld & HAZ) Attachment 1

Note: Code reqmt (PWHT or not, per ASME B31.3, Para. 331.1.7b)

PLANT PIPING,

VESSELS &

API TANKS

SAES-A-301*,

Para. 5.2.2 &

Table 6

(*ISO 15156)

See Note

PLANT PIPING,

PIPELINES,

VESSELS &

API TANKS

D2

Procedure states: If any welds are found to be unacceptable, then two

additional welds from the same lot* shall be tested. If more than one weld

in a lot is found unacceptable, then all welds in that lot shall be tested.

(Plant Piping, Pipelines as applicable).

Note 1: Applies to Sour Service welds (10% sample) & P-No 10H or

Duplex SS welds (20% sample). Additional welds selected shall be from

same welder, and selection of welds shall sample work from all welders.

Note 2: For Furnace "Batch" welds PWHT & HT'd 10%, ANY result

unacceptable shall be cause for entire "batch" to be tested.

PLANT PIPING

S-PM-G000-1520-

0011,

Para. 16.5

D1

Procedure states: If any reading exceeds specified limits by no more

than 10 BHN, a minimum of (3) additional indentations shall be made

near the original high reading. If all (3) retests are below the specified

limits, then the joint is acceptable. If any retest readings exceed specified

limits, the weld shall be considered unacceptable.

D4

Procedure details Additional HT strategies as related to the following

three items (See Checklist Items D5, D6, D7 respectively) :

A) Proactive Quality Measures for HT on receipt (CPI)

B) Investigation Practice for unacceptable HT (Weld, HAZ)

C) Completion of partially fabricated assemblies subject to PWHT &

HT (Vessel components, Boiler & Heater tubes, coils, etc)

S-PM-G000-1520-

0011,

Para. 16.5,

Sch. Q, Att IV,

Table 2.1

D3

Procedure defines/distinguishes "Lot" relative to progressive

sampling or testing (For Welds, Consumables, Fittings) : A)

Welds - Lot shall be defined as all of the same kind* of welds made since

the last acceptable weld, for a given welder from any previous production

on specific line class. Progressive exams shall be limited to specific

welder with unacceptable HT results. Note:

The "same kind" of weld is: Same process or combination, same joint

type (groove vs. fillet), & same P-No. (Diameters & wall thicknesses may

vary for "same kind" of weld). B)

Consumables - Lot is the same type consummable & heat or Control

number "as marked" on manufacturer packaging & certs.

C) Fittings - Lot is all items of same type & maximum thickness which

are produced from same heat of steel & subjected to same heat

treatment, or finishing, etc. (02-SAMSS-011, Para. 4.1.2)

PLANT PIPING

S-PM-G000-1520-

0011,

Para. 19.1.9

02-SAMSS-011,

Para 4.1.2

Page 4 of 9







No.REFERENCE

Same as above,

& SAES-A-206,

Section 7.7

D6

Investigation Practice (Unacceptable HT results HAZ, Weld):

A) Fittings (Flanges, Wrought Ells, tees, etc) per 02-SAMSS-005/11 can

arrive IK "out of spec" with unacceptable hardnesses, despite OOK

quality efforts to obtain acceptable* values (*See Item D8).

B) When HAZ unacceptable readings are found, investigate fittings first,

then weld consumables next. Take two readings on fittings in question

(180 degrees apart) to verify the LOT (fittings same heat) meets specified

hardness limits. If unacceptable material hardness is found, take

additional readings (as agreed upon, per procedure) within the same LOT

& take appropriate Vendor action on Projects. C)

Unacceptable weld values require investigation of consumable lots, WPS

values, & welders making such welds, especially when adjacent piping &

fittings are within specified limits. See Item D5

Same as above

D5

Proactive Quality Measures for HT (CPI) include:

A) Random HT checks on fittings "by lot" on receipt. Increase OOK HT

surveillance. Fittings & Lots with high HT values are identified for

Remedial* action (Increased Pre-Heat temp, PWHT). *See Item D8.

B) Welding Consumables* (by lot) as received on projects shall have

sample hardness tests taken as early in projects as possible using

approved WPS to assure quality & prevent rework. Timely QC monitoring

is essential to prevent consumable problems.

*Take BHT readings & PMI together per SAES-A-206, Section 7.7

D7

Partial fabricated assemblies subject to completion on projects, PWHT

& HT (Vessel components, Boiler & Heater tubes, coils, etc) :

A) OOK work shall be sampled to extent necessary based on

Receiving Insp Observation (minimum = random HT).

Note: In 2002, RT Refinery Project BI-3503 (Unit J-64) received over

3,000 heater tubes (coils) for final assy & testing. No visible indentations

were noted & data dossier with reports showed 100% acceptance of

Hardness Testing. Random sampling revealed HT values between 350 &

400, indicative of a lack of required PWHT.

B) Inspect incoming matl BHT indentations (Visible, round)

Retest any missing, unacceptable or suspect indentations

Same as above

REMARKS: Procedure shall contain the elements listed in the checklist above as a minimum: Originator & Reviewer verify conformance of written

procedure with reqmts specified in "Reference" column of this checklist. Procedure cannot be combined with PWHT procedure. Review all Project

Specs (Lines Classes, Design Sheets) & verify spec accuracy relevant to these HT requirements.

Special Precaution (Heat Sinks): Welds with great base metal disproportion often have low heat input & large sections act as significant heat sinks

that result in high cooling rates. Tray support rings in Pressure Vessels are one such example (NACE RP0472, Para 4.5). Tray Support Rings & Other

similar type welds having great disproportionate base metal thicknesses shall be tested in the HAZ as well as center of weld. This includes ANY similar

welds. HAZ HT testing shall verify proper pre-heat & NACE recommended control measures were taken during fabrication (Include in HT Procedure).

Test such welds at or near weld center & at HAZ as close as possible to weld. (MIC-10)

Page 5 of 9







No.REFERENCE

2. SAES-A-301 (30 March 2005) Materials Resistant to Sulfide Stress Corrosion Cracking … Now ISO15156

3. S-PM-G000-1520-0010 Welding Requirements for Pressure Vessels

4. S-PM-G000-1520-0011 Welding Requirements for On-Plot Piping

5. SAES-W-012 (31 December 2002) Welding Requirements for Pipelines

ATTACHMENTS: Attachment 1 - ASME B31.3 (Table 331.1.1, Requirements for Heat Treatment)

Attachment 2 - NACE RP0472, Appendix A (Suggested Guidelines (12-Steps) for Portable Brinell Hardness Testing (BHT) of Welds)


1. NACE RP0472 (2005 Edition) Methods & Controls to Prevent In-Serv Cracking of CS Welds in P-1 Mat'l in Corr. Petroleum Refining Environ.


7. SAES-W-014 (29 June 2005) Weld Overlays and Welding of Clad Materials

8. SAES-W-016 (30 March 2005) Welding of Special Corrosion-Resistant Materials

9. SAES-W-017 (7 December 2005) Welding Requirements for API Tanks

10. ASME B31.3 (2004 Edition) PROCESS PIPING


Name, Initials and Date:Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed

Work Verified


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




Work Verified



Initials and Date:


Page 6 of 9




(Plant Piping, Pipelines, Vessels & Tanks)SAIC-W-2012 11-Dec-13 WELD-

Attachment 1

ASME B31.3 Section 331.1.7 Hardness Tests (Mandatory). Hardness tests of production welds and of hot bent and hot formed piping are intended

to verify satisfactory heat treatment. The hardness limit applies to the weld & the heat affected zone (HAZ) tested as close as practicable to the edge of

the weld. (a) Where a hardness limit is specified in Table 331.1.1, at least 10% of welds, hot bends, and hot formed components in each furnace heat

treated batch and 100% of those locally heat treated shall be tested. (b) When dissimilar metals are joined by welding, hardness limits specified for the

base and welding materials in Table 331.1.1 shall be met for each material.

Page 7 of 9





Attachment 2 - NACE RP0472, Appendix A(12-Steps) for Portable Brinell Hardness Testing (BHT) of Welds

1. Grind hardness test area flush with base metal. A smooth, relatively flat surface improves accuracy of hardness readings. One method to achieve

this is finish grinding with an 80 or finer grit sandpaper disc. Do not take hardness readings on scaled or discolored areas.

2. Insert the hardness test bar into the holder with the spacing button in the extreme forward position.

3. Ensure that the hardness test block is flat on the test surface.

8. Determine the Brinell hardness number by using the slide calculator supplied by the manufacturer

9. Subtract the determined weld hardness from the test bar hardness. The difference should be -10 to +50; if not, discard the hardness reading and do

a retest with a new hardness test bar. The new hardness test bar should have a hardness closer to the weld hardness to improve the hardness reading

accuracy. (Note: See Reference Bar Requirements below)

10. All hardness impressions at one test location should have at least 6.4 mm (0.25 in.) between their nearest edges.

11. Hardness impressions can be made on only two adjacent sides of the hardness test bars.

4. Make the impressions by striking the anvil nut squarely with a 1.4- to 2.3-kg (3.0- to 5.0-lb) hammer. Pull the hammer away so it does not rebound or

restrike the anvil. Note (Technique): Training/practice is needed for consistency in BHT. Technique is checked by indentation roundness (Step 5).

Tolerance for roundness is 0.1mm. If the indentation does not appear to be perfectly round to the human eye, it almost always is not within specified

tolerances & retest is required. Use eyepiece to verify suspected out of round impressions visually spotted.

5. Measure the impression on weld hardness test site by placing the microscope so that the impression is approximately in the center of the scale.

Adjust eyepiece so the scale and the top of the impression are in sharp focus. Measure the diameter of the impression to nearest half division (0.050

mm [0.002 in.]); it should be between 3.0 to 4.0 mm (0.12 to 0.16 in.) (if not, discard the hardness test and redo it). Rotate eyepiece 90 degrees and

obtain a second diameter reading. If the two diameter readings vary by more than 0.100 mm (0.004 in.) (i.e., the impression is oblong), discard the

hardness test & redo it. If acceptable, average the two diameter readings for a recorded result.

6. Repeat the procedure in Step 5 to measure the impression on the hardness test bar.

7. To do subsequent hardness testing, move the spacing button one notch toward the rear. This ensures that impressions on the hardness test bar are

properly spaced and avoids double impressions. Continue this practice for succeeding impressions until one-half of one side of the bar is covered with

impressions. Then remove and reverse the bar, and again move the spacing button to the extreme front position.

Example 1: A 188 BHN value test bar is used for HT of welds (200 BHN Sour Service line, test bar is P-No-1, within +/- 10% of max BHN). Test results

show 159 BHN value. Per Step # 9 of procedure, the result is invalid & retesting is required & should be performed with a bar of a hardness value

closer to 159 BHN value to obtain a valid result, even if it is below 200. Retests with same bar will result in retesting (over & over again). Per CSD, this

general retest policy is waived and is unnecessary as the final result will be under 200 & acceptable.

1. Be from a Certified source (QC Record, CMTRs) to attest to their quality & HT Value per their applicable ASTM mfg requirements.

2. Have their hardness value clearly marked at the ends of each bar by the manufacturer.

3. Test Bar Selection (Material type & Hardness value) shall be selected to be "SIMILAR" to the test piece. (SAEP-355, Section 6)

3a. Test Bar Material shall be the same P-No as the Test Piece, unless CSD specifies otherwise.

12. Replace indenter ball when it is out-of-round. (Inspect & rotate ball regularly, disassemble to rotate & inspect for flat spots)

REFERENCE (TEST) BAR REQUIREMENTS (Step # 9 of Procedure)

Note: Brinell Hardness Testing (BHT) is a self-calibrating method based on hardness impression comparison. Reference bars are M&TE, simply

Calibration standards of "Known" Material Composition & Hardness Values. (SAEP-355, Sect 6)

BHT Reference (Test) Bars are M&TE and shall:

Example 2: Same 188 BHN value test bar is used for testing (235 BHN P-No 5 Heater Tubes ASTM A335, bar is the wrong P-No mat'l & not within +/-

10% of Max BHN value). Test bar must be selected per Example # 1 & P-No 5 Test bars of higher HT value are needed.

Example 3: A 225 BHN value test bar is obtained for testing Example # 2 Heater Tubes (P-5 mat'l within +/- 10% of Max BHN value). Weld readings

(U-bends) show 351 BHN value. Metallurgical Investigation of U-bends & welds finds all sampled readings (300+) using correct range of test bars.

Investigation follows. CSD rejects the welds & requires PWHT & RT (disposition). Further investigation revealed that the Heater Tubes (over 3,000

total) were never PWHT'd, yet all had been accepted by HT reports using Equotip method. See Checklist Item D7.

3b. Test Bar Hardness Value shall be within +/- 10% of Maximum Specified Hardness (either 200 BHN, 225, 235, 248) allowed by SA.

NOTE: SELECT CORRECT "RANGE" OF TEST BARS: A range of test bars (100 - 400 BHN are sold) is required for BHT Test bars for production

work must be within +/- 10% of maximum specified Hardness (200 for Sour Service, ALL PLANT PIPING), 200 for vessel work or as specified in SAES-

A-301 at 225, 235, 248 for alloy steels). Check job specs for Matls to be PWHT (Piping Line Class, Data Sheets) as applicable. Before work begins,

ensure an available range/adequate supply of test bars is based on “KNOWN” material specs (CMTRs).

3c. RETESTING PRACTICE & INVESTIGATION OF UNACCEPTABLE RESULTS (PER STEP # 9) FOLLOW EXAMPLES BELOW

Page 8 of 9





1a. Krautkramer Microdur 10 (MIC-10) Manual Probes req'd for tight convex geometries are: Article (Model) MIC 201/ 205 with Test Load 10 N (1

kgf) / 50N (5 kgf). Portable kits must have calibration standards of known Rockwell Hardness, Hardness Conversion Tables, instructions & laminated

cards for calibration (Keep these on site with equipment to demonstrate calibration accuracy)

2. MiniBrineller (a miniature version of the Telebrinell) is also acceptable per COMPANY. Information on these unit complete kits can be obtained

@ http://www.ndtech.net/products/minibrineller.html Verify 5-10% of Minibrineller readings by BHT (Telebrinell), same as MIC-10.

Alternative Hardness Testing Equipment for Branch Connection & Fillet welds, etc

1. Krautkramer Microdur 10 (MIC-10) is one of two equipment types allowed. Rebound type or Leeb portable testers that use spring-loaded probes

(specifically Proceq Equotip and others) are prohibited for use in SA. (See SAEP-355, Para. 6.2.1). Krautkramer Microdur MIC 10 portable hardness

testers require a careful selection of interchangeable probes to obtain Hardness readings from welds with geometries inaccessible to BHT (branch

connections, fillets, curved/convex surfaces, etc). Provide/document/demonstrate operator training. Careful test surface prep (fine grind/finish, 400 grit

per COMPANY for reliable result) is required. Verify 10% of MIC-10 readings by BHT comparison. (Once daily with testing/minimum). Take BHT

readings as close as possible to MIC-10 readings, accuracy to be within 10% with acceptable BHT results. (NACE RP0175, Para. 3.4,

owner/user option for alternative equip).

2. MIC-20 & later generations of Krautkramer Microdur technology can be applied (pending COMPANY approval).

Page 9 of 9



Inspection of Repair on Weld Joints or Base Metal by

Welding (Prior to Weld Acceptance)SAIC-W-2013 11-Dec-13 WELD-







S-PM-G000-1520-

0011,

Para. 20.7

QUALITY PLAN

REQUIREMENT

A GENERAL REQMTS (See Note 1, Attachment 1, SAIC-W-2008, SAIC-W-2016 & SAIC-W-2036 Related to Repairs)

A1

COMPANY was notified before Repairs. (RT results, etc).

An agreed upon system shall be set in place on all projects .

Prime Contractor shall witness repair excavation by Sub Contactor. SA

Inspector shall have a chance to witness any such excavation of repairs.

" GLASS WINDOW POLICY " exists regarding repairs.

QUALITY PLAN

REQUIREMENT

NDE Kickoff

Meeting Topic

A3

S-PM-G000-1520-0006 Database and recording of repairs and status:

A) Meets S-PM-G000-1520-0006 Sect. 8 Weld Tracking. (SAIC-W-2008)

B) Backlogs are tallied and reported.

C) COMPANY has received any RT Film (original & repairs)

D) Tracer welds are selected and tested for repair joints

Repair is actually reported in Database & documented .

QUALITY PLAN

REQUIREMENT

A2

Weld did not meet code or standard acceptance criteria.

NDE PROCESS CONTROL PROCEDURE details Repair Practice.

This was strictly followed regarding repair verification, weld ID, NDE &

repair markings, NDE reporting, & disposition of repairs.

Prime Contractor & Sub, NDE Service Provider follow protocol

NDE markings are verified, and correct joint was repaired by

qualified welders with approved JCCs.

B Repair of Welds Rejected by Radiography or Other NDE Methods

B1

Weld cut-out was performed on welds that has been repaired twice. Note:

Exception to this is when additional repair attempts are allowed by

COMPANY .

S-PM-G000-1520-

0011,

Para. 20.1

S-PM-G000-1520-

0011,

Para. 20.2

B2

Cracked welds (except for crater cracks) are repaired by cut-out unless a

repair is approved by COMPANY assigned inspector. Crater cracks are

ground out & MT examined (or PT).

S-PM-G000-1520-

0011,

Para. 20.2

C2

If a repair to a crack is approved, Repair & Inspection Procedure was

reviewed & approved by COMPANY prior to excavation of defects.

Note 1: Additional checklist items shall be added to this checklist to

include conditions & inspection reqmts and acceptance criteria for repair

of weld. See examples below .

Note 2: When tie-in welds to existing piping in services such as

Hydrogen, Caustic, Sulphur Recovery, Acid Gas, Wet H2S, other services

as covered in API 571, etc ... Weldability shall be considered as well as

additional cleaning beyond the 25mm rule, ph testing for process

saturated surfaces, and crack preventive measures such as "FULL OR

PARTIAL BAKE OUTs" & increased PREHEAT TEMPSs ... as outlined

in API 571. Determine

reason for cracking (Weld Service environment)

S-PM-G000-1520-

0011,

Para. 20.2

C Repair of Welds due to Base Metal or Welding Consummables (Tie-Ins to Existing Equipment or Piping, etc)

ITEM


C1

Cracks related to base metal or welding consumables shall be

evaluated by COMPANY BEFORE any repair attempt. See

Note 2 in C2.

Page 1 of 14



Weld Repair Inspection SAIC-W-2013 11-Dec-13 WELD-


C3

Repair of Parent material mechanical damage, pitting marks: The

extent of repair allowed is as per parent material specification / code. If

needed the section of parent material / item with damage shall be

replaced. All the repair shall follow the approved project repair procedure

/ method statement.

ASME Sec II

C4

Consumable related repairs have been identified & corrective action

has been taken regarding WPS Parameter monitoring & removal of

existing consumables (same lot, batch number) to prevent reoccurrence.

Furthermore, Quality Manager has taken action regarding SAIC-W-2009,

Attachment 1 regarding Acceptable Storage Practices & maintaining a

Dry Environment for Electrodes. NCR was

issued & defective consumables were removed from site

Root cause and corrective actions implemented was determined and

agreed upon by the authorized SA Inspector covering Repairs.

S-PM-G000-1520-

0011,

Para. 20.2

D ASME B31.3 CODE REQUIRED CONSIDERATIONS, WELDER & QUALITY INSPECTOR RESPONSIBILITY (DEFECT EXCAVATION)

Action: Construction & Quality Mgrs shall ensure that Welders & Inspectors perform the following checks with due diligence in a spirit of cooperation &

getting Costly Repair done right on FIRST REPAIR ATTEMPTS. The need for a 2nd Repair Attempt indicates a failure and a Quality system

breakdown (lack of knowledge, diligence & communication), especially related to NDE findings (markings, repair instruction). Second Repair Attempts

(costly, inefficient) are easily preventable. In all cases, 2nd repair excavations shall be attended by Stakeholders & their Supervision who shall witness

& determine that excavations & rewelding are successful (retrain welders, Inspectors as needed).

SA INSPECTORS SHOULD NEVER HAVE TO BE APPROACHED IN ORDER TO APPROVE A 3RD WELDING REPAIR ATTEMPT.

D1

ASME B31.3, Para 328.6 Weld Repair:

A) A weld defect to be repaired shall be removed to sound metal.

B) Repair welds shall be made using a qualified welding procedure.

C) Repair welds shall be made recognizing that the cavity to be repaired

may differ in contour & dimensions from the original joint.

WELDER & INSPECTOR ACHIEVE RESULTS (FIRST REPAIR)

ASME B31.3,

Para. 328.6

ASME B31.3,

Para. 328.6

Weld Repair

Considerations

D2

INSPECTOR VERIFIES THAT THE DEFECT HAS BEEN REMOVED.

1. Inspector verifies NDE marks & joint ID are accurate (excavation).

2. Inspector uses face shield to witness excavation (safe practice).

3. Welder excavates "in careful stages" (defect location)

4. Inspector checked that defects were "Chased until removed".

5. Inspector rechecks excavated area vs. exact film defect location.

6. Inspector conferences with welder & both make the call for any further

excavation based on a) welder intimate knowledge b) the excavation

dimensions & contour favor total cut out c) excavation does not

accurately match NDE results or d) "Nothing was found".

Decision: Was the excavation successful? Can a repair weld be made

after clean up grinding & NDE (root opening size, slope, etc).

Additionally NDT may be requested as needed to confirm the

removal defective areas (MT, UT and RT )

ASME B31.3,

Para. 328.6

Weld Repair

Considerations

D4

INSPECTOR VERIFIES EXCAVATION IS ACCEPTABLE.

1. Sound Metal is visible in the area identified by the repair.

2. Inspector witnesses NDE (MT or PT) of the excavated area.

3. Where a root opening exists, Inspector verifies Post-Cleaning

thoroughly removes residues (MPT particles, PT developer) by flushing or

use of compressed air AND Preheating while brushing to remove residual

contaminants that can affect weld repair quality.

ASME B31.3,

Para. 328.6

Weld Repair

Considerations

D3

EXCAVATION CONTOUR IS WELDABLE (NO CUT-OUT REQ'D):

1. Sound Metal shall be visible in the area identified by the repair.

2. Inspector checks contour of excavation prior to NDE to verify that any

steep sharp angles/slopes are contour ground (weldable).

3. Verify clean metal after regrinding (use magnification as needed)

This is especially critical on 2nd repair attempts, and this is often

the very reason a second repair was required.



Page 2 of 14







D5

COMPANY Assigned INSPECTOR WAS NOTIFIED & WITNESSED

2ND REPAIR ATTEMPT (EXCAVATION & REWELDING) ... WITNESS

POINT! ANY

SUPPLEMENTAL NDE IS PERFORMED (AS REQUESTED).

S-PM-G000-1520-

0011,

Section 20

E REWELDING OF EXCAVATIONS (WPS & NDE)

E1

Repair procedure may utilize a welding procedure previously approved by

COMPANY in conjunction with a separate method statement or it may be

a separate detailed welding procedure.

S-PM-G000-1520-

0011,

Para. 20.4

E2

Replacement weld (Cut-out) was inspected as a repair by the use of the

relevant Inspection Checklist covered in the applicable SATIP for

Welding. Per S-PM-G000-1520-0006, Change weld ID (W01-R1 suffix).

Suffix shall no longer be identified as R1, R2.

S-PM-G000-1520-

0011,

Para. 20.5 &

S-PM-G000-1520-

0006,

Section 8

S-PM-G000-1520-

0011, Para. 9.1.8

E3

All repaired welds shall be inspected using the original testing method.

Additional test methods may also be required, if deemed necessary by

the authorized COMPANY inspector.

S-PM-G000-1520-

0011,

Para. 20.5

E5Welding is performed by Qualified welders and in possession of the

applicable Job Clearance Cards).

SAEP-324,

Para. 6.2.5

E4 Approved WPS applicable to the weld repair is available on site.

F Casual Repairs Based on Workmanship & Weld Profile, Visual or NDE Examination Results (See also SAIC-W-2007)

F1Welds (Piping, Structural) are evaluated per Visual Acceptance Crtieria

of SAIC-W-2007 (ASME B31.3, AWS D1.1 code welds)

SAIC-A-2007

As Referenced

F2

Undercuts are ground to a smooth contour with the adjacent metal

surface. NOTE: Weld build-up performed on undercuts that exceed the

allowable limits indicated in the applicable code (SAIC-W-2007)

S-PM-G000-1520-

0011,

Para. 13.5

S-PM-G000-1520-

0011, Para. 13.8

F3 Arc strikes are removed by grinding.

S-PM-G000-1520-

0011,

Para. 13.5

F5 Crater cracks are removed by grinding. (MT/PT)

S-PM-G000-1520-

0011,

Para. 20.2

F4 MPT or PT, as applicable, is carried out after grinding of arc strikes.

F6Gouges and other indications of careless workmanship are removed by

grinding

S-PM-G000-1520-

0011,

Para. 13.5

S-PM-G000-1520-

0011,

Para. 13.6

F7

Repair of welds for alignment purpose should not be allowed with out

written approval of Aramco. All these repair welds shall undergo

PWHT/NDT/HT/Pressure testing as per the Approved repair procedure /

Method statement

Project weld

repair procedure

F9MPT or PT, as applicable, is carried out after repair by grinding or

re-welding on the ground areas.

S-PM-G000-1520-

0011, Para. 13.8

F8

Temporary welded attachments or temporary tack welds are removed by

grinding. NOTE: Attachments are cut off no closer than 3 mm to the base

metal surface, prior to the required grinding.

REMARKS:

Page 3 of 14







NOTE 1: Use this checklist in conjunction with SAIC-W-2016 (Assessment of Weld Repairs). Weld Repair Reporting shall follow new

S-PM-G000-1520-0006, Section 8 Details. See Attachment 1 - S-PM-G000-1520-0006 SPECIFICATION FOR WELDING PROCEDURE

APPROVAL AND WELD STATUS WITH NDT TRACKING

See also SAIC-W-2036 for Weld Modification or Re-Work After Weld Acceptance. Know the difference and the reqmts.




3. SAEP-324, Certification Review and Registration of Project Welders and Brazers, (30 June, 2003)

4. S-PM-G000-1520-0006 SPECIFICATION FOR WELDING PROCEDURE APPROVAL AND WELD STATUS WITH NDT TRACKING

5. API RECOMMENDED PRACTICE 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry (First Edition, Dec. 2003)


Work Verified



Contractor QC Inspector COMPANY InspectorPerformed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed


Name, Organization,

Initials and Date:






Page 4 of 14


Attachment 1 - S-PM-G000-1520-0006 SPECIFICATION FOR WELDING PROCEDURE APPROVAL AND WELD

STATUS WITH NDT TRACKING

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


ITEM

No.ACCEPTANCE CRITERIA PASS FAIL N/A

B4

RE-INSP DATE

B5

EXTREME CARE shall be taken when grinding welds flat (Flat-top) to

prevent any / minimize base metal removal. Base metal removal was

checked by Inspection. No need exists for additional NDE (UT, etc) to

verify adequate remaining wall exists per material specs.

B6

A 1.4 - 2.3-kg (3-5 lb) hammer for Telebrinell Portable Hardness Testers

(BHT) is being used. "As stamped" hammer head weight at 3-5 lb has

been verified to assure reliable HT results.

Note: Tests performed with incorrect weight hammer are invalid.

See Technique Note in Attach 2, Step 4 (QC Surveillance)

NACE RP0472,

Appendix A,

Step # 4

NACE RP0472,

Appendix A,

Step # 1

Reference Bars with effective range for HT are available with QC

documenatation (Material composition, Hardness Value, etc).

See Attachment 2 Notes* for Reference Bar requirements

NACE RP0472,

Appendix A,

(*SAEP-355)

B3

MIC-10 with correct model probes or Minibrinell Kit is available for HT of

fillet welds, branch connections, etc, where Telebrinell method is

inaccessible. See Attachment 2 Detailed Notes

Note 1: Equipment is available & personnel are trained in its calibration,

care & use to assure valid HT results. Ten (10) % of all results are

verified/compared against the Telebrinell method.

NACE RP0472,

Para 3.4

B2Portable Telebrinell Hardness Tester (Test Kit) is available for full

penetration groove and butt welds.

NACE RP0472,

Appendix A

B

TECHNIQUE & EQUIPMENT VERIFICATION (NACE RP0472, Appendix A, 12-Step Mandatory Guideline)


(Para 13.1)

B1

Test Personnel follow step by step method for hardness testing using

Portable Brinell Hardness Tester & NACE RP0472, App. A.

Verify Performance step by step per Attachment 2

Note 1: Procedure is available & personnel are trained in its use.

Note 2: Applicable project specs reflect this: NACE HT Exemption based

on welding processes in RP0472 are not applied at SA.

NACE RP0472,

Appendix A

A3

Welds & items for Hardness Test shall have a unique ID clearly visible to

hardness test personnel & QC documenting test results. System is in

place to prevent errors in testing & documentation.

S-PM-G000-1520-

0006

Para 8.1

A2

Data Mgmt & Tracking System (Database) is approved by COMPANY

prior to the start of work.

A) Full penetration groove & butt weld hardness tests are tracked

B) Socket & Fillet welds (Includes "other" weld or components specified

for Hardness Testing) are tracked.

Note: Reporting follow Welding Database reqmts as applicable

S-PM-G000-1520-

0006

Para. 8.1

A

GENERAL REQUIREMENTS (SPECIAL PROCESS CONTROL PER CONTRACT SCH Q & SAEP-1160) Note:

Checklist applies to Plant Piping (S-PM-G000-1520-0011), Pipelines (SAES-W-012), Vessels (S-PM-G000-1520-0010) & Tanks (SAES-W-

017)

A1

Procedure is COMPANY approved and details criteria for weld ID &

weld selection for Hardness Testing including all responsibilities:

A) HT Sampling reqmts for specific production welds is available.

B) HT of PWHT welds (Service & thickness) is available (List).

Checklist SAIC-2012 has been utilized for the HT Procedure.

Scope of HT is known. Project specs are reviewed/approved.

S-PM-G000-1520-

0006,

Para. 8.1


REFERENCE


TRAVEL TIME

SAUDI ARAMCO USE ONLY





Verify Hardness Testing - All Applications




Page 1 of 8

FAIL N/A RE-INSP DATEITEM


C3

P-No 1 & Alloy Steel Production Welds subject to PWHT for any

reason* (Service, Thickness, Code, COMPANY preference, etc) receive

Hardness Testing as specified below:

A) PWHT Furnace Batch method = 10% Hardness Testing

B) Localized PWHT method = 100% Hardness Testing

C) SA specifies: 200 BHN for ALL P-No 1 welds. Other P-Nos &

Dissimilar welds follow HT criteria in Checklist Item C8.

D) Hardness Testing applies to groove, butt, fillet, other welds, etc


Note: If it gets heat treated for COMPANY, it gets Hardness Tested to

verify satisfactory PWHT as intended by the code.

PLANT PIPING

S-PM-G000-1520-

0011, Para 16.2

&

Para. 16.3 &

ASME B31.3

Para 331.1.7

Attachment 1

C2

P- No 1 Sour Service Production Welds receive 10% HT (min)

sampling for Plant Piping & Pipelines (*IF COMPANY specified on

Pipelines):

A) All welders making such welds are monitored by sampling.

B) All weld categories are sampled (groove, butt, fillet, other).

C) All weld repairs "as marked" are sampled.

D) Readings shall be taken at weld center & HAZ as close to weld edge

as possible after flat-topping welds

Note: Verify all Sour Line Classes on project are 10% sampled. Ensure

Line Class (Summary) & Specs do not contain errors.

PLANT PIPING

NACE RP0472,

Para 3.7,

S-PM-G000-1520-

0006,

Para. 8.1

C

HARDNESS TESTING (HT) APPLICATION VERIFICATION

Note 1: Checklist Application covers Plant Piping, Pipelines, Vessels & Tanks as referenced. Use as "applicable to workscope".

Note 2: PWHT for Service at COMPANY includes: Caustic, MEA, DGA, ADIP, Boiler Deaerator, Hydrogen, DEA, etc. Review Specs carefully!

C1

COMPANY has specified PWHT & Production Weld HT including

sampling extent & Hardness Test criteria.

Note 1: Pipeline PWHT & HT (Production Welds) is extremely rare at

Saudi Aramco. This checklist does address HT as follows.

Note 2: If COMPANY specifies HT for Pipeline Production welds, follow

applicable equipment requirements & sampling practices within this

checklist for Plant Piping, unless otherwise specified by COMPANY.

PIPELINES

SAES-W-012,

Para 13.1

B10

BHT shall not be performed until AFTER welds are sufficiently cool and

an adequate time period has elapsed to ensure valid HT results.

WPS & Specification special instructions for PWHT & BHT were followed.

(No Delayed Hydrogen cracking concerns exist).

Sch. Q, Att IV,

Table 2.1 &

NACE RP0472,

Para 3.2

B9

Weld deposits were hardness tested on the side contacting service

process whenever possible. If process side access is impractical, (piping

or small diameter vessels), HT was done on opposite side.

Sample accessible internal welds "randomly" & safely.

NACE RP0472,

Para 2.2.3

NACE RP0472,

Appendix A,

Steps #

4, 5, 7, 11

B8

System for identifying rejected readings (Retests) on Test bars &

Production welds was followed. Indentations found out-of-round, double

impressions, out of 3-4 mm range, etc, require retesting. Permanent mark

(Sharpy pen, etc) "X" was placed over the invalid indentation(s) for retest.

Welds unmarked with unacceptable indentations on Production welds

shall be investigated and retested to extent necessary to ensure valid

Brinell Hardness test results.

Identify invalid test results & ensure Quality of HT results

NACE RP0472,

Appendix A,

Steps #

4, 5, 7, 11

B7

Test bars are available for test verification by QC & SA Inspection. Visual

verification of test bars & Production welds shall verify that proper BHT

technique is used. Double impressions and use of more than 2 adjacent

sides is not allowed. Technicians made indentations within .1mm

roundness tolerance & followed the 12-step procedure

Note: Call for retraining & closer supervision* (Witness/Hold) for any

deficiencies found during witness of technician performance.



(Plant Piping, Pipelines, Vessels & Tanks)SAIC-W-2014


12/11/2013WELD-


Page 2 of 8







12/11/2013WELD-


ALL

SAES-W-STDs

Plant Piping,

Pipelines,

Vessels &

API Tanks

D1

Criteria is Properly Evaluated: If any reading exceeds specified limits by

no more than 10 BHN, a minimum of (3) additional readings shall be

made near the original high reading. If all (3) retests are below specified

limits, then the joint is acceptable. If any retest reading(s) exceed

specified limits, the weld is unacceptable.

This is a common requirement for all COMPANY applications

D

EVALUATE TEST RESULTS & PROVIDE DISPOSITION OF UNACCEPTABLE RESULTS (Use SATR-W-012)


(Para 13.1)

C8

ACCEPTANCE CRITERIA (Alloy steel listed by P-No) per ASME B&PV

Code Section IX. P-Nos meet maximum HBW values below:

A) 225 for P-3, P-4, P-10 (A, B, C, F), P-11

B) 235 for P-5A, P-5B (exception in C below), P-5C, P-6, P-7

Note: P-5C is listed at 241 in ASME B31.3 Heat Treatment Table

C) 248 for P-5B for 9Cr-1Mo-V grades (F91, P91, T91, WP91, Gr 9, and

C12A)

Note 1: HBW = Brinell Hardness Value taken @ weld

Note 2: SAES-A-301 supercedes ASME PWHT Table HT values for Item

"B" above (235 HBW). Attachment 1 lists a 241 value.

D) All dissimilar welds are HT'd (weld & HAZ) Attachment 1

Note: Code reqmt (PWHT or not, per ASME B31.3, Para. 331.1.7b)

ALL

SAES-A-301,

Para. 5.2.2 &

Table 6

Attachment 1

C7

Vessel or Tank Fillet welds, a minimum of one location per each

attachment shall be HT'd. In addition, One HT shall be made for each 3 m

(10 ft) of total attachment fillet weld length. Note

1: Each WPS used shall be hardness tested.

Note 2: Each weld is tested at or near middle of weld bead*.

Note 3: *Follow Special Precautions (for Heat sinks) & test HAZ of

certain welds per NACE guidelines. See Remarks.

VESSELS &

API TANKS

NACE RP0472,

Para 3.6,

Para 4.5

C6

Vessel or Tank Butt welds, a minimum of one location per weld seam

shall be HT'd. One HT shall be made each 3 m (10 ft) of weld seam. In

addition, one hardness test shall be made on each nozzle flange-to-neck

and nozzle neck-to-shell/head weld.



VESSELS &

API TANKS

NACE RP0472,

Para 3.5

PRESSURE

VESSELS

S-PM-G000-1520-

0010, Para 15.1

C5

API TANKS (API 650) HT extent:


(due to Service), test per Checklist Items C6, C7, C8 below




Note: Test on internal side of all welds per Steps C6, C7.


API TANKS

SAES-W-017,

Para 13.1

C4

PRESSURE VESSEL (ASME VIII, Div 1 & 2) HT :


(due to Service) test as per Checklist Item C6, C7, C8 below.




C) Vessels of P-No 4 or 5 Material Note:

Test on internal side of all welds per Steps C6, C7.


Page 3 of 8







12/11/2013WELD-


REMARKS: Procedure shall contain the elements listed in the checklist above as a minimum: Originator & Reviewer verify conformance of written

procedure with reqmts specified in "Reference" column of this checklist. Procedure cannot be combined with PWHT procedure. Review all Project

Specs (Lines Classes, Design Sheets) & verify spec accuracy relevant to these HT requirements.

Special Precaution (Heat Sinks): Welds with great base metal disproportion often have low heat input & large sections act as significant heat sinks

that result in high cooling rates. Tray support rings in Pressure Vessels are one such example (NACE RP0472, Para 4.5). Tray Support Rings & Other

similar type welds having great disproportionate base metal thicknesses shall be tested in the HAZ as well as center of weld. This includes ANY similar

welds. HAZ HT testing shall verify proper pre-heat & NACE recommended control measures were taken during fabrication (Include in HT Procedure).

Test such welds at or near weld center & at HAZ as close as possible to weld. (MIC-10)

D5

Partial fabricated assemblies subject to completion on projects, PWHT

& HT (Vessel components, Boiler & Heater tubes, coils, etc) :

A) OOK work shall be sampled to an extent necessary based on

Receiving Insp Observations (Minimum = Random* HT).

B) Inspect incoming matl for BHT indentations (Visible, round)

Retest missing/unacceptable indentations or suspect results

same as above,

& S-PM-G000-

1520-0011, Para.

19.1.3*

D4

Verify Proactive Quality Measures for HT (CPI option):

A) Random HT checks on fittings "by lot" on receipt. Increase OOK HT

surveillance. Fittings & Lots with high HT values are identified for

Remedial* action (Increased Pre-Heat temp, PWHT). *See Item D.

B) Welding Consumables (by lot) as received (used on projects), shall

have sample hardness tests taken as early in projects as possible using

approved WPS to assure quality & prevent rework. Timely QC monitoring

is essential to prevent consumable problems.

Don't wait until hardness problems adversely affect projects

same as above

(Best Practice)N/A N/A N/A

D3

Investigation Practice (Unacceptable HT results HAZ, Weld):

A) Fittings (Flanges, Wrought Ells, tees, etc) per 02-SAMSS-005/11 can

arrive IK "out of spec" with unacceptable hardnesses, despite OOK

quality efforts to obtain acceptable* values (*See Item D8).

B) When HAZ unacceptable readings are found, investigate fittings first,

then weld consumables next. Take two readings on fittings in question

(180 degrees apart) to verify the LOT (fittings same heat) meets specified

hardness limits. If unacceptable material hardness is found, take

additional readings (as agreed upon, per procedure) within the same LOT

& take appropriate Vendor action on Projects. C)

Unacceptable weld values require investigation of consumable lots, WPS

values, & welders making such welds, especially when adjacent piping

and fittings are found within specified limits.

See Item D4 for Best Practice. ISO 9000 QPs follow CPI

S-PM-G000-1520-

0011,

Para. 16.5,

Sch. Q, Att IV,

Table 2.1 &

(CPI)

D2

Verify: If any welds are found to be unacceptable, then two additional

welds from the same lot* shall be tested. If more than one weld in a lot is

found unacceptable, then all welds in that lot shall be tested. (Plant

Piping, Pipelines as applicable).

Note 1: Applies to Sour Service welds tested (10%). Additional welds

selected shall be from same welder. Sample all welders.

Note 2: Furnace "Batch" welds PWHT & HT'd at 10% rate, ANY result

unacceptable shall be cause for entire "batch" to be tested.

PLANT PIPING

S-PM-G000-1520-

0011,

Para. 16.5

Page 4 of 8







12/11/2013WELD-



Subcontractor QC Inspector COMPANY PMT Representative




Initials and Date:


Work Verified


Name, Initials and Date: Name, Initials and Date:Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed


Name, Initials and Date:Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified

6. ASME B31.3 (2004 Edition) PROCESS PIPING

7. SAEP-355 (29 February, 2004) Field Metallography and Hardness Testing

8. NACE RP0472 (2005 Edition) Methods & Controls to Prevent In-Serv Cracking of CS Welds in P-1 Mat'l in Corr. Petroleum Refining Environ.



3. SAES-W-012 (31 December 2002) Welding Requirements for Pipelines

4. SAES-W-017 (7 December 2005) Welding Requirements for API Tanks

5. SAES-A-301 (30 March 2005) Materials Resistant to Sulfide Stress Corrosion Cracking … Now see ISO 15156

ATTACHMENTS: 1. Attachment 1 - ASME B31.3 (Table 331.1.1, Requirements for Heat Treatment)

2. Attachment 2 - NACE RP0472, Appendix A (Suggested Guidelines (12-Steps) for Portable Brinell Hardness Testing (BHT) of Welds)


1. S-PM-G000-1520-0010 Welding Requirements for Pressure Vessels

Page 5 of 8

ASME B31.3 Section 331.1.7 Hardness Tests (Mandatory). Hardness tests of production welds and of hot bent and

hot formed piping are intended to verify satisfactory heat treatment. The hardness limit applies to the weld & the heat

affected zone (HAZ) tested as close as practicable to the edge of the weld. (a) Where a hardness limit is specified in

Table 331.1.1, at least 10% of welds, hot bends, and hot formed components in each furnace heat treated batch and

100% of those locally heat treated shall be tested. (b) When dissimilar metals are joined by welding, hardness limits

specified for the base and welding materials in Table 331.1.1 shall be met for each material.

Attachment 1





Page 6 of 8





1a. Krautkramer Microdur 10 (MIC-10) Manual Probes req'd for tight convex geometries are: Article (Model) MIC 201/ 205 with Test Load 10 N (1

kgf) / 50N (5 kgf). Portable kits must have calibration standards of known Rockwell Hardness, Hardness Conversion Tables, instructions & laminated

cards for calibration (Keep these on site with equipment to demonstrate calibration accuracy)

Example 2: Same 188 BHN value test bar is used for testing (235 BHN P-No 5 Heater Tubes ASTM A335, bar is the wrong P-No mat'l & not within +/-

10% of Max BHN value). Test bar must be selected per Example # 1 & P-No 5 Test bars of higher HT value are needed.

Example 3: A 225 BHN value test bar is obtained for testing Example # 2 Heater Tubes (P-5 mat'l within +/- 10% of Max BHN value). Weld readings

(U-bends) show 351 BHN value. Metallurgical Investigation of U-bends & welds finds all sampled readings (300+) using correct range of test bars.

Investigation follows. COMPANY rejects the welds & requires PWHT & RT (disposition). Further investigation revealed that the Heater Tubes (over

3,000 total) were never PWHT'd, yet all had been accepted by HT reports using Equotip method. See Checklist Item D5.

Alternative Hardness Testing Equipment (2 Approved by COMPANY) for Branch Connection & Fillet welds, etc

1. Krautkramer Microdur 10 (MIC-10) is one of two equipment types allowed. Rebound type or Leeb portable testers that use spring-loaded probes

(specifically Proceq Equotip and others) are prohibited for use in SA. (See SAEP-355, Para. 6.2.1). Krautkramer Microdur MIC 10 portable hardness

testers require a careful selection of interchangeable probes to obtain Hardness readings from welds with geometries inaccessible to BHT (branch

connections, fillets, curved/convex surfaces, etc). Provide/document/demonstrate operator training. Careful test surface prep (fine grind/finish, 400 grit

per COMPANY for reliable result) is required. Verify 10% of MIC-10 readings by BHT comparison. (Once daily with testing/minimum). Take BHT

readings as close as possible to MIC-10 readings, accuracy to be within 10% with acceptable BHT results. (NACE RP0175, Para. 3.4,

owner/user option for alternative equip).

2. MIC-20 & later generations of Krautkramer Microdur technology can be applied (pending COMPANY approval).

3b. Test Bar Hardness Value shall be within +/- 10% of Maximum Specified Hardness (either 200 BNH, 225, 235, 248) allowed by SA.

NOTE: SELECT CORRECT "RANGE" OF TEST BARS: A range of test bars (100 - 400 BHN are sold) is required for BHT Test bars for production

work must be within +/- 10% of maximum specified Hardness (200 for Sour Service, ALL PLANT PIPING), 200 for vessel work or as specified in SAES-

A-301 at 225, 235, 248 for alloy steels). Check job specs for Matls to be PWHT (Piping Line Class, Data Sheets) as applicable. Before work begins,

ensure an available range/adequate supply of test bars is based on “KNOWN” material specs (CMTRs).

3c. RETESTING PRACTICE & INVESTIGATION OF UNACCEPTABLE RESULTS (PER STEP # 9) FOLLOW EXAMPLES BELOW

Example 1: A 188 BHN value test bar is used for HT of welds (200 BHN Sour Service line, test bar is P-No-1, within +/- 10% of max BHN). Test results

show 159 BHN value. Per Step # 9 of procedure, the result is invalid & retesting is required & should be performed with a bar of a hardness value

closer to 159 BHN value to obtain a valid result, even if it is below 200. Retests with same bar will result in retesting (over & over again). Per

COMPANY, this general retest policy is waived and is unnecessary as the final result will be under 200 & acceptable.

1. Be from a Certified source (QC Record, CMTRs) to attest to their quality & HT Value per their applicable ASTM mfg requirements.

2. Have their hardness value clearly marked at the ends of each bar by the manufacturer.

3. Test Bar Selection (Material type & Hardness value) shall be selected to be "SIMILAR" to the test piece. (SAEP-355, Section 6)

3a. Test Bar Material shall be the same P-No as the Test Piece, unless COMPANY specifies otherwise.

12. Replace indenter ball when it is out-of-round. (Inspect & rotate ball regularly, disassemble to rotate & inspect for flat spots)

REFERENCE (TEST) BAR REQUIREMENTS (Step # 9 of Procedure)Note: Brinell Hardness Testing (BHT) is a self-calibrating method based on hardness impression comparison. Reference bars are M&TE, simply

Calibration standards of "Known" Material Composition & Hardness Values. (SAEP-355, Sect 6)

BHT Reference (Test) Bars are M&TE and shall:

8. Determine the Brinell hardness number by using the slide calculator supplied by the manufacturer

9. Subtract the determined weld hardness from the test bar hardness. The difference should be -10 to +50; if not, discard the hardness reading and do

a retest with a new hardness test bar. The new hardness test bar should have a hardness closer to the weld hardness to improve the hardness reading

accuracy. (Note: See Reference Bar Requirements below)

10. All hardness impressions at one test location should have at least 6.4 mm (0.25 in.) between their nearest edges.

11. Hardness impressions can be made on only two adjacent sides of the hardness test bars.

4. Make the impressions by striking the anvil nut squarely with a 1.4- to 2.3-kg (3.0- to 5.0-lb) hammer. Pull the hammer away so it does not rebound or

restrike the anvil. Note (Technique): Training/practice is needed for consistency in BHT. Technique is checked by indentation roundness (Step 5).

Tolerance for roundness is .1mm. If the indentation does not appear to be perfectly round to the human eye, it almost always is not within specified

tolerances & retest is required. Use eyepiece to verify suspected out of round impressions visually spotted.

5. Measure the impression on weld hardness test site by placing the microscope so that the impression is approximately in the center of the scale.

Adjust eyepiece so the scale and the top of the impression are in sharp focus. Measure the diameter of the impression to nearest half division (0.050

mm [0.002 in.]); it should be between 3.0 to 4.0 mm (0.12 to 0.16 in.) (if not, discard the hardness test and redo it). Rotate eyepiece 90 degrees and

obtain a second diameter reading. If the two diameter readings vary by more than 0.100 mm (0.004 in.) (i.e., the impression is oblong), discard the

hardness test & redo it. If acceptable, average the two diameter readings for a recorded result.

6. Repeat the procedure in Step 5 to measure the impression on the hardness test bar.

7. To do subsequent hardness testing, move the spacing button one notch toward the rear. This ensures that impressions on the hardness test bar are

properly spaced and avoids double impressions. Continue this practice for succeeding impressions until one-half of one side of the bar is covered with

impressions. Then remove and reverse the bar, and again move the spacing button to the extreme front position.

(12-Steps) for Portable Brinell Hardness Testing (BHT) of Welds1. Grind hardness test area flush with base metal. A smooth, relatively flat surface improves accuracy of hardness readings. One method to achieve

this is finish grinding with an 80 or finer grit sandpaper disc. Do not take hardness readings on scaled or discolored areas.

2. Insert the hardness test bar into the holder with the spacing button in the extreme forward position.

3. Ensure that the hardness test block is flat on the test surface.

Attachment 2 - NACE RP0472, Appendix A

Page 7 of 8





2. MiniBrineller (a miniature version of the Telebrinell) is also acceptable per COMPANY. Information on these unit complete kits can be obtained

@ http://www.ndtech.net/products/minibrineller.html Verify 5-10% of Minibrineller readings by BHT (Telebrinell), same as MIC-10.

Page 8 of 8



A7Initial production work of contractor welders shall be monitored by

the project inspector to determine their ability to make sound welds.

SAEP-324,

Para. 6.2.6

A6

Results of RT Film Evaluation by COMPANY

A) Welds rejected for weld quality requiring repair have their original

weld id numbers modified by suffix & progression

(R1, R2, T1, T2, T1R1, T1R2, T2R1, T2R2, etc)

B) Welds rejected for film quality (error exists in SAEP-1160) require

reshoot as follows:

W-01 (Reshoot) ... using lead letter ID

See also SAIC-RT-2010 Checklist

S-PM-G000-1520-

0006,

Section 8.1

A5

Selection of Tracer Welds ... See Attachment 1

A) Two tracer welds must be selected for each rejected weld in a 10% RT

system. The two welds must have been welded by the same welder using

the same welding process and use the NDT method as the initial weld for

evaluation.

B) Progressive sampling of welds (tracer welds) shall follow the

progressive sampling method as stated in governing SAES. Tracer welds

are not to be counted in the 10% sampling process.

S-PM-G000-1520-

0006,

Section 8.1

A4

NDT Control and Identification ... See Attachment 1

This number, once assigned to a weld, shall remain with weld until final

acceptance. Repeated NDT on a weld shall be indicated by adding or

modifying the NDT Report Number suffix similar to that used for weld

repair as stated below.

NDT Process Control Procedure is also req'd. See Notes.

S-PM-G000-1520-

0006,

Section 8.1

A3

Weld Selection for NDT ... See Attachment 1

A) Sequence of Process & NDT is critical. (NDT of PWHT welds for P-

Nos 3, 4 & 5 materials prior to PWHT should be considered for

information only & not final acceptance. The intent is to evaluate the weld

quality prior to PWHT so any unacceptable discontinuities can

be repaired prior to PWHT. (Spec shall state sequence of NDE)

B) NDE Process Control Procedure is used (SAIC-NDT-2010 Series)

C) Design Information & Code Criteria (Based on Service)

... Ex: Severe Cycle Service has different code acceptance criteria

S-PM-G000-1520-

0006,

Section 8.1

A2

Weld Selection for NDT shall be identified (collected, linked, &

maintained for each weld applicable) on an S-PM-G000-1520-0006

Database. When UT is used in lieu of RT the tracking & reporting

requirements shall remain the same. See also SAIC-W-2008 Checklist.

S-PM-G000-1520-

0006,

Section 8.1

AGeneral Requirements for S-PM-G000-1520-0006 Database (Selection of Welds for NDT shall meet S-PM-G000-1520-0006

Reqmts)

A1

Weld Selection for NDT shall be identified in design along with the

Welding specification per line class & per line (SAES-L-310, Sect 7) This

is set forth in a proposed project NDE specification for owner Inspector

approval (COMPANY Assigned Inspector responsibility per ASME B31.3

& COMPANY). Follow

the NDE SATIP & NDE Process Control Procedure

Project NDE

Spec Reqmt,

SAES-L-310,

Section 7






Selection of Welds for NDE (On-Plot Piping & Structures) SAIC-W-2015 11-Dec-13 WELD-




Page 1 of 20

ITEM


C SAES-W-011, Section 17.5 (NDT Coverage) & ASME B31.3 NDE Selection Requirements

B3

INITIAL WELD QUALITY & WELDER STATUS SHALL BE THAT

WELDERS PASS ALL THREE WELDS (INITIAL PRODUCTION).

Note: Welder proceeds with Production subject to the NDE spec.

Welder shall maintain an acceptable repair rate as agreed upon

FAILURE OF ANY OR ALL OF FIRST THREE WELDS SHALL:

A) Result in welder disqualification (Pull JCC, Return to SA)

B) Result in welder close monitoring and retraining and:

1) Additional 100% RT for 1 entire week's production after the initial three

welds were tested (RT) to determine if a welder can make Quality Welds

0.50% Linear, 10% Joint Basis per SAIC-W-2016.

2) Welder shall be given a maximum of 2 full week's production, each

evaluated separately (weekly) or 10 joints minimum to demonstrate his

ability to COMPANY to make sound welds.

SAEP-324,

Para. 6.2.6 &

SAES-W-011,

Para. 8.4 &

S-PM-G000-1520-

0011, Para 19.1.3

See

SAIC-W-2016

(Pre-Job

Agreement)

B2Initial 3* socket welds for each welder are selected for RT.

Welders shall meet all requirements listed in SAIC-W-2037.

B

Initial Testing of Newly Certified Welders (JCC cards have been issued) ... Selection shall be based as follows:

1) Welders shall prove themselves capable of quality welding at the start of production.

2) Quality welding is clearly defined below as related to the start of a Project.

3) Project NDE Specs (Notes) or Process Control Procedure shall specify initial quality to maintain qualifications.

B1

Initial 3* butt welds of each welder are selected for RT.

*Other numbers exceeding 3 may be tested per Contractor. *List

amount tested ____________.

SAEP-324,

Para. 6.2.6

SAEP-324,

Para. 6.2.6

A10

The last acceptable weld is defined as a weld that has been examined

and accepted by both RT (or UT) and all other specified NDT methods

(visual, PT, MT).

A12

CONTRACTOR DATABASE MAKES EVERY ATTEMPT TO MINIMIZE

EXCESSIVE NDE ON 10% LINES BY UTILIZING AN NDE DATABASE

PER WELDER WEEKLY PRODUCTION. This requires "lot & kind" be

established by agreement at the start of the project. Using an "ISO-

based" lot and kind results in excessive NDE exceeding 10% reqmt.

Note: Where less than 100% radiographic coverage is reqd, random

selection of welds is based on the weekly weld production.

S-PM-G000-1520-

0011,

Para. 19.1.9 &

Para. 19.5.2 &

BEST PRACTICE

A11

The "same kind" of weld is defined as: the same process or

combination of processes, same type of joint (groove vs. fillet), and

same P-Number. Different diameters and wall thicknesses may be

classified within the "same kind" of weld.

S-PM-G000-1520-

0011,

Para. 19.1.9

S-PM-G000-1520-

0011,

Para. 19.1.9

A9The progressive examination shall be limited to the specific welder with

the defective welds.

S-PM-G000-1520-

0011,

Para. 19.1.9

A8

For progressive examination requirements, a lot shall be defined as all of

the same kind of welds made since the last acceptable weld, excluding

"penalty" examinations, for a given welder from any previous production

on a specific line classification.

S-PM-G000-1520-

0011 Para.

19.1.9





Selection of Welds for NDE (On-Plot Piping & Structures)

Page 2 of 20

ITEM







C8For on-shore piping, 100% RT is performed on the following:

SEE ATTACHMENT 3

RT Exams

S-PM-G000-1520-

0011,

Para. 19.5.2.1

C7

For on-shore piping, at least 10% of the each week's production weld

(circumferential girth welds), are radiographed for:

SEE ATTACHMENT 3

Shop is an indoor facility approved by COMPANY per SAIC-L-2031.

RT Exams

S-PM-G000-1520-

0011,

Para. 19.5.2.1

C6

Onshore Piping RT & Offshore Piping RT Reqmts:

See Attachment 3 Tables & Notes. Note: Error in Note 2. It should read P-3, P-4, & P-5. These P-Nos are

for Low & Intermediate Alloys. P-6 is not used at COMPANY.

RT Exams

S-PM-G000-1520-

0011,

Para. 19.5.2.1

C5

Weld joints selected due to progressive examination requirements (after

weld defects are found) shall not count toward the required overall exam

frequency (%). Tracer shot is the correct term per S-PM-G000-1520-

0006. Many still refer to the term Penalty* shot. *This implies just

what it is, a Penalty requiring extra work

RT Exams,

S-PM-G000-1520-

0011,

Para. 19.1.9

C4

For welds below 100% RT requirements, selection of welds is based on

the weekly weld production at a minimum. The detailed requirements of

S-PM-G000-1520-0006 apply. (Backlog basis = 7 days)

RT Exams

S-PM-G000-1520-

0011,

Para. 19.5.2

C3

Butt welds in piping shall be RT'd as required below and:

A) If a weld falls under multiple classifications, the most stringent

requirement is applicable.

B) Minimum percent coverage of specified NDT method may be

increased (at any level up to 100%) if, in the opinion of authorized

COMPANY inspector, welds are of questionable workmanship or if NDT

indicates an excessive number of defects.

C) Additional or alternative NDT methods may be used at the discretion of

the authorized COMPANY inspector in order to assist in determining the

type or extent of defects.

RT Exams

S-PM-G000-1520-

0011,

Para. 19.5.2

C2

Visual Examination: (Table 341.3.2 Criteria)

A) All welds shall be visually examined. Visual exam shall be performed

(and accepted) prior to other NDT.

B) Where accessible, welds shall be visually examined from root side to

ensure that proper penetration & fusion have been achieved

C) Service & Category (Normal, D, M, Severe Cycle) must be known

Verify SAIC-W-2007 Final Inspection Checklist is covered thoroughly

& understood by Inspectors performing visuals. Those supervising

NDE ensure techs understand the criteria.

Visual Exams

S-PM-G000-1520-

0011,

Para. 19.5.1

C1

NDT Coverage

All welds are inspected per ASME B31.3 & S-PM-G000-1520-0011.

SERVICE CATEGORY IS DESIGNATED & KNOWN:

A) CATEGORY D = D B)

CATEGORY M = M

C) NORMAL SERV = N

D) SEVERE CYCLE = S

NEVER SELECT OR EVALUATE NDE WITHOUT USING THE

CORRECT SERVICE CATEGORY AND CODE CRITERIA!

SEE ATTACHMENT 2 (ASME TABLE 341.3.2)

S-PM-G000-1520-

0011,

Para. 19.5

Page 3 of 20

ITEM







Special Process

E AWS D1.1 Structural Steel Welding, Repairs & NDE (All Applications of AWS D1.1)

E1

Welding & Selection of NDE meets AWS D1.1 requirements:

A) Visual Examination Criteria

B) Repair Methods & Required Selection of NDE

See Attachment 4 for AWS D1.1 Required NDT.

See

SAIC-M-2012

12-SAMSS-007,

Para. 6.1.6

D2

NDE Process Control Procedure was followed. Database was used to

record NDE results. NDE sequence was followed relative to any special

process such as PWHT. SA Inspector witnessed the NDE.

D WELD MODIFICATIONS AFTER FINAL ACCEPTANCE (SEE ALSO SAIC-W-2036, SAIC-W-2013 & SAIC-W-2015)

D1Engineering Change Notice Procedure* covers such work.

ID, Numbering, NDE & Special Processes are controlled.

C18

All attachment welds on pressurized components that are not

hydrotested after making the attachment weld shall be 100%

examined.

MT/PT Exams

S-PM-G000-1520-

0011,

Para. 19.5.3.2

C17

Pressure containing welds, other than butts, 100% MT/PT.

Includes Branch Connections, Weldolets, Sockolets, & Welding

Bosses ... Any other Groove welded fittings.

MT/PT Exams

S-PM-G000-1520-

0011,

Para. 19.5.3.1

C16

Magnetic Particle Testing & Liquid Penetrant Testing

Magnetic particle testing (MT) for ferromagnetic materials.

Liquid penetrant testing (PT) for non-ferromagnetic materials.

Exception: PT shall be allowed for small diameters where MT (yoke)

is cumbersome & impractical. This includes SW

MT/PT Exams

S-PM-G000-1520-

0011,

Para. 19.5.3

C14

Where multiple welders are used to weld a particular joint, daily weld

record shall indicate the weld area covered by each welder, ie: Root weld,

hot pass, capping etc.

S-PM-G000-1520-

0006, Section 8

C13Weld joints completed by the welder each day are recorded per S-PM-

G000-1520-0006 requirements, Section 8.

S-PM-G000-1520-

0006, Section 8

C12Selection of welds for 10% RT includes welds completed by each welder.

{ASME B31.3, Para. 341.4.1 (b) (1)}as referenced

C11

Selection of welds for 10% RT is strictly controlled by procedure.

RT Process Control Procedure details all aspects of Weld Selection for

NDE. Refer to SAIC-RT-2010 for details.

SAIC-RT-2010

C10

For off-shore top side piping (includes all lines over water, over tidal flats,

or within 30 m of the shoreline), 100% of the welds of piping systems

listed below are selected for radiography:

a. All services other than Category D fluids

b. Stainless steel in chlorinated sea water service.

S-PM-G000-1520-

0011, Para.

19.5.2.2

C9

For off-shore piping top side piping in Category D fluid service above -

18°C (includes all lines over water, over tidal flats, or within 30 m of the

shoreline), 10% of the weekly production welds are random selected for

radiography. These are:

a. Firewater systems

b. Raw water system

c. Pressure sewer system

d. All open non-pressure vents and drains

(NOTES: a. Stainless steel in chlorinated sea water is excluded.

b. Results are interpreted to "normal fluid service".)

S-PM-G000-1520-

0011, Para.

19.5.2.2

Page 4 of 20

ITEM









Initials and Date:






Contractor QC Inspector PID RepresentativePerformed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified



1. SAES-W-011, Welding Requirements for On-Plot Piping, 30 th March, 2005


3. S-PM-G000-1520-0006 SPECIFICATION FOR WELDING PROCEDURE APPROVAL AND WELD STATUS WITH NDT TRACKING


5. American Welding Society (AWS) D1.1 Structural Steel Welding Code (Latest Edition)

6. ASME B31.3, Process Piping, (Latest Edition)



Attachments:

Attachment 1 - S-PM-G000-1520-0006 SPECIFICATION FOR WELDING PROCEDURE APPROVAL AND WELD STATUS WITH

NDT TRACKING

Attachment 2 - ASME B31.3 Process Piping Welding Acceptance Criteria (Table 341.3.2)

Attachment 3 - S-PM-G000-1520-0011 Onshore & OffShore NDE Requirements

Attachment 4 - Structural Steel Welding Requirements, Repairs & NDE (AWS D1.1)


REMARKS:

NOTES: 1) Contractor's NDE Specification (Based on Line Class Tables & Design) & NDE Process Control Procedure shall cover elements

of this checklist and provide clear direction for NDE Service Provider Companies, along with close supervision. This requires training and

coordination between the Prime Contractor supervising the work, any Subcontractor (also supervises work) & the NDE Service Provider.

DO NOT BYPASS THIS CHECKLIST IN LIEU OF A PROJECT NDE SPECIFICATION. USE APPLICABLE ELEMENTS & ATTACHMENTS.


Page 5 of 20


Attachment 1 - S-PM-G000-1520-0006 SPECIFICATION FOR WELDING PROCEDURE

APPROVAL AND WELD STATUS WITH



Page 6 of 20

Page 7 of 20

Page 8 of 20

Page 9 of 20

Page 10 of 20



ASME B31.3 EQUAL LEG FILLET WELD (Fig 328.5.2A) - Acceptable Fillet Weld Shape & Contour

Note: Leg Size shall be determined by Fillet Gage* (Properly Used Depending upon the weld contour)




Page 11 of 20


Page 12 of 20


Page 13 of 20


Attachment 3 - S-PM-G000-1520-0011 Onshore & OffShore NDE Requirements



Page 14 of 20

MT & PT REQUIREMENTS

Page 15 of 20

Mill Discontinuities are resolved per AWS D1.1, NDE dispositioned & repaired as per Table 5.4 below.

AWS D1.1 Allowable Repairs (Note NDE Required)

NOTICE: ENGINEER & SA AUTHORIZED INSPECTOR* APPROVAL REQ'D. (AWS D1.1)





Page 16 of 20

Measurement shall be per calipers or Ultrasonic Thickness Meter if excess weld metal removal is checked

REPAIR OF WELD DEFECTS* FOUND DURING NDT(*Prohibited Discontinuity)

bearing secondary applications are spliced with 100% CJP (10% RT Optional). Visual Exam = OK With Hold Points.

4. Contractor shall specify flush, smooth surface after welding per 5.24.4.1 "as required" for service application.

5. Contractor Inspection (NDE HOLD POINTS): Perform 100% VISUAL ON FIT-UP, ROOT PASS, FINAL

6. Contractor shall notify Authorized SA Inspector of ANY repair or splice weld BEFORE welding.

7. Contractor shall perform supplemental NDT based on Visual Exam (suspect areas, laminations, discontinuities).

QA/QC MGRs & ENGINEER ARE RESPONSIBLE TO IMPLEMENT ABOVE REQUIREMENTS ON PROJECTS.

BEAM & COLUMN SPLICING WELD REPAIRS (NOTICE TO THE CONTRACTOR)1. Contractor shall have approved WPS & Repair Procedure. Cut edges shall be examined* for discontinuities.

2. Contractor shall specify 100% CJP (complete joint penetration) RT Quality welds as detailed in Procedure.

3. RT OR UT SHALL BE SPECIFIED BY ENGINEER AT 100% on butt-welded load bearing* members.

*Main frames and any extensions that are part of the lateral load carrying system such as splice welds for horizontal

piperack beams or vertical columns supporting piping loads in SA Plants. Other shapes (angles, etc) in non-load

AWS NDT Specs (Section 6, Part C)

Notice: NDE shall be clearly defined (as stated in this Attachment or as agreed upon).

NDT SHALL BE SPECIFED (Noted in WPS) - SUBMITTED TO SA INSPECTOR FOR APPROVAL.

UT, MT, PT, RT shall be performed per detailed requirements & Acceptance Criteria Tables of this section.


Mislocated Holes (Common Repair in Plants)

526.5 (1) = VT, MT or PT .... 526.5 (2) = VT, MT or PT & RT (depending on location, severity) ... 526.5 (3) = VT, MT or PT & RT

Page 17 of 20


Page 18 of 20


12-SAMMS-007 WELDING INSPECTION REQMTS

Page 19 of 20

12-SAMMS-008 CORRECTION OF ERRORS (REPAIR PROCEDURE SHALL COPY & PASTE ELEMENTS)

PIP STS05130 CORRECTION OF ERRORS (REPAIR PROCEDURE TO INCLUDE)

Page 20 of 20

ITEM


A8

Weekly Weld Data is submitted each week per S-PM-G000-1520-0006,

Sections 8 & 9 (Butt weld, Socket & Fillet for Special Processes).

See Attachment 1

Note: For limited scope project work, fewer than 500 groove/butt weld

joints, contractor may elect to use hardcopy tracking system with

approval of SA Insp Dept. Reporting for these projects shall use the

applicable SATR such as:

SATR weld/welder reports: SATR-W-2013

Weekly Welders Reject Rate, SATR-W-2018

Weekly Welder Repair & Tracer, SATR-W-2019

Weekly Weld Status Report, SATR-W-2008 Weld Summ Report

S-PM-G000-1520-

0006

A7

Root cause or causes of weld defects are determined, evaluated and

recorded. Corrective actions on the root causes are initiated to prevent

recurrence of the weld deficiencies.

Schedule "Q",

Para. 7.3.4,

Para. 7.3.5

A6

Progressive examination is performed for every weld of the welder whose

weld has failed the RT. Refer to Attachment 2 for the method of

progressive examination. ( ASME B31.3, Para. 341.3.4)

S-PM-G000-1520-

0011,

Para. 19.1.9

A5Project Quality Plan has indicated corrective actions for welders whose

weld repair rate has exceeded agreed weld repair rate.Procedure

A4

Project Weld repair rate and individual Welder repair rate have not

exceeded maximum weld repair rate agreed upon in the project.

NOTE: Indicate the agreed Target Weld Repair Rate: __________%

Procedure,

Basis is:

(Linear, Joint)

A3

Placing welders with unacceptable "BUTT WELD" repair rates on

socket welding IS PROHIBITED unless:

A) Welder passes qualification on first 3 production socket welds per

the detailed requirements of SAIC-W-2037.

B) Welder is closely monitored for conformance to approved WPS

regarding technique (QW 410 & other WPS Process Parameters.

Procedure,

Basis is:

(Linear, Joint)

A2

Monitoring of Weld Repair Rate as stated in the Contractor Procedure

[COMPANY Assigned Inspector Targets 5% (Joint Basis) & 0.10%

(Linear Basis) quality] with attention to the welders who do not conform

to Quality goals. Welders exceeding 10% (Joint Basis) & 0.50%

(Linear Basis) shall be retrained, monitored, & subject to additional*

NDE: A) Random

additional* weekly Production is examined for that week and evaluated on

a weekly & overall basis. (Up to 100% per COMPANY)

B) Three weeks in a row (repair rate evaluated each week) above these

limits shall result in a loss of welder qualification (butt welds).

COMPANY shall request return of JCC & welder reassignment/removal

BUTT WELDS

Procedure

Requirement,

Basis is:

(Linear, Joint)

S-PM-G000-1520-

0006,

Section 9 &

Sch Q

A Repair Rate Assessment (S-PM-G000-1520-0006 & PROCEDURE REQMTS)

A1Type of defects found either by visual or by NDE (welds rejected) are

identified & recorded per SAEP-1160. See Attachment 1.

S-PM-G000-1520-

0006,

Section 8






Production Weld & Welder Repair Rate Assessment for

On-Plot Piping SAIC-W-2016 11-Dec-13 WELD-




Page 1 of 8








Initials and Date:






1, Schedule Q, Contractor's Quality Requirements, (December 2005 Edition & later)


3. S-PM-G000-1520-0006 SPECIFICATION FOR WELDING PROCEDURE APPROVAL ANDWELD STATUS WITH NDT TACKING

4. ASME B31.3, Process Piping, (Latest Edition)

REMARKS:

ATTACHMENTS:

ATTACHMENT 1 - S-PM-G000-1520-0006 SPECIFICATION FOR WELDING PROCEDURE APPROVAL ANDWELD STATUS WITH NDT TACKING

ATTACHMENT 2 - Progressive Examination Requirements for COMPANY Plant Piping

A9

Actual Backlogs in accordance with S-PM-G000-1520-0006, Section 8.3.

shall be reported. See last page of Attachment 1 for elements.

Note: A backlog exists when Special Process results are not received &

recorded within a project-specific time, usually 7 days, after the welds

have been visually accepted.

S-PM-G000-1520-

0006,

Para. 8.3






Page 2 of 8



Attachment 1 - S-PM-G000-1520-0006 SPECIFICATION FOR WELDING PROCEDURE APPROVAL ANDWELD

STATUS WITH NDT TACKING



Page 3 of 8

Page 4 of 8

Page 5 of 8

Page 6 of 8

Page 7 of 8

doing "fill & cap" for joints have to be assessed a repair against their record. Determined by RTFI & verified by Inspector

witnessing excavation (SAIC-W-2013)

S-PM-G000-1520-0006 SECTION 8 PROGRESSIVE SAMPLING REQUIREMENTS

S-PM-G000-1520-0006 SECTION 8 PROGRESSIVE SAMPLING REQUIREMENTS

Clarifications (S-PM-G000-1520-0006 & S-PM-G000-1520-0011): There may be situations where only one Tracer Weld can

be selected. This shall be documented by Quality with reason listed for a single Tracer (Approved by Prime Supervising

Contractor & COMPANY). Per S-PM-G000-1520-0011, weld repairs of welds using "multiple welders" shall attribute such

repairs (and penalty shots) to a given welder. This gets complicated when welders making "root & hot pass" & welders



Attachment 2 - Progressive Examination Requirements for COMPANY Plant Piping



Page 8 of 8

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cut-off - June 2008) Rev 3 30-Jun-08


Control of Welding Consumables - Plant Piping

(Site Storage, Handling, Conditioning & Issuance) SAIC-W-2032 11-Dec-13 WELD-







A CONTROL OF WELDING CONSUMABLES (General Requirements)

A1

An approved procedure exists that has incorporated the following:

A) SAIC-W-2009 Checklist (Procedure for Welding Consumables)

B) SAIC-W-2010 Checklist (Receiving Inspection of Consumables)

C) SAIC-W-2032 Checklist (Control of Welding Consumables)

D) SATR-W-2009 - Rod Oven Calibration (Storage, Bake, Portable)

E) SATR-W-2010 - Welding Consumable Issuance Record

F) SATR-W-2020 - Recv Insp Detail Form & QC log (Consumables)

SCH. Q, Att. IV

Table

(Procedure)

A2

Personnel involved in handling, storage, conditioning, issuance & controls

for use of welding consumables are identified with detailed responsibilities

and trained in the procedure use as follows:

A) Material Controller (Receipt, Control, Storage, Handling, Issue, etc)

B) Welding Foreman/Supervisor (Issue, Distribution, Control, Return)

C) QC Inspector (Monitors approved procedure and all activities)

D) Welders (Follows approved procedures and controls)

Note: Clear cut responsibilities are understood by all.

SCH. Q, Att. IV

Table

(Procedure)

A3

Procedure has provided details on how welding consumables are controlled

by the following but not limited to:


B) Material controller- Stock control (First in, First out) & issuance

C) Requestor/User - Issue & Receiving of consumables (Daily Basis)

D) Return of un-used consumables, ID system & reconditioning

Procedure is being followed by all responsible for the work.

SCH. Q, Att. IV

Table

(Procedure)

S-PM-G000-1520-

0011

Para. 8.3

B Storage of Welding Consumables (SAIC-W-2009 is to be incorporated into a Consumable Control Procedure)

B1

GTAW filler metals have either AWS/ASME identification or the

manufacture's identification marked on each individual rod, by the

manufacture, with flags, stencils or stamps.

S-PM-G000-1520-

0011

Para. 8.3

B3Storage ovens have continuous power supply during working and non-

working hours or days (nights and weekends).

SAES-W-011,

Table 1

B2

Partially used GTAW filler metals have either AWS/ASME identification

(with flags, stencils or stamps) or the manufacture's identification marked

on each individual rod for traceability.

B4Re-bake ovens have calibrated Temperature Gauge.

(Note 1 of SAES-W-011, Table 1)

SAES-W-011,

Table 1

SAES-W-011,

Table 1

B5Portable electrode storage ovens are regularly checked for keeping

temperature at a minimum of 65C.

SAES-W-011,

Table 1

B7Atmospheric exposure of low hydrogen electrodes shall not exceed

Manufacture recommendation time period.

S-PM-G000-1520-

0011

Para. 8.2

B6Low hydrogen electrodes, stainless steel and other non-ferrous electrodes

are kept in hermetically sealed metal containers.



Page 1 of 10






C Handling & Conditioning of Electrodes

C1

The electrodes which has exceeded the permitted atmospheric exposure

as stated in Item B7 above and electrodes belongs to damaged

hermetically sealed containers shall undergo drying prior to its re/issue

for welding as per Manufacture recommendation.

S-PM-G000-1520-

0011

Para. 8.2

S-PM-G000-1520-

0011

Para. 8.2

C2Electrodes are re-dried as per Manufacture recommendation and marked

or segregated prior to re-issue as per SAES-W-011.

SAESS-PM-G000-

1520-0011

Para. 8.2/SAES-

W-011,Table 1

C4

Dried electrodes & electrodes removed directly from its hermetically

sealed containers are stored in holding ovens as per Manufacture

recommendation.

S-PM-G000-1520-

0011

Para. 8.2

C3Drying of electrodes was performed as per Manufacture recommendation.

C5Any electrodes (low hydrogen or non-low-hydrogen) and fluxes that have

been wet or moist are discarded.

SAES-W-011,

Attachment 1&2

S-PM-G000-1520-

0011

Para. 8.2

C6Electrodes exposed to the atmosphere for less than the permitted

duration are re-conditioned as per manufacture recommendation.

S-PM-G000-1520-

0011

Para. 8.2

C8 All fluxes are stored in sealed containers in a dry environment.SAES-W-011,

Attachment 2

C7Non-low hydrogen electrodes to A5.1 or A5.5 are stored as per

manufacture recommendation.

C9Opened SAW flux containers are stored continuously in ovens at 65C

minimum, or at mfg's recommendation, whichever is greater.

SAES-W-011,

Attachment 2

SAES-W-011,

Attachment 2

C10

All electrodes are stored as per manufacture recommendation & filler

wires for SAW, GTAW, GMAW, & FCAW are stored in sealed containers

in dry environment. Attachment 1/3.

SAES-W-011,

Attachment 2

C12GTAW Tungsten Consumable Preparation & Redressing or Repair:

Practices utilize the proper equipment. See Attachment 2.

SAES-W-011,

Attachment 2

C11All electrodes and filler wires for SAW, GTAW, GMAW, and FCAW that

have visible rusting or contamination are discarded.

C13

Shielding gases have vendor certs attesting to the purity of their products

for the gases listed below:

A) Carbon dioxide (CO2): Federal Specification BC-C-101, Type B or


B) Argon (Ar): Compressed Gas Association CGA G-11.1 (99%+)

See Attachment 4

S-PM-G000-1520-

0011

Para. 8.7

C14Stainless Steel & Non-Ferrous electrodes have color coded ends to

prevent mixing electrodes. (Lessons Learned)

Procedure

Requirement

D1

A project specific procedure or method statement for electrode issuance,

receiving and return was approved by SAPMT and Inspection (PID) per

SAIC-W-2009.

Best Practice

D Control of Electrode Issuance and Return

D2

A detailed list of checkpoints are added to this checklist after approval of

the procedure for control of electrode issuance, receiving and return is

approved.

Best Practice



Page 2 of 10








REMARKS:

Page 3 of 10












ATTACHMENTS: 1 - Consumable Control Practices Acceptable to COMPANY

Attachment 2 - GTAW Consumable Control Procedural Elements (Tungsten Electrodes & GTAW Filler Metal, Purging Consumables & Control)

Attachment 3 - SAES-W-011 - Conditioning, Storage & Exposure of Consumables (SAW Att. 2)




Contractor QC Inspector COMPANY InspectorPerformed Inspection Work / Rework May Proceed T&I Witnessed


Name, Organization,






Page 4 of 10



B) Electrodes older than 2* years shall not be used to make production welds on Saudi Aramco Projects. Electrodes shall be discarded or removed

from site to prevent their inadvertent use. Contractor shall assure electrode issue control follows a "First In, First Out" Rule.

*Note 1: Three (3) years shelf life is acceptable when demonstrated that mfg storage guidelines were met. (Temp/Humidity Controls)

*Note 2: When storage climate is questionable* (*Dry Environment = Air conditioned/dehumidified with calibrated hygrometer in use) electrodes

shall be limited to a shelf life of 2 years (max). See AWS Table for acceptable "storage before opening" limits.

*Note 3: Lincoln currently recommends a 3-year shelf life in certain brands of SMAW electrodes. When a manufacturer data sheet specifically states

detailed storage conditions (humidity & temperature) and a shelf life beyond three years, and storage requirements have been followed (as verified by

Quality), electrodes may be used for a period per manufacturer's instructions (to a three-year limit).



Attachment 1 - Consumable Control Practices Acceptable to COMPANY

C) Electrodes found open and stored outside acceptable Manufacturer & Welding Industry recommended ranges shall be declared unfit for use

and removed from site to prevent their inadvertent use on Saudi Aramco Projects. Check E6010 storage closely.

Dry Environment Note: Air conditioned or climate controlled storage in cabinets within recommended temp ranges and relative humidity values

(verified by hygrometer) shall be demonstrated. In any disagreement, Electrode Mfg recommendations shall be made available and COMPANY shall

resolve all conflicts. Unacceptable is storage of Electrodes in open buildings subject to wide humidity ranges.

Typically, relative humidity can range from 5%-nearly 100% in Saudi Arabia in open areas without climate controls

Note: The Table above applies to AWS A5.1 & AWS A5.5 and is intended for reference only relative to the COMPANY requirement for a DRY

ENVIRONMENT. SAES-W-011 Attachments 1 & 2 shall be affixed to procedures and followed.

4. STORAGE & HOLDING TEMPS AFTER OPENING: 1. Per Lincoln, Electrode cans shall never be placed in ovens as cardboard liners char &

electrode temps are not uniform. CSD concurs with this point. 2. Per Lincoln, store non low hydrogen electrodes (6010, 7010, etc) from freshly

opened containers in heated cabinets at 100 to 120 degrees F (40 – 50 degrees C). AWS table above suggests 75 to 125 F.

SAES-W-011 states Dry Environment. CSD concurs that AWS & Lincoln temp ranges & a 50-70% relative humidity (typical air conditioned

room) constitute a "dry environment" acceptable for storage of opened non low hydrogen electrodes. CSD also concurs that opened non

low hydrogen electrodes (6010, 7010, etc) shall never be stored above 130F or below 50%RH

Best Practice is to operate a small oven (Bench, cabinet or Portable type) set at 100 F to maintain these conditions.

1. All Welding Consumables (electrodes*, filler wires, and fluxes) shall conform to ASME SEC IIC. (SAES-W-011, Para. 6.1) & shall meet an

applicable AWS specification & classification as packaged. Identification labelling shall clearly identify the product & Manufacturer certs (test reports)

shall attest to the correct AWS specification & classification. When "other" Non-ASME electrodes have been specified & are COMPANY approved

(through the WPS process), the same general controls shall apply. A Roster or Log shall be kept for each project(s) with documentation available for

Receiving (SATR-W-2010) and storage. Storage shall conform to the mfg detailed storage requirements as listed and available (attach to records with

Mfg Certs for all consumables). All welding consumables shall have manufacturer data sheets that show detailed storage requirements (temperature &

humidity limits at a minimum), or correspondence to provide adequate instruction in this regard. Shelf life shall be considered. Note: * Electrodes

shall include tungsten electrodes for GTAW process per AWS A5.12

Note: Welding Consumables shall have a SAP ID number to show their purchase from an approved vendor for specific consumable.

Best Practice for Vendor Uninspectable Welding Consumables is close receipt inspection & test report review, and by Inspection visit* to Vendor at

least once (COMPANY recommended). Currently, inspection visits are not required. Best Practice for electrodes* is their purchase specifically for

new projects in quantities based on Workscope using COMPANY-approved WPS as a basis for ordering consumables.

2. New consumables shall be received into Contractor's Quality system by recording pertinent information as listed on SATR-W-2020.

3. Existing consumables (shelf life) intended for use on Saudi Aramco Projects shall be evaluated for their quality and condition as follows & they

shall meet COMPANY, Welding Industry & Manufacturer recommended minimum quality requirements (with disposition) as follows: When meeting

applicable quality conditions, existing consumables shall be recorded into the Contractor's Quality System.

A) Electrodes without proper AWS Spec/Class labelling and/or traceability to manufacturer certs (records shall be kept for all consumables)

shall not be used on Saudi Aramco Projects and shall be removed from site to prevent their inadvertent use on Project work.

Page 5 of 10





Attachment 2 - GTAW Consumable Control (Procedural Elements)TUNGSTEN ELECTRODES & GTAW FILLER METAL CONSUMABLES

























































Page 6 of 10






Page 7 of 10






Individual gas components are identified by the following codes:

A - Argon

C - Carbon Dioxide

He -Helium

H - Hydrogen

N - Nitrogen

O - Oxygen

CGA-G4 Oxygen

CGA-G5 Hydrogen

Table 4 - AWS Classifications for Typical Gas Mixtures:

All cylinders and containers shall be marked in accordance with DOT regulations plus the following information, legibly

marked on, or attached to, each cylinder: i) AWS specification and classification designation (year of issue may be excluded).

ii) Supplier’s name and product trade designation (name of gas)

CGA-G6 Carbon Dioxide

CGAG6.3 Carbon Dioxide Cvlinder Filling and Handling Procedures

CGA-P-9 The Inert Gases Argon, Nitrogen, and Helium

P- 1 Safety Handling of Compressed Gases in Containers

iii) Approved DOT warning label

The following example designates the minimum labeling requirement to comply with this specification:

Table A l - Additional Information From Compressed Gas Association (CGA):-

REFERENCEITEM


D2

Welding power supplies are calibrated as per BS 7570 or an approved

equivalent, if impact toughness test is required by COMPANY or industry

specifications or codes. Calibration records shall be available to

COMPANY.

S-PM-G000-1520-

0011,

Para. 21.2

D Miscellaneous Requirements:

D1When field welding in "remote" locations, remote Current controls shall be

used if the welding is > 30 m from welding power sources.

S-PM-G000-1520-

0011,

Para. 21.1

C4Fittings re-cut or re-beveled shall have cut surface examined for

laminations before welding. COMPANY shall specify NDT method for use.

S-PM-G000-1520-

0011,

Para. 13.2.3

C3Thermal cut surfaces of stainless steel and non-ferrous materials shall be

ground to bright (unoxidized) material prior to welding.

S-PM-G000-1520-

0011,

Para. 13.2.2.3

C2Thermally cut or gouged surfaces for all materials, including carbon

steels, shall be power brushed or ground prior to welding.

S-PM-G000-1520-

0011,

Para. 13.2.2.2

C Joint Preparation:

C1

Oil, moisture, rust, scale, sand, paint or other foreign matter shall be

removed from weld surface ≥ 25 mm of adjacent base metal prior to

welding, including any such coatings on temporary attachments.

S-PM-G000-1520-

0011,

Para. 13.2.1

B2Buttering of joints between dissimilar metal joints requires prior approval

by COMPANY. (Through WPS review process)

S-PM-G000-1520-

0011,

Para. 13.2.5.2

B ALIGNMENT / Fit-up:

B1

Buttering or weld build-up on prepared surfaces shall not exceed the

lesser of ⅓ of the base metal thickness or 10 mm without the approval of

COMPANY. If the buttering or buildup exceeds this, then the following

requirements shall apply: a) The

buttering operation shall be witnessed by COMPANY.

b) The buttering shall be inspected by RT, and PT or MT after completion

of the build-up but before final welding of the joint.

S-PM-G000-1520-

0011,

Para. 13.2.5.1

A3

All welders and welding operators shall be qualified in accordance with

either ASME SEC IX, as applicable, for all welding, including tack,

temporary, and repair welds.

S-PM-G000-1520-

0011,

Para. 10.1

A2All WPSs & PQRs shall conform to the latest edition of the relevant

Code (API STD 1104 or ASME SEC IX, as appropriate).

S-PM-G000-1520-

0011,

Para. 9.2.1

A Documentation:

A1All WPS's, PQR's, & weld maps/tables to be used, shall have been

submitted as a complete package, for technical approval by COMPANY.

S-PM-G000-1520-

0011,

Para. 9.1.1


SAUDI ARAMCO USE ONLYSAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?




Buttering and / or Weld Build-up - Plant piping SAIC-W-2033 11-Dec-13 WELD-




Page 1 of 2






Initials and Date:








2. BS 7570:2000, Code of practice for validation of arc welding equipment.


REMARKS:

Buttering and / or Weld Build-up - Plant piping SAIC-W-2033 11-Dec-13 WELD-




Page 2 of 2

ITEM


A11Welders shall carry an ID card that includes a photo, welders name,

company ID No. and welder symbol.

SAEP-324,

Para. 6.3.1

A10

A Welders List shall be submitted to COMPANY Assigned Inspector prior

to the start of work. This list shall be maintained up to date by fabricator.

The list shall include welders name, symbol, processes qualified and all

other important essential variables as well as certification issue dates.

S-PM-G000-1520-

0011, Para.

10.2

A9

Validation is maintained for each welder's work continuity within the range

of his qualification in full project. When welder has not welded with a

process during 6 months or more, his qualifications shall expire, per

ASME IX, QW-322.1

S-PM-G000-1520-

0011, Para.

10.1

A8

COMPANY Assigned Inspector shall audit welder certifications to ensure

fabricator compliance with the Codes, standards and approved Quality

Plan.

SAEP-324,

Para. 6.3.3

A7

Initial production work of contractor welders shall be monitored by the

project inspector to determine their ability to make sound welds.

SAIC-W-2015 shall be utilized (Socket & Butt welds) for this purpose.

The first three welds (or more*) are to be RT'd. Use SAIC-W-2015 or

approved procedure* (*if more than 3). Return JCCs

when welders fail to meet this Quality requirement .

SAEP-324,

Para. 6.2.6

See

SAIC-W-2015

A6Certifications of contractor welders shall be reviewed by the COMPANY

Assigned inspector prior to the start of work. A roster shall be provided.

S-PM-G000-1520-

0011, Para.

10.2

A5

Essential Variables of Welder Qualification Certificate meet project

welding requirements, or, service condition and material type of piping &

structures being welded. Essential variables are per ASME Section IX,

QW-350 for the applicable process. See Attachment 1

SAES-W-011,

Para. 8.1

A4Contractor welders working on projects shall be tested & certified by an

COMPANY approved independent welder testing agency.

SAEP-324,

Para. 6.2.2

A3Contractor welders shall be tested as per either ASME SEC IX, AWS

D1.1, or API STD 1104 as required, for ALL types of welding.

S-PM-G000-1520-

0011, Para.

10.1

A2For SMAW performance qualification testing, welders shall be qualified

for all passes and the full thickness of the test coupon.

SAEP-324,

Para. 6.1.4

A General Requirements (Certification Review & Issuance of JCCs)

A1All welders and welding operators shall be qualified in accordance with

the ASME SEC IX as applicable for all welding.

S-PM-G000-1520-

0011, Para.

10.1






Welder & Welding Operator Certification, Issuance of JCC (Job

Clearance Card) & Review of Performance (Plant Piping)SAIC-W-2035 11-Dec-13 WELD-




Page 1 of 6

ITEM







Initials and Date:







REMARKS:




3. ASME SECTION IX (1 July 2004), Welding and Brazing Qualifications

B2

A) JCCs may be withdrawn at any time 'for cause', if the welder is not

producing work of acceptable quality (per approved procedure)

B) JCCs are reissued only after documented retraining (clearly

documented on welders performance/continuity record)

See Attachment 2 - Weld Quality Guideline @ COMPANY

Welder performance according to ASME SEC IX

SAEP-324,

Par 6.5.4

B1

JCC's shall be returned to COMPANY Assigned Inspector when

contractor welder goes on home leave or is terminated from the project.

NOTE: Contractor welders that return to work within three months from

home leave (to the same project) may be reinstated without retesting.

SAEP-324,

Para. 6.5.5

BSpecific Requirements (Return JCCs, Evaluate Performance / Revoke & Reissue JCCs)

Note: Pre-Job Agreement & Welding Process Control Procedure are required

N/A RE-INSP DATE






Page 2 of 6

with each welding process, exclusive of any weld reinforcement, this thickness shall be considered the

test coupon thickness as given in QW-452. In any given production weldment, welders may not deposit a

thickness greater than that permitted by QW-452 for each welding process in which they are qualified.

Socket welding note: Qualification shall also require RT of the first three production welds per SAIC-W-2037 reqmts.

QW- 351: A Welder shall be requalified whenever a change is made in one or more of essential variables

listed for each welding process. Where a combination of welding processes is req'd to make a weldment,

each welder shall be qualified for the particular welding process or processes he will be required to use

in production welding. A welder may be qualified by making tests with each individual welding process,

or with a combination of welding processes in a single test coupon. The limits of weld metal thickness for

which he will be qualified are dependent upon the approximate thickness of the weld metal he deposits



Attachment 1 - ASME Section 9 (QW-350 & Tables, QW-452 & Tables) for Common Welder Qualifications



Page 3 of 6

Attachment 1 - ASME Section 9 (QW-350 & Tables, QW-452 & Tables) for Common Welder Qualifications

Page 4 of 6

Pre-Job Agreement by Procedure: Job Clearance Cards may be withdrawn by the project inspector at any time for cause

if the contractor welder is not producing work of acceptable quality. Weld Quality Guidelines must be agreed upon and

stated in the Contractor's Welding Process Control Procedure BEFORE the start of welding on Projects. Once

withdrawn, JCC's will only be reinstated upon receipt of written proof of training, and the successful completion of a

recertification test. Recertification test shall be supported by NDT on an agreed upon number of production welds (3

minimum) after retraining as a minimum. The welder must pass these welds and maintain an acceptable weekly repair

rate as stated in the Procedure. Reinstated Welders with JCC cards who fail to produce quality work may not reapply for

another JCC (in that process) for a minimum period of retraining to be approved by the Company.

Performance measurement: % Repairs obtained per joint and linear basis. Both methods shall be calculated and

the higher percentage rate shall govern. The maximum weekly repair rate for each welder should not exceed

3.0%.

Performance monitoring frequency: Daily (reported weekly)

Acceptance criteria % repair rate:

≤3.0% = Acceptable

4.99＜,＞3.0% = Warning letter issued by Subcontractors QC Manager

≥5.0% = Training and Requalification

Criteria for requalification shall be minimum 7 days training followed by a requalification test. Welder raining

and records shall be maintained. If the welder fails the requalification test further training may be given and a

second test may be taken. If the welder fails the second test then CONTRACTOR will not allow the welder to

weld on the Project.

Attachment 2 - Weld Quality Guideline at COMPANY (Reference - Welding Process Control Procedure)





Page 5 of 6

3. Procedure shall detail NDT requirements of initial Welder production to determine

acceptability of welder performance, especially with new welders.

a. First three joints as a minimum shall be examined. Procedures may require a

quantity greater than the first three (first 5, first 10, etc), especially for new welders.

b. Welders shall not make additional initial production welds until their “initial

performance” has been verified and is acceptable per the procedure.

PROCEDURE NOTES … Welder Performance Evaluation Guideline

6. Pipeline Projects using Semiautomatic / Automatic / Combination Processes may

utilize even more stringent Weld Quality Guidelines than those listed above for

Manual process. Procedure & Pre-Job agreement define Quality targets.

7. In all cases, Welder performance should target “A” Classification results with

the lowest possible Linear & Joint Repair Rates achievable. (Continual Process

Improvement)

1. Contractor’s Welding Process Control Procedure (Company approved) shall clearly

state acceptable Welding Performance parameters for each welder's initial, weekly &

overall production. This is agreed opon BEFORE Work begins.

2. Procedure shall define Linear & Joint method performance targets and these

quality targets shall be acceptable to COMPANY and approved before welding

begins.

4. Procedure states maximum number of consecutive weeks that a welder can

exceed performance targets before being removed from work. Severe weather or

other factors beyond welder control may be considered. (Schamaal months)

5. Procedure shall state the amount of NDT up to 100% when target repair rates are

exceeded or when a welder has been removed from Work.

Page 6 of 6



Inspect/Verify Piping & Weld Modifications* After Initial Welding

Acceptance (Modifications, Repair and Rework)SAIC-W-2036 11-Dec-13 WELD-








Note

This checklist is to ensure that Piping & Weld Modifications* are properly identified, reported to SA, tracked & documented by Quality

Systems on IK Projects. Contractor QA/QC Mgrs shall incorporate these quality elements into their two Procedures for WELDING PROCESS

CONTROL & FIELD ENGINEERING CHANGE CONTROL. QA/QC Mgr Action on IK Projects.

A IDENTIFICATION OF CHANGES & CONTROLS FOR QUALITY (PRIOR TO WELD REWORK & REPAIRS)

A1Quality Procedure for Field Engineering Change Control has been

reviewed and approved by the COMPANY PQM.

SCH Q, ATT VI

TABLES

A2

Quality Procedure for Field Engineering Change Control identifies

scenarios for the basis of weld modifications. Such

possibilities are detailed in the checklist below to aid QC.

SCH Q, ATT VI

TABLES

A3

Quality Procedures utilize a "common sense" approach for Piping &

Weld Modifications by (definition):

Rework is when entire weld(s) or piping spool(s) or system requires

change from existing conditions per Field Engineering:

A) Weld joint misalignment & damage (dogleg, bent, damaged)

B) Rework to achieve specified fabrication tolerance (slope, spacing

for other piping & insulation, structural clearances, etc.

C) Rework for any drawing & piping specification revisions that may

or may not affect existing identified welds.

D) Rework due to unacceptable root pass (Internal FBE)

Rework proposed is carefully planned and shall follow procedure.

Rework may or may not require Weld Repairs to identified welds.

Rework can include one or more "Repairs" to identified welds.

SCH Q, ATT VI

TABLES

S-PM-G000-1520-

0006, Section 8

A4

Repair is when an "identified" weld requires any excavation, cutting,

grinding, heating or physical change not associated with the normal WPS

approved process, interpass cleaning & surface prep for final acceptance

and any NDE surface conditioning.

SCH Q, ATT VI

TABLES

A6

The minimum distance between parallel butt welds shall be 20 mm or

three times wall thickness of the joint, whichever is greater.

Repairs shall not violate this "encroachment" rule.

Distances shall be measured between the edges of the adjacent cap

passes. These restrictions do not apply if one of the welds has been

PWHT'd prior to making a second weld or both welds have been PWHT'd

& inspected. Radiography of butt welds is always req'd when minimum

separation is not achieved.

S-PM-G000-1520-

0006, Para

11.15.1

A5

Weld Modification (Repair) of a Previously Welded joint requires:

A) Was given a Unique Welding ID number per S-PM-G000-1520-0006.

B) Was accepted by the QC Inspector responsible for Fit-Up

C) Was welded out and completed or was partially welded before STOP

WORK was issued on the piping system under construction or other

direction was given to welder(s) responsible for the joint.

Welds modified at this stage in any way are "Repairs", once welding

has begun following fit-up acceptance by Inspection, even if no NDT was

performed on the joint. Correction methods shall follow an approved

"Repair" procedure using an approved WPS.

Example: Dogleg joint (cracked tack, etc). Excavation & removal of any

weld metal shall follow an approved procedure.



Page 1 of 2



Inspect/Verify Piping & Weld Modifications* After Initial Welding

Acceptance (Modifications, Repair and Rework)SAIC-W-2036 11-Dec-13 WELD-


A7Welds requiring re-work are physically identified on site, marked &

verified by Inspection prior to performimg any repair/rework.

Special Process

Procedure

A8 Method of identifying weld re-work follows a procedure.Special Process

Procedure

A9Procedure or method statement for repair/rework is submitted and

approved by COMPANY.

Special Process

Procedure

S-PM-G000-1520-

0011,

Para. 20.1

A10 Weld Map has indicated the location of weld to be re-worked.Special Process

Procedure

A12

Detailed checklist identifies inspection requirements/acceptance criteria

in the same fashion as the SAICs is formed and submitted for

concurrence. (Required if a relevant SAIC is not available.)

Special Process

Procedure

A11

History of the weld was verified and if found to have been repaired twice

shall be recommended for additional repair attempt or be cut-out at the

descretion of the assigned COMPANY Inspector.

A13

Welds requiring re-work by heating shall require approval by COMPANY.

If approved, all conditions & inspection requirements / acceptance criteria

are added to this checklist or in a separate checklist.

Special Process

Procedure

S-PM-G000-1520-

0011,

Para. 20.5

A14Welds requiring re-work by cutting and re-welding are prepared &

inspected per applicable inspection checklists & Welding SATIPs

Project Quality

Plan

A16As-built of weld map and weld summary reports are updated to reflect the

status of the new or modified weld.

S-PM-G000-1520-

0011,

Para. 20.5

A15Reworked welds requiring re-welding are inspected using the original

testing method (as minimum requirement).


REMARKS:



2. SAES-W-012, Welding Requirements for Pipelines, (31 December, 2002)





Contractor QC Inspector COMPANY InspectorPerformed Inspection Work / Rework May Proceed


ITEM



REFERENCE


PASS FAIL N/A RE-INSP DATE


Name, Organization,

Initials and Date:





Page 2 of 2

Z


SAUDI ARAMCO TEST REPORT SATR NUMBER DATE APPROVED QR NUMBER

Positive Material Identification (PMI) Report SATR-A-2012 12/11/2013 MECH-




SCHEDULED TEST DATE & TIME ACTUAL TEST DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME



Material Type: (Weld, Valve, Pipe, Weld, etc.) Item Description: (Material Spec/Grade)

Type Of Instrument Used:

Model:

Serial No:

Date Of Calibration:

Required Element Composition per Spec

(Verify against ASME IIC Spec Tables)C

_____Cr

_____Ni

_____Mo

_____Nb

_____Ti

_____Cu

___ _____

Analysis Result: (Evaluate Results in conjunction with SAIC-L-2010 Checklist & Attachments)

Elements Verified (per SAES-A-206, Table 1) Results of Chemical Analysis

C Cr Ni Mo Nb Ti Cu Zn Accept Reject Pending

Analysis

NOTES: C=Carbon, Cr=Chrome, Cu=Copper, Ni=Nickel, Mo=Molybdenum, Nb=Niobium, Ti=Titanium, Zn=Zinc

1. Alloys are acceptable if the alloying elements are each within 10% of the specified range of values. (S-PM-G000-1520-0008, Para. 12.1)

2. Welds with consumables that match, or nearly match, the base metal composition shall be within ±12.5% of the ranges allowed in ASME SEC IIC

for each element. (S-PM-G000-1520-0008, Para. 12.2). Chemical Composition of Material specs must be verified/available.

3. For weld overlays, the chemistry on the surface of overlays shall be in accordance with S-PM-G000-1520-0008, Para. 12.3

4. For dissimilar metal alloy welds (other than weld overlays), the effects of dilution from the different base metals and the filler metal shall be taken

into account for determining the nominal as-deposited weld metal composition. (S-PM-G000-1520-0008, Para. 12.3)

REMARKS:


1. S-PM-G000-1520-0008, Positive Material Identification,





*Person Responsible for Implementation of Test and Analysis of Results Y = YES N = NO F = FAILED



Initials and Date:



Equipment/

Line Number/

P.O. & line item

Color Code

00-SAIP-07 Att III

& PFI ES-22

Weld

or

Part

No

Contractor QC Inspector COMPANY InspectorPerformed Inspection Work / Rework May Proceed T&I Witnessed

Page 1 of 1



Positive Material Identification (PMI) Log Sheet SATR-A-2013 12/11/2013 MECH-







NOTES: Per S-PM-G000-1520-0008, Para. 14.1.2 - The log shall identify each component and weld corresponding to an individual equipment item or

piping spool and shall include the equipment or spool number and purchase order number. To supplement this log, where applicable (per S-PM-G000-

1520-0008, Para. 14.2.3), the field Fabricator shall prepare a detailed PMI map of the pressured equipment being fabricated. The map shall show the

alloy material specification of each alloy component and the extent of PMI required per this standard.

Log No. Plant / P.O. # Equipment / Line # Item DescriptionPMI Report No. &

DateRemarks

REMARKS:


1. S-PM-G000-1520-0008 - Positive Material Identification










Initials and Date:



REMARKSSERVICE DIA. WTHEAT

RATE

COOL

RATE

SOAK

TEMP.

SOAK

TIME

Item

No.

ITEM

DESCRIPTIONDRAWING NUMBER

MAT.

TYPE

Name, Sign and Date: Name, Initials and Date:

Verified

QC Supervisor COMPANY Inspector



Contractor / Third-Party Saudi AramcoEngineering/Construction Representative* COMPANY PMT Representative


PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR LOCATION

QR NUMBER

Post-Weld Heat Treatment Request SATR-W-2004 11-Dec-13 WELDING


SAUDI ARAMCO TEST REPORTSATR NUMBER DATE APPROVED

Page 1 of 1


SAUDI ARAMCO TEST REPORT SATR NUMBER DATE APPROVED PRODUCTION DATE

PWHT Report Form SATR-W-2005 11-Dec-13

PROJECT TITLE CONTRACT NUMBER CONTRACTOR LOCATION

PWHT PWHT Recorder

Weld IDReq. No.

Chart

No.

Loading Temp

(0C)

Rate of

Heating

(oC/Hr)

Soaking

Temp (0C)

Soaking Time

(Mins)

Rate of

cooling

(oC/Hr)

Unloading

Temp (oC) Serial No Cal. Due date

Item # Line class SizeWelder

IDRemarksDrawing No. Material

Type of

JointWeld ID

Req. No.Chart

No.

Loading Temp

(0C)

Rate of

Heating

(oC/Hr)

Soaking

Temp (0C)

Soaking Time

(Mins)

Rate of

cooling

(oC/Hr)

Unloading

Temp (oC) Serial No Cal. Due date

Note: PWHT chart should be attached with this report. This form should be used with applicable PWHT procedure.

PREPARED BY QC VERIFIED REVIEW & VERIFIED REVIEW

Technician (Third Party) QC Insp. / Supervisor - Subcon QC Insp. / Supervisor COMPANY Inspector

Name, Sign

and Date:

Name, Sign

and Date:Name, Sign

and Date:

Name, Sign

and Date:

Item # Line class SizeWelder

IDRemarksDrawing No. Material

Type of

Joint

Size Sch Type Item Heat No Size Sch Type ItemHeat

No.

1

2

3

4

5

6

7

8

9

10


DAILY WELD FIT-UP and PRODUCTION REPORT-PLANT PIPING SATR-W-2006 WELD-


Page NO. 1of 1

Project Fit-Up Inspection Welder ID No.

DAILY WELD FIT-UP and PRODUCTION REPORT

(WIR)

Record No.

Rev. No. 0

ITP No.

“A” Material “B” Material

Note: Joint Type : BW-BUTT WELD, SW-SOCKET WELD, TR-THREADED, BR-BRANCH, RP-PAD, OL-OLET Item: P-PIPE, F-

FLANGE, E-ELBOW, T-TEE, R-REDUCER,WO-WELDOLET,SO-SOCKOLET,C-CAPSubcontractor COMPANY PMT

Name

Signature

Date

Serial

No

ISO

Drawing

No.

Sht No. Rev. No.Joint

No.

Joint

TypeS/F

WPS

NoRoot &

Hot

Fill &

Cap

VT

QR NUMBER

WELD-

CONTRACTOR

1of 1

0

Note: Joint Type : BW-BUTT WELD, SW-SOCKET WELD, TR-THREADED, BR-BRANCH, RP-PAD, OL-OLET Item: P-PIPE, F-

FLANGE, E-ELBOW, T-TEE, R-REDUCER,WO-WELDOLET,SO-SOCKOLET,C-CAP

COMPANY PMT

Remark

Inspecti

on

Date

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

DIA

ME

TE

R

TH

ICK

NE

SS

LE

NG

TH

(M

TR

)

WE

LD

NO

.

ND

E C

AT

10

% o

r 1

00

%

PIPEHEAT

NO.

QR

NUMBER

MA

TE

RIA

L

SP

EC

IFIC

AT

ION

an

d G

RA

DE

RE

J RT

UT

MT

PT

OT

HE

R

FIT-UP

INSPPOST VISUAL

DA

TE

FIT

-UP

PR

EH

EA

T

TE

MP

ER

AT

UR

E

DA

TE

WE

LD

ING

CO

MP

LE

TE

D

COMPANY PMT REPRESENTATIVE NAME SIGN DATE

COMPANY Inspector NAME SIGN DATE

DATE

Contractor QC Inspector NAME SIGN DATE

Subcontractor QC Inspector NAME SIGN

DRAWING NO. LINE NO. LINE CLASS

SPOOL ID WELDER I.D. NDE REQUESTED

ITE

M

BE

ND

ING

DE

G.

RO

OT

A

RO

OT

B

FIL

L A

FIL

L B

CA

P A

CA

P B

WE

LD

PR

OC

ES

S

TY

PE

OF

WE

LD

WP

S

AC

C

RE

J

AC

C


SATIP NUMBER SATIP ACTIVITY NUMBER CONTRACTOR INSP LEVEL SUBCONTRACTOR INSP LEVEL ARAMCO INSP LEVEL QTY INSP MH's SPENT TRAVEL TIME

DAILY WELD FIT-UP and PRODUCTION REPORT (Field Weld)-PIPELINE SATR-W-2007 WELD-



SAUDI ARAMCO TEST REPORT SATR NUMBER DATE APPROVED QR NUMBER REPORT DATE

PW

HT


TRAVEL TIME

LOCATION

30-Jun-08

REPORT DATE

1

2

3

4

5

6

7

NAME: NAME:

SIGN: SIGN:

DATE: DATE:

PM

I R

EP

OR

T N

UM

BE

R

DA

TE

ND

E W

AS

CO

MP

LE

TE

D

RE

MA

RK

S

TR

AC

ER

WE

LD

S

OT

HE

R N

DE

RE

PO

RT

NU

MB

ER

PW

HT

PW

HT

RE

PO

RT

NU

MB

ER

HA

RD

NE

SS

TE

ST

ING

HA

RD

NE

SS

TE

ST

ING

RE

PO

RT

NU

MB

ER

PM

I

TE

ST

ING

AC

C

RE

J

OT

HE

R N

DE

OT

HE

R N

DE

TY

PE

FILM

QUALITY

WELD

QUALITY

10%

100%

%

REVIEWED

AC

C

RE

J

T1 T2

2nd R

T R

EP

AIR

1

RE

PO

RT

NU

MB

ER

RE

SU

LT

3rd

RT

RE

PA

IR 2

RE

PO

RT

NU

MB

ER

RE

SU

LT

PE

RC

EN

TA

GE

OF

ND

E

RE

QU

IRE

D

DA

TE

ND

E W

AS

RE

QU

ES

TE

D

ND

E R

EQ

UE

ST

QR

NU

MB

ER

1st R

T

RE

PO

RT

NU

MB

ER

RE

SU

LT

DA

TE

WE

LD

ED

WP

S N

UM

BE

R

WP

S P

AR

AM

ET

ER

S

VE

RIF

IED

PO

ST

VIS

UA

L

RE

SU

LT

PO

ST

VIS

UA

L

INS

PE

CT

ION

QR

NO

.

FIL

L A

FIL

L B

CA

P A

CA

P B

DIA

ME

TE

R

WE

LD

PR

OC

ES

S

FIT

-UP

DA

TE

FIT

-UP

IN

SP

EC

TIO

NQ

R

NU

MB

ER

RO

OT

A

RO

OT

B

GR

AD

E

SP

OO

L N

UM

BE

R

WE

LD

TY

PE

SC

HE

DU

LE

DATE: DATE:

SIGN: SIGN:

WELDING SUPERVISOR SUBCONTRACTOR QC INSPECTOR CONTRACTOR QC INSPECTOR COMPANY Inspector

NAME: NAME:

PREPARED BY: VERIFIED BY: REVIEWED AND APPROVED BY: REVIEWED BY:

ITE

M N

UM

BE

R

WE

LD

NU

MB

ER

LIN

E N

UM

BE

R

LIN

E C

LA

SS

MA

TE

RIA

L

WELD SUMMARY, WELDER PERFORMANCE & SPECIAL PROCESS (NDE, etc) TRACKING SYSTEM WELDERS SYMBOL SAUDI ARAMCO RT FILM EVALUATION

ISO

ME

TR

IC

DW

G N

UM

BE

R


DATE

WELD SUMMARY, WELDER PERFORMANCE and NON-DESTRUCTIVE (NDT) TRACKING SYSTEM SATR-W-2008 WELD-


SAUDI ARAMCO TEST REPORT SATIP NUMBER SATR NUMBER DATE APPROVED QR NUMBER

A

B

C

D


Test Performed Successfully and Results are Acceptable:


Name, Sign and Date:


Contractor QC Supervisor Proponent and OthersT&I

WitnessedQC Record Reviewed Work Verified

Name, Organization,

Initials and Date:



Witnessed Test Work / Rework May ProceedT&I


Name, Title, Department,

Company, Initials and Date:

Contractor /Subcontractor Saudi AramcoTechnician Performing Test* COMPANY PMT Representative

T&I


REMARKS:

REFERENCE DOCUMENTS: 2. S-PM-G000-1520-0010, Welding Requirements for Pressure Vessels


3. SAES-W-012, Welding Requirements for Pipelines, (31 December, 2002)

4. SAES-W-017, Welding Requirements for API Tanks, (7 December, 2005)

Re-Calibration Due Date

C3Approved as Portable

Oven

C2Approved for

Electrode drying

RESULT

C1Approved for

Electrode storage

B2 430°C

THERMOSTAT SETTINGThermometer

ReadingThermometer Reading Thermometer Reading Thermometer Reading

B1 120°C

A2 Serial Number

A1 Brand/Make:

WELDING ROD OVEN TEMPERATURE CALIBRATION/VERIFICATION

Electrode Oven/Quiver No. UNIT # ____ UNIT # ____ UNIT # ____ UNIT # ____






Welding Rod Oven Calibration/Verification Report SATR-W-2009 11-Dec-13 WELD-




Page 1 of 1

% +

/ -

Pass

Fail



Welding Machines Verification Report SATR-W-2011 11-Dec-13 WELD-


NOTES:

1) Switch on the equipment 5 minutes before any calibration measurements.

2) Start with the minimum output setting, energize and stabilize the power source for 10 s; then take a reading.

Repeat this procedure for each of the measurement points below the maximum.

3) After a further 10 seconds take a second reading at the maximum setting, and repeat this procedure for each of

the measurement points down below the minimum.

4) The power source should not be loaded greater than that shown on the rating plate.

5) If validation at a particular current and/or voltage is required, but the nature of the load does not permit that

current or voltage at the corresponding load voltage or current to be achieved, take points over and below the

desired values and calculate the required value.

Ambient Temp: ____ ° C Supply Voltage: _______ V Function under test: Current Control Voltage Control

Validation method:

Load Resistor Meter Yype

Type of validation:

Accuracy PrecisionGrade of validation (Att. 1 - Table's 1 ): STANDARD

Range of function under validation: a) full range of the control or meter; b) partial range of the control or meter;

c) selected points over the range of the control or meter. (Note: Items b) or c) shall be agreed upon by Contr. & S. Aramco )

External load: Conventional load (BS EN 60974-1, Para. 7.4); Arc Load

Current Control Verification Voltage Control Verification

Power Source

Dial Setting -

(amps)

Power

Source Meter

Reading -

(amps)

Test

Instrument

Reading

(amps)

% +

/ -

Pass

Fail

Power Source

Dial Setting -

(volts)

Power

Source Meter

Reading -

(volts)

Test

Instrument

Reading

(volts)

1 - 1 -

2 - 2 -

1 -

2 - 2 -

1 - 1 -

2 - 2 -

1 - 1 -

2 - 2 -

Avg:

_____

1 -

2 - 2 -

Avg:

_____

Avg:

_____

1 -

RESULT:



2. BS 7570, Code of Practice for validation of Arc Welding Equipment, (2000)

3. BS EN 60974-1, British Standard - Arc Welding Equipment-Part 1: Welding Power Sources, (30 September, 2003)

ATTACHMENTS:

1. Acceptance Criteria for STANDARD Grade of Validation: * Table 1 - Validation accuracies for standard grade power sources;

* Table B.1 - Validation accuracies for wire feed equipment: * Conventional Load (Test) to BS EN 60974-1, Para. 7.4











Initials and Date:

Avg:

_____

Avg:

_____

Avg:

_____

1 -

Avg:

_____

Avg:

_____

Avg:

_____

Avg:

_____

Page 1 of 1

Attachment 1 - Acceptance Criteria for STANDARD Grade of Validation


SAUDI ARAMCO TEST REPORTSATR NUMBER DATE APPROVED QR NUMBER

Conventional Load (Test) to BS EN 60974-1, Para. 7.4

Welding Machines Verification Report SATR-W-2011 MECH.



UNIQUE WELD IDENTIFICATION

Isometric, Line Class/Line No, Weld

Joint No, Spool No, (Welder ID No),

Other unique ID No

DIA. THK

SOUR

SERV

Y/N

RESULT/COMMENTS

(Accept, Unacceptable**)

** Further Investigation req'd

T&I Witnessed QC Record Reviewed Work VerifiedName, Organization,

Initials and Date:

QC Record Reviewed





Contractor QC Inspector COMPANY InspectorWitnessed Test Work / Rework May Proceed T&I Witnessed Work Verified

Name, Title, Department,

Company, Initials and Date:

Test Performed Successfully and Results are Acceptable:

Contractor / Third-Party Saudi AramcoTechnician Performing Test* COMPANY PMT Representative



REMARKS: 1. Tech & QC followed SAIC-W-2014 Checklist (Approved Procedure per SAIC-W-012) before accepting results.

2. Joint code is: B = Butt weld (aligned in same plane, use Telebrinell), F = Fillet weld (Use MIC-10 or Minibrineller for small fillets),

O = Other joint (Groove welds such as weld bosses, O-lets, others with extreme curved geometry, inaccessible to Telebrinell)

3. Identify any randomly selected welds for Sour Service Line Classes & show Random Sampling Extent (Use Comments)

TEST BAR & WELD RETESTS MARKED (Y / N or N/A): 10% Random Selection* (Y / N / Other Extent):

Note*: 10% Random Weld Selection (Per Sour Service Line Class, By Welder, Joint Type, & Repairs (Use Comments Section):

EQUIVALENT BRINELL TEST

RESULT

HAZ WELD HAZ

PWHT

Y/N

JT*

Type

B/F/O

CODE: MAT'L/Class/Gr/P-No:

EQUIPMENT (Check or list as applicable): Telebrinell _____ MIC 10 _____ Minibrineller _____ CSD App'd Other:

TEST BAR(S) - BNH VALUE AS STAMPED: BHN CRITERIA (SAIC-W-2014):






Hardness Test Report (With S-PM-G000-1520-0006 Weld Tracking

Criteria)SATR-W-2012 11-Dec-13 WELD-



SAUDI ARAMCO TEST REPORTSATR NUMBER DATE APPROVED QR NUMBER

Page 1 of 1

SUB-CONTRACTOR INSP LEVEL

100% 10% 100% 10% 100% 10% 100% 10% 100% 100% 10% 100% 10% 100% 10% 10% 100% 10% 100% 10% 100% 10%

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

SIGN DATE

SIGN DATE

SIGN DATE

SIGN DATE

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - June 2008) Rev 3 6/30/08

SAUDI ARAMCO TEST REPORT SATR NUMBER DATE APPROVED QR NUMBER REPORT DATE

WEEKLY WELDER REPAIR RATE REPORT SATR-W-2013

PROJECT TITLE CONTRACT NUMBER CONT. LOCATION


SATIP NUMBER SATIP ACTIVITY NUMBER CONTRACTOR INSP LEVEL ARAMCO INSPECTION LEVEL QTY INSP MH's SPENT TRAVEL TIME

WEEKLY WELDER REPAIR RATE REPORT

LINEAR/JOINT BASIS

THIS WEEK CUMULATIVE THIS WEEK CUMULATIVE

10% 100%

ITE

M

REJECT

%

INCHES

REMARKS

NUMBER JOINTS

WELDED

NUMBER JOINTS

RT

NUMBER JOINTS

REJECTED

REJECT

%

JOINT

NUMBER

JOINTS

WELDED

REJECT

%

INCHES

NUMBER

INCHES

WELDED

Subcontractor QC Inspector NAME

Contractor QC Inspector NAME

COMPANY PMT REPRESENTITIVE NAME

COMPANY Inspector NAME

NUMBER

INCHES

RT

NUMBER

INCHES

REJECTED

NUMBER

INCHES

REJECTED

SYMBOL

NUMBER JOINTS

RT

WELDERS

NAMENUMBER OF

JOINTS

REJECTED

REJECT

%

JOINT

NUMBER INCHES

WELDED

NUMBER INCHES

RT

SATR NUMBER

WELDER's SYMBOL

SIGN

SIGN

SIGN

SIGN


SAUDI ARAMCO TEST REPORT DATE APPROVEDQR NUMBER REPORT DATE

WELDER REPAIR ASSESSMENT and TRACER WELD REPORT-WEEKLY SATR-W-2018 WELD-



SATIP NUMBER SATIP ACTIVITY NUMBER CONTRACTOR INSP LEVEL SUBCONTRACTOR INSP LEVEL ARAMCO INSP LEVELMH's SPENT TRAVEL TIME

WELDER's NAME QUALIFICATIONS

REPAIR WELD RESULTS TRACER WELD RESULTS

ITE

M

CUT OUT

R1 R2 R1 R2

RESULT

NDT

REPORT

NUMBER

NDT

REPORT

NUMBER

P2

P1

P1

P2

P2

P1

P1

P2

P2

P1

Subcontractor QC Inspector NAME DATE

Contractor QC Inspector NAME DATE

Contractor QC Supervisor NAME DATE

COMPANY Inspector NAME DATE

1

2

3

4

5

RESULT RESULT

NDT

REPORT

NUMBER

WP

S

NU

MB

ER

INITIAL

WELD DEFECTS

DRAWING

NUMBER

RE

JE

CT

ED

WE

LD

NU

MB

ER

TR

AC

ER

WE

LD

NU

MB

ER

DA

TE

WE

LD

ED

LINE

NUMBER

RESULT

WE

LD

PR

OC

ES

S

NDT

REPORT

NUMBER

CUT OUT

QTY. INSP. MHR's SPENT TRAVEL TIME

FROM TO

A B C D E F G H I J K L M N O P Q R

Categories

Joints

Welded

This Week

RT

Requested This

Week

RT

Completed This

Week

RT

Accepted This

Week

RT

Rejected

This Week

Tracer

Welds

Required

This Week

Joints

Re-Shoot

This Week

Joints

Re-Shoot

Last Week

(Backlog)

Number

of

RT Crews

Weld

Length

RT'd

(Inches)

This Week

Length

Weld

Defects

(Inches)

This Week

Reject Rate (%)

Joint

Method

This Week

Reject Rate (%)

Linear

Method

This Week

RT

Backlog

RT

Backlog

Alarm

Reject Rate Alarm

(Green-<5%)

(Red>5%)

1 100% 0 0 0 0 0 0 0 0 0 0 0 #DIV/0! #DIV/0! 0 0 #DIV/0!

2 10%+ 0 0 0 0 0 0 0 0 0 0 0 #DIV/0! #DIV/0! 0 0 #DIV/0!

3Additional Welds

100% 0 0 0 0 0 0 0 0 0 0 0 #DIV/0! #DIV/0! 0 0 #DIV/0!

4 Sub-Total 0 0 0 0 0 0 0 0 0 0 0 #DIV/0! #DIV/0! 0 0 #DIV/0!

5 100% 0 0 0 0 0 0 0 0 0 0 0 #DIV/0! #DIV/0! 0 0 #DIV/0!

6 10%+ 0 0 0 0 0 0 0 0 0 0 0 #DIV/0! #DIV/0! 0 0 #DIV/0!

7Additional Welds

100% 0 0 0 0 0 0 0 0 0 0 0 #DIV/0! #DIV/0! 0 0 #DIV/0!


FROM TO

A B C D E F G H I J K L M N O P Q R

Categories

Joints

Welded

To Date

RT

Requested

To Date

RT

Completed

To Date

RT

Accepted

To Date

RT

Rejected

To Date

Tracer

Welds

Required

To Date

Tracer

Welds

Completed

To Date

Re-Shoot Required

To Date

Re-Shoot

Completed

To Date

Weld

Length

RT'd

(Inches)

To Date

Length of

Weld

Defects

(Inches)

To Date

Reject Rate (%)

Joint

Method

To Date

Reject Rate (%)

Linear Method

To Date

RT

Backlog

RT

Backlog

Alarm

Reject Rate Alarm

(Green-<5%)

(Red>5%)

1 100% 0 0 0 0 0 0 0 0 0 0 0 #DIV/0! #DIV/0! 0 0 #DIV/0!

2 10%+ 0 0 0 0 0 0 0 0 0 0 0 #DIV/0! #DIV/0! 0 0 #DIV/0!

3Additional Welds

100% 0 0 0 0 0 0 0 0 0 0 0 #DIV/0! #DIV/0! 0 0 #DIV/0!


5 100% 0 0 0 0 0 0 0 0 0 0 0 #DIV/0! #DIV/0! 0 0 #DIV/0!

6 10%+ 0 0 0 0 0 0 0 0 0 0 0 #DIV/0! #DIV/0! 0 0 #DIV/0!

7Additional Welds

100% 0 0 0 0 0 0 0 0 0 0 0 #DIV/0! #DIV/0! 0 0 #DIV/0!


NAME NAME NAME

SIGN SIGN SIGN

DATE DATE DATE

DATE

WEEKLY and CUMMULATIVE WELD STATUS REPORT SATR-W-2019


PROJECT TITLE WBS/BI/JO NUMBER CONTRACTOR/SUBCONTRACTOR LOCATION


SATIP NUMBER SATIP ACTIVITY NUMBER CONTRACTOR INSPECTION LEVEL MAIN CONTRACTOR (LSTK) INSP. LEVEL SAUDI ARAMCO INSPECTION LEVEL

PROJECT WELD STATUS REPORT

WEEKLY WELD REJECTION STATUS

0 0 0 0

Fab Shop

Welds

Field Welds

WEEKLY

TOTALS0 #DIV/0!0 0 0 0

CUMULATIVE WELD REJECTION STATUS

#DIV/0! 0 0 #DIV/0!0 0

0 0 0 0

Fab Shop

Welds

Field Welds

COMMULATIVE

TOTAL0 #DIV/0! #DIV/0!0 0 0 0

PREPARED BY: QC VERIFIED BY: REVIEWED & VERIFIED BY: REVIEWED BY:

0 0 #DIV/0!0 0

NAME

CONSTRUCTION REPRESENTITIVE QC INSPECTOR/SUPERVISOR MAIN CONTRACTOR or LSTK REPRESENTITIVE COMPANY Inspector

DATE

SIGN


Name, Organization,

Initials and Date:


Work is Complete and Ready for Inspection:

PASS FAIL N/A RE-INSP DATEREFERENCE


Date

Rec'd

SIZE

Diam/L

Manufacturer & Product Description

(UNIT PACKAGE TYPE & WEIGHT)



INSPECTION REMARKS

* See Attachment for Tests on

Received Consumables



QC Supervisor Proponent and OthersT&I Witnessed QC Record Reviewed Work Verified

Witnessed Test Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified


QC Inspector COMPANY Inspector

Issue

Consumables for

Project & WPS

listed below

REMARKS:

Contractor / Third-Party Saudi AramcoConstruction Representative* COMPANY PMT Representative

A6

Above material (certs) were reviewed against the intended welding application

(WPS, PQR). Essential variables & SA rqmts were checked per the applicable

"SAIC" for Consumable Control (incl any WPS Cover Sheet Remarks by CSD).

Consumable is acceptable for use on the WPS listed in Remarks

ASME SEC II C,

Consumables

Applicable

SAES-W-Std

A5

The above specified materials were received into stock for use on SA Projects on

date(s) shown. Physical Inspection was performed along with review of the SA

Approved Consumable Manufacturer Test Reports (attached to report). Records

included material & test certifications. These were checked against the applicable

ASME II C Consumable specification (SFA 5.1, 5.4, 5.5, etc) and all material &

testing reqmts met the listed minimum acceptable requirements.

Complete section using the applicable SAIC for Receiving Insp.

ASME SEC II C,

Consumables

SFA 5.01

Check

Application

(WPS & PQR)

before Issuing

Consumables

A4

PMI test of weld metal* (*deposited or undiluted "buttons") was performed prior to

welding or during initial welding process. Note: Certain weld rods have alloying

elements contained in the flux, & do not meet alloy spec until welded. To weld

"buttons" ... simply open the applicable spec (SFA 5.5, etc) and refer to the Figure 1

- Pad for Chemical Analysis of undiluted Weld Metal ... follow instruction

SAES-A-206,

Section 7.7

(See Attachment)

A3

One consumable from each lot is PMI-tested. Remainder of lot shall be compared

to the identified consumable to verify that markings of electrodes & filler wires are

correct. Log any unique markings (mfg codes)

SAES-A-206,

Section 7.7

A2Ensure inventory control is established to account for ALL of those consumables

that are checked-out. (Issue Slip/Proc). SATR-W-2010

SAES-A-206,

Section 7.7

INSTRUCTIONS: DO NOT USE ELECTRODE OR FILLER MAT'L "LOTS" on SA Projects for production welding until PMI tests verify composition.

At the latest, test the first production weld. Test consumables immediately after receipt to avoid "surprise" of "bad batches". Specs requiring PMI at COMPANY are:

SFA-5.4 SS Electrodes (SMAW) --- SFA-5.5 Low-Alloy Electrodes (SMAW) --- SFA-5.6 Copper & Alloy Electrodes --- SFA-5.7 Copper & Alloy Rods & Electrodes

SFA-5.9 Bare SS Electrodes & Rods --- SFA-5.11 Nickel & Alloy Electrodes (SMAW) --- SFA-5.12 Tungsten & Alloy Electrodes --- SFA-5.13 Surfacing Electr. (SMAW)

SFA-5.14 Nickel & Alloy Bare Electrodes & Rods --- SFA-5.21 Bare Electrodes & Rods, Surfacing --- SFA-5.22 SS Electrodes (FCAW) & SS Flux Cored Rods (GTAW)

SFA-5.23 Low-Alloy Electrodes & Fluxes (SAW) --- SFA-5.28 Low-Alloy Electrodes & Rods (GMAW) ---SFA-5.29 Low-Alloy Electrodes (FCAW)

A1Electrodes are properly stored & segregated in stores, shops, or ovens to avoid mix-

up. Use separate ovens for different type* consumables. (*CS, Low Alloy)

SAES-A-206,

Section 7.7

ITEM


ASME II C / AWS Unique ID No.

SPEC CLASSBatch/

Blend/

Mix/Heat Lot*


SAUDI ARAMCO USE ONLYSAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?




Welding Consumable Receiving Insp Report SATR-W-2020 11-Dec-13 WELD-PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR



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