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

REV 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

SAIC-M-2012

Inspection of Structural Welding (Per AWS D1.1)


PROJECT TITLE

CONTRACT NUMBER

Rabhic Phase II Petrochemical Project CP2

6600030687

EQUIPMENT ID NUMBER(S)

EQUIPMENT DESCRIPTION

LAYOUT DRAWING NUMBER

REV. NO.

SCHEDULED INSPECTION DATE & TIME

ACTUAL INSPECTION DATE & TIME

30-Jun-08
DATE APPROVED QR NUMBER

11-Dec-13

MECH -

CONTRACTOR

ASYAD / DAELIM
EQPT CODE

SYSTEM ID.

PURCHASE ORDER NUMBER

PLANT NO.

EC / PMCC / MCC NO.


QUANTITY INSP.

MH's SPENT

TRAVEL TIME

25 June to 30 June - 2016/08:00AM to 06:00PM 25 June to 30 June - 2016/08:00AM to 06:00PM


SAUDI ARAMCO TIP NUMBER

SAUDI ARAMCO ACTIVITY NUMBER

SATIP-M-001-01

3.11, 3.12, 3.13

SAUDI ARAMCO INSPECTION LEVEL

CONTRACTOR INSPECTION LEVEL

CONTRACTOR INSPECTION LEVEL

ITEM
No.

ACCEPTANCE CRITERIA

REFERENCE

General Requirements

A1

Procedure (Prequalified per AWS D1.1 2004 or earlier edition) has been
12-SAMSS-007,
reviewed and approved for application by Project Inspection.
Para. 7.5
Welders have valid JCCs and are qualified for structural welding.

A2

12-SAMSS-007,
Materials to be welded have been received & inspected and are
Material
properly identified & traceable to Certified Mill Test Reports or Certificate
Specifications
of Compliance (Specification). SAIC-M-2003

A3

Approved Drawings are available for the work and provide detailed
12-SAMSS-007,
instruction for the weld joint & weld dimensions.
Para. 6.4.1
Shop drawings and erection drawings shall be prepared per the AISC
& Para. 7.10
documents listed in 12-SAMSS-007.

B1

B2

B3

B4

B5

WORK PERMIT REQUIRED?

YES
PASS

FAIL

N/A

Pre-Welding Inspection ... Assumes Equipment Checks are accepted for Associated Welding (Piping, Vessels, etc)
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)
12-SAMSS-007,
Para. 7.5
C) Checks for
Attachment 2
laminations
Observance of
smoke with objectionable fumes may indicate welding is being done on
fouled
surfaces for
(Cleaning
inadequate)
Joint alignment
Butt Welds
shall be 10% offset or 1/8" (3mm)
AWS D1.1,
whichever is smaller. Stiffener & gusset plates shall be fitted per dwg
Section 5.22
tolerances (max gap 1/16" or 2mm) See Attachment 4.
& Section 5.23
Welding environment is acceptable for welding. Attachment 2.
Similar rules for Piping are followed (Same Procedure)
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.
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. 5.12
AWS D1.1,
Para. 5.6 &
Para. 3.2
(Preheat Tables)

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

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
AWS D1.1,
into the final weld shall be cleaned thoroughly. Multiple-pass tack welds
Section 5.18
shall have cascaded ends.

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RE-INSP DATE

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

REV 3
SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC-M-2012

Inspection of Structural Welding (Per AWS D1.1)


PROJECT TITLE

ITEM
No.

ACCEPTANCE CRITERIA

REFERENCE

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.

ASYAD / DAELIM
PASS

FAIL

N/A

RE-INSP DATE

AWS D1.1,
Section 5.18

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


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

FINAL Welding Inspection & Acceptance

D1

Repairs 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

D4

MECH -

CONTRACTOR

6600030687

C3

D3

12/11/2013

CONTRACT NUMBER

Rabhic Phase II Petrochemical Project CP2

C2

30-Jun-08
DATE APPROVED
QR NUMBER

12-SAMSS-007,
Para. 7.6 (a)

Visible & measured welding distortion is within AWS D1.1 tolerances AWS D1.1,
listed in Attachment 4.
Section 5.23
VISUAL EXAMINATION CRITERIA (Use Attachment 3):
A) Weld Profiles are acceptable per Attachment
3.
B) Table 6.1 Visual acceptance criteria was AWS D1.1,
met
8 Imperfections are listed.
Section 5.18
Welds were gauged & accepted

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
Subcontractor QC Inspector

Saudi Aramco
COMPANY PMT Representative

Performed Inspection

Work / Rework May Proceed

Name, Initials and Date:

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

Name, Initials and Date:

Contractor QC Inspector

COMPANY Inspector

Performed Inspection

Work / Rework May Proceed

Name, Initials and Date:

Name, Initials and Date:

Contractor QC Supervisor

Proponent and Others


Quality Record Approved:

Name, Initials and Date:

Name, Organization,
Initials and Date:

*Person Responsible for Completion of Quality Work / Test

Y = YES

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N = NO F = FAILED

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

REV 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

SAIC-M-2012

Inspection of Structural Welding (Per AWS D1.1)

30-Jun-08
DATE APPROVED
QR NUMBER

12/11/2013

MECH -

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

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

REV 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

30-Jun-08
DATE APPROVED
QR NUMBER

SAIC-M-2012
11-Dec-13
MECH Attachment 2 - Structural Steel Pre-Welding, In-Process Inspection & Repair Requirements (AWS D1.1)

Inspection of Structural Welding (Per AWS D1.1)

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

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

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

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Attachment 2 - Structural Steel Pre-Welding, In-Process Inspection & Repair Requirements (AWS D1.1)
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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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 2 (Standards Cutoff - June 2008)

REV 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

30-Jun-08
DATE APPROVED
QR NUMBER

SAIC-M-2012
12/11/2013
MECH Attachment 3 - Structural Steel Welding Acceptance Criteria (AWS D1.1)
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.
Inspection of Structural Welding (Per AWS D1.1)

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


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


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"

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)

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

REV 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

30-Jun-08
DATE APPROVED
QR NUMBER

SAIC-M-2012
11-Dec-13
MECH Attachment 4 - Structural Steel Welding Reqmts & Tolerances at Saudi Aramco (Per AWS D1.1)

Inspection of Structural Welding (Per AWS D1.1)

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)

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

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

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

REV 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

30-Jun-08
DATE APPROVED
QR NUMBER

SAIC-M-2012
12/11/2013
MECH Attachment 5 - Structural Steel Welding Requirements, Selection of NDE (AWS D1.1)

Inspection of Structural Welding (Per AWS D1.1)

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)

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

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.

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

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


12-SAMMS-007 WELDING INSPECTION REQMTS

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

PIP STS05130 CORRECTION OF ERRORS (REPAIR PROCEDURE TO INCLUDE)

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