Experience Base - QA/QC Standards

Experience Base - 2019
With ARAMCO Engineering

Standard & Procedure
SHAHID ALI
Course Provider (CSWIP, B.Gas, API, NDT, ISO, HSE)
Cell#: 00966-599-807084
Cell#: 0092-334-7497876
Email: ss_aakash@yahoo.com
Web: www.qctrainer.com
What is QA?
Quality Assurance is the system of action and planning, which is required to provide maximum
confidence for quality requirements.
What is QC?
Quality Control is the operational techniques i.e (Inspection, Testing & Examination) that are used to
fulfill requirement for quality.
What are the basic responsibilities of a QA/QC personal?

To ensure the execution of works are comply fully as per approved Code, standard & procedure.
What is schedule Q?
Schedule Q is a part of contract agreement between Client and Contractor that does contain client’s
minimum quality requirements for specific project or contract.
What is PQP?
Project Quality Plan – It is the document which describes that how contactor will manage the scope of
work based their quality system correlated to client’s Schedule Q.
What is PQR?
Procedure Qualification Record -A PQR is a record of welding data (variables) during weld a test coupon
that performed and tested (more carefully) to ensure that the procedure will produce a good weld.
What is WPS?
Welding Procedure Specification - It is a written document that provides the direction to the welder or
welding operator for making production welds.
What is WQT?
Welder Qualification Test –Check the ability of welder to deposit (make) of sound weld metal.
(Details in: SAEP-321)
Welding:
A permanent union between two metals caused by heat of pressure.
Welder: (ASME Sec-IX)

One who performs a manual or semiautomatic welding operation.
Welding Operator: (ASME Sec-IX)

One who operates machine or automatic welding equipment.
What is ITPs?
ITP: ITP means Inspection and Test Plan. Details of work scope and required types of inspections
What are QA/QC’s ITP’s?

This is procedure informs about the kinds of quality check (surveillance inspection witness or hold points)
means quality of works is being done in proper sequences.
Hold point (H) is the level of inspection that client inspection must required through RFI and cannot be
proceed until inspection is done by client.
Witness point (W) is the level of inspection that inspection activity can be proceeded without client
inspection or if client is not available as per RFI timing.
Surveillance: Client Inspection to monitor work in progress without notice from Construction
organization
Complied By: Shahid Ali (Pak: 0334-7497876)–(KSA: 0599-807084) Email: ss_aakash@yahoo.com P: 1/44
What is NCR? Why does it need for a QA/QC personal?
NCR means Non-Conformance Report, QA/QC personal has reserve the right to issue a warning if
contractor doesn’t comply or violate with the standard procedure.
Contractor shall respond to all NCRs issued by COMPANY in writing within 48 hours of receiving
notification of nonconformance, including his proposed corrective action.
Contractor shall forward Internal NCR (INCR) respond to all NCRs issued by COMPANY in writing
within 48 hours of receiving notification of nonconformance, including his proposed corrective action.
Contractor shall investigate the root cause of nonconformities and initiate Corrective Actions to prevent
recurrence of nonconformities maximum 7 days of the issue date.
(i) Violation (ii) Root Cause (iii) Corrective Action (iv) Preventive Action (Correction)
What is RFI? When an RFI will be raised?

Request for Inspection (RFI), RFI shall be raised only when the status of the preliminary inspection is
satisfactory, and the works (items) are hold or witness point.
What is standard?
A Standard can be defined as a set of technical definitions and guidelines that function as instructions for
designers, manufacturers, operators, or users of equipment. Ex ASME31.3 is a standard for process piping.
What is code?
A standard becomes a Code when it has been adopted by one or more governmental bodies and is
enforceable by law, or when it has been incorporated into a business contract.
What is specification?
Specification is describing the technical requirements of any given product or process and are used heavily
by purchasing departments for controlling the quality of incoming materials. Ex API5L
ASME 31.1 (Pressure Piping, Power Piping)

ASME 31.3 (Process Piping)
ASME 31.4 (Pipeline Transportation Systems for Liquids and Slurries)
ASME 31.8 (Gas Transmission and Distribution Piping Systems)
API-1104 (Welding of Pipelines and Related Facilities)
ASTM - American Society of Testing Materials
A WS D 1.1 - American Welding Society (Structural Welding)
A WS D 1.6 - American Welding Society (Structure SS Welding)
Info:-
Pressure Vessel Inspections (API 510)
Risk Based Inspection (API 580/ ASME PCC-3)
Piping Inspections (ANSI B 31.3 / 31.4, API 570)
Welding Inspection (CSWIP 3.1 / API 577)
Daily Using SAIC & STAR as Per SATIP-W-011-01
Welding of On Plot Piping (ASME 31.1 & 31.3)
Daily Using SAIC & STAR as Per SATIP-W-012-01
Welding of On Pipeline (ASME 31.4, 31.8 & API-1104)
Welding Consumable:
For Receiving Consumable Storage, Handling, Issuance
SATIP-W-011-01 Rev-08 SATIP-W-011-01 Rev-08
SAIC-W-2010 SAIC-W-2032
SATR-W-2009 SATR-W-2010
For Receiving Consumable Storage, Handling, Issuance
SATIP-W-011-02 Rev-08 SATIP-W-012-01 Rev-08
SAIC-W-2010 SAIC-W-2032
SATR-W-2009 SATR-W-2010
Welding Consumable Control Room

Non Stop electricity should be available.
Humidity: 40% to 50% <50% RH
o
Temperature: 5-60 c (Ideal Temp 25 oc to 30 oc)
Monitor & Fulfill the Requirements:
Available trained ROD Issuer

Hygrometer placed on appropriate place and should be Calibrated
All Equipment should be calibrated
Safety Equipment should be installed.
Receiving Inspection of Welding Consumables (Pipelines & Plot Piping)
Control of Welding Consumables - Plant Piping (Site Storage, Handling, Conditioning & Issuance)
Welding Rod Oven Calibration/Verification Report
Electrode Test Certificate
Manufacture recommendation should be available.
*(SFA = Specification of filler analysis)
ASME SEC II C - Specification for Welding rods, Electrodes & Filler metals
CHEMICAL ANALYSIS (PMI ... "BUTTON"):
Details vary per Spec. Refer to Fig. 1 - Pad for Chemical Analyses of Undiluted Weld Metal
Button Size:-
ASME Sec-II C (SFA 5.5, etc) and refer to the Figure 1 - Pad for Chemical Analysis of undiluted Weld Metal
ASME Sec-II-C
M = Military requirements (Greater toughness and lower Moisture Contents)

(i.e E7018M As received 0.1% Moisture Contents & As exposed 0.4%)
C1 = Improved toughness (due to presence of Ni)

(i.e E8018-C1 ranges are 2 to 2.75% Ni but Considered 2.4% at -75⁰C)
HZ= Diffusible Hydrogen Test, an optional supplement test of the weld metal from Low “H”
electrodes as received or conditioned with as average valve not exceeding “Z” ml of H2 Per 100g of
deposited metal where “Z” is 4,8,16 (Example – E7018 H4, E7018 H8)
R = Electrode meets the requirements of the absorbed Moisture Test.

Normally E 7018 has 0.6% Moisture as received But
E7018R has 0.3% Moisture as received and 0.4% as exposed
E7018M has 0.1% Moisture as received and 0.4% as exposed
E6010 or E6011 has = 3% to 7% Moisture Level
B2 = Moisture Resist Pickup Coating
Note:
1.43g/Kg = Atmospheric condition shall be an absolute humidity of dry air at the time of welding.
P1 =
The P1 has a CVN requirement of 20 ft-lbs @ 0 degrees F.
The P1 has a slightly higher yield strength requirement (60 ksi vs 57 ksi) than the G classification.
The P1 does not require PWHT to achieve it's optimum mechanical properties, aging accomplishes
this.
The G classification may require PWHT if the proponent requires.
The P1 has a CVN requirement of 20 ft-lbs @ 0 degrees F. CVN testing is not required for the G
classification.
I also don't think I would compare the E7010G as being "better" then the E7010-P1 due the fact that
the P1 has more stringent mechanical property requirements. I would approach this issue as "Does
the E7010G electrode meet the requirements of an E7010-P1 electrode?" My answer would be "no".
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 SA are:
For Specification of
Intervie Filler Analysis Electrode , Electrode Wire & Filler Wire F No.
w (SFA)
1- SFA-5.1 Carbon Steel
2- SFA-5.4 SS Electrodes (SMAW)
3- SFA-5.5 Low-Alloy Electrodes (SMAW)
5- SFA-5.6 Copper & Alloy Electrode
6- SFA-5.7 Copper & Alloy Rods & Electrodes
7- SFA-5.9 Bare SS Electrodes & Rods
8- SFA-5.11 Nickel & Alloy Electrodes (SMAW)
9- SFA-5.12 Tungsten & Alloy Electrodes
10- SFA-5.13 Surfacing Electrode (SMAW)
11- SFA-5.14 Nickel & Alloy Bare Electrodes & Rods
12- SFA-5.17 SAW Solid Wire – i.e EM12K
13- SFA-5.18 GTAW Wire
14- SFA-5.21 Bare Electrodes & Rods, Surfacing
15- SFA-5.22 SS Electrodes (FCAW) & SS Flux Cored Rods (GTAW)
16- SFA-5.23 Low-Alloy Electrodes & Fluxes (SAW)
17- SFA-5.28 Low-Alloy Electrodes & Rods (GMAW) i.e ER80S-Ni1 also LTCS
18- SFA-5.29 Low-Alloy Electrodes (FCAW) ``
19- SFA- 5.36 FCAW = E81T8 6

Consumable: (ASME Sec-II-C)
ER70S-2 & 3:
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.
ER70S-6: Not Use is Saudi ARAMCO without prior Approval:

This electrode is greater than 200 BHN and unfit for sour services, PWHT required.
Because: Maximum hardness for P-1 after heat treatment should be less than or equal to:
Sweet Service = 225 BHN Sour Services = 200BHN
Welding Consumables shall have a SAP ID number to show their purchase from an approved vendor
for specific consumable.
PMI (Positive Material Identification) SAES-A-206
There are two globally accepted analytical methods for simple on-site Positive Material Identification:
1- X-ray Fluorescence (XRF)
2-Optical Emission Spectroscopy (OES).
Hand Held Spectrometer is used for performing PMI PMI by XRF Metal Analyzer X-MET8000
Methods
The instruments and methods used for PMI testing shall be suitable for identifying the material by
quantitative measurement of the major alloying elements required in the applicable material
specification or welding procedure specification.
The primary acceptable method is X-ray emission analysis, also known as X-ray fluorescence (XRF)
analysis with a calibrated portable instrument
Because of inherent limitations of some XRF analysers, it is not possible to detect all elements.
Elements lighter than sulfur (S) cannot be detected by these tools. Therefore, this technique can not
be used to detect carbon (C).
An optical emission spectrograph may be used to check for all the required elements, including
carbon. A hot work permit may be required before using this equipment. Any burn damage resulting
from the usage of the emission spectrograph shall be removed by grinding.
It is noted that some newer XRF analysers can analyze elements such Mg, Al, Si, P, S which are lighter
than sulfur (S),
PMI: Positive Material Identification – Verification that the nominal chemical composition of an alloy
material is as specified and ordered. The term applies to programs, processes, procedures, and tests in
accordance with this standard.
PMI Testing: Any physical evaluation or test of a material, meeting the requirements of this standard, to
confirm that the material which has been or will be placed into service is consistent with the selected or
specified alloy material.
Lot: Same batch of particular components -- the same supplier, type of component, size, rating, material,
etc., and from the same shipment. Material Specifications: ASME SEC II, Parts
Acceptance Criteria
10.1 For acceptance, it must be demonstrated that materials contain the amounts of alloying elements
shown in the material specification. Alloys shall be acceptable if the alloying elements are each within
10% of the specified range of values.
(Weld Metal VS Base Metal = 10% Variation accepted)
10.2 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.
(Consumable = ±12.5% Variation accepted)
Results showing Copper Content greater than 0.7% indicate unacceptable "cross contamination".
Tungsten Electrode: (Non-Consumable)
Zirconated (Brown) or Pure (Green) Use for AC (Cooper / Alloy, Mg, Mi, Plain Carbon, SS)
Thoriated (Red) 2% Use for DC-ve (Steel & Most Metals)
Thoriated or Zirconated Use on DE+ve
Note: Ceriated (Orange) and Lanthanated (Gold) can be used in place of Thoriated.
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
Properly prepare new tungsten with diamond type cutting equipment specifically designed for
Tungsten (Tungsten Sharpener Model-Piranha, etc)
Filler Metal Procurement Guidelines - AWS A5.01
Lot Classification
Covered Electrodes (C1, C2, C3, C4, C5)

Bare Solid Electrodes and Rods, Brazing and Braze Welding Filler Metal, and Consumable Inserts (S1, S2, S3, S4)
Flux Cored Electrodes and Metal Cored Electrodes and Rods (T1, T2, T3, T4)
Flux for Submerged Arc Welding and Brazing and Braze Welding (F1, F2)
All electrodes shall be purchased with certified lot testing in accordance with AWS A5.01 or BS EN ISO
14344.
Note: The Lot classification shall be S2, T2, C2, F2 or higher.
The schedule of testing shall be "4 or I" or higher for AWS A5.01 and "Schedule 4" or higher for BS EN
ISO 14344.
DRYING & RE-DRYING (Drying mean Backing)
A 5.1 A 5.5
Low Hydrogen Electrode Low Hydrogen Electrode
60XX 70XX & 80XX
Dried: 260-430 For 2-Hrs Dried: 370-430 For 2-Hrs
The drying step may be deleted if the electrodes are supplied in the dried condition in a hermetically
sealed metal can with a positive indication of seal integrity or vacuum sealed package (Vac-Pack)
Electrodes may be re-dried only once.

After drying the electrode shall be stored continuously in oven at 120-200 minimum
Exposure Limitation:-
A 5.1 (Carbon Steel) A 5.5 (Low Alloy Steel)

Low Hydrogen Electrode Low Hydrogen Electrode
60XX 70XX & 80XX
Not be exposed if:- Not be exposed if:-
4-Hr Open in Atmosphere 2-Hr Open in Atmosphere
8-Hr in Portable Oven minimum 65oC 4-Hr in Portable Oven minimum 65oC
Re-Conditioning:
Electrodes exposed to the atmosphere for less than the permitted time period may be returned to a
holding oven maintained at 120°C minimum;
After a minimum holding period of 4-hours at 120°C minimum the electrodes may be reissued.
Stainless Steel & Non Ferrous Electrodes:-
Exposure Limitation:
Drying: 120C – 250C (2-Hr) Not be exposed if:-
Store: 120C – 200C Minimum 4-Hr Open in Atmosphere
8-Hr in Portable Oven minimum 65oC
Electrode Shelf Life = 2-Year maximum

Note: 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).
Contractor shall assure electrode issue control follows a "First In, First Out" Rule.
Check E6010 storage closely.
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 pipe-rack).
Surface Porosity, uneven Profile and undercut remove by grinding.
Inert gas flow time over an extinguishing arc follows the "15 second rule" = Zero Contamination
Note: 15* seconds cooling under gas flow will result in zero oxidation
As Per Aramco Standard (SAES-W-012)
Shielding Gases shall conform to the requirements of AWS A5.32 or BS EN ISO 14175.
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.
Note:
1) Use of other gases and gas mixtures shall require CSD approval.
2) Certs attest to purity, check dew point, moisture content, etc
DUTIES BEFORE WELDING CHECK ACTION
Application Standard
Approved WPS / PQR & Drawing (welding package)
Have been approved and WPS is available to welders (and inspectors)
Composition & Condition:
Material (Base
In accordance with drawing/WPS>Identified and can be traced to a test certificate
Metal) Traceability
In suitable condition (free from damage and contamination
Welding equipment In suitable condition and calibrated as appropriate
Those to be used are as specified by the WPS are being stored/controlled as
Welding consumables
specified by the QC Procedure
Identification of welders qualified for each WPS to be used.
Welder qualifications
All welder qualification certificates JCC are valid (in date)
Weld preparations In accordance with WPS (and/or drawings)Edge Preparation:
In accordance with WPS/drawings tack welds are to good workmanship standard
Joint fit-ups
and to code/WPS
Weld faces are free from defects, contamination and damage
Preheat (if required) Minimum temperature is in accordance with WPS
All base materials (by spec, grade, P-No, Piping Diameter range) and wall
thicknesses to be used shall be included in the Weld Table.
Weld Table
Each Weld Table shall be completed & show all line designations to be used for the
entire complete job or contract.
DUTIES DURING WELDING (CHECK ACTION)

Ensure weather conditions are suitable/comply with Code
Site/field welding
(conditions will not affect welding)
Welding process In accordance with WPS
Preheat Temperature (if required) Minimum temperature is being maintained in accordance with WPS
Inter-pass temperature Maximum temperature is in accordance with WPS
Welding consumables In accordance with WPS and being controlled as Procedure (Handling)
Welding parameters Current, volts, travel speed are in accordance with WPS
Root run Visually acceptable to Code (before filling the joint) (for single sided welds)
Gouging/grinding By an approved method and to good workmanship standard
Interrun cleaning To good workmanship standard
Welder On the approval register/qualified for the WPS being used
DUTIES AFTER WELDINGCHECK ACTION
Weld Each weld is marked with the welder's identification and is identified in accordance with
identification drawing/weld map
Ensure welds are suitable for all NDT (profile, cleanness etc)-
Weld appearance
Visually inspect welds and sentence in accordance with Code
Dimensional survey Check dimensions are in accordance with drawing/Code
Drawings Ensure any modifications are included on as-built drawings
NDT Ensure all NDT is complete and reports are available for records
Repairs Monitor in accordance with the Procedure
PWHT (if required) Monitor for compliance with Procedure (check chart record)
test (if required) Ensure test equipment is calibrated Monitor test to ensure compliance
Pressure/load
with Procedure/Code. Ensure reports/records are available
Documentation Ensure all reports/records are completed and collated as required
Records
ASME Sec-IX
Welding, Brazing, and Fusing Qualifications
(Qualification Standard for Welding, Brazing, and Fusing Procedures; Welders; Brazers; and Welding,
Brazing, and Fusing Operators)
ASME SECTIONS
(ASME - American Society of Mechanical Engineers)
SECTION-1 Rules for Construction of Power Boilers

SECTION II Materials
Part A - Ferrous Material Specifications (Iron)
Part B - Nonferrous Material Specifications (Al, Cu, Ni, Ti, Zinc, Brass)
Part C - Specifications for Welding Rods, Electrodes, and Filler Metals
Part D - Properties (Customary)
Part E - Properties (Metric)
SECTION- III Subsection NCA
SECTION -IV Rules for Construction of Heating Boilers
SECTION-V Nondestructive Examination
RT (Article-2)
UT (Article-4 for Testing of Welds & Article 23 (Thickness measurement only)
PT (Article-6 All methods)
MT (Article 7 (Yoke & Prod Methods only)
SECTION-VI Recommended Rules for the Care and Operation of Heating Boilers
SECTION-VII Recommended Guidelines for the Care of Power Boilers
SECTION VIII Rules for Construction of Pressure Vessels
Division 1- (PWHT)
Division 2 - Alternative Rules
Division 3 - Alternative Rules for Construction of High Pressure Vessels
SECTION IX Welding and Brazing Qualifications
SECTION X Fiber - Reinforced Plastic Pressure Vessels
SECTION XI Rules for In service Inspection of Nuclear Power Plant Components
SECTION XII Rules for Construction and Continued S e r v i c e of Transport T a n ks.
ASME B16.1 Cast iron pipes flanges & flanged fittings

Flanges ASME B16.5 Carbon steel pipes flanges & flanged fittings. (Up to 24”)
ASME B16.47 Large Diameter steel flanges. (Above 24”)
Butt welded ASME B16.9 Steel butt welding fittings
fittings ASME B16.28 Butt-welded short radius elbows & returns bends.
ASME B16.20 / API -601 Metallic gaskets for pipe flanges- Spiral wound
Gasket
ASME B16.21 Non metallic gasket
Socket &
Threaded ASME B16.11 Forged steel socket welding & threaded fittings
fittings
ASME B16.10 Face to face & end to end dimension of valves.
Valves Flanged & butt-welded ends steel valves (Pressure &Temperature
ASME B16.34
ratings) except Ball, Plug & Butter fly Valves
Table QW/QB-422
Ferrous/Non Ferrous P-Numbers
Grouping of Base Metals for Qualification
Min Tensile
Spec No. Type or Grade P. No. Group No.
(MPa)
API-5L A 49 1 1
API-5L B 60 1 1
API-5L X52 67 1 1
API-5L X60 75 1 2
API-5L X65 78 1 2
API-5L X70 83 1 3
API-5L X80-Q 91 1 4
A 106 A 48 1 1
A 106 B 60 1 1
A 106 C 70 1 2
A-234 WPB 60 1 1
A-234 WPC 70 1 2
P – Numbers:-
To reduce the number of welding procedure qualification required, BASE METALS have been assigned P –
Numbers. Weld ability and Mechanical properties. (P No.2 is not applied)
P – Numbers Types of Material

1 Carbon-Manganese steel
3 Carbon - ½ % Mo. (Alloy Steel)
4 1 % Cr – ½ % Mo. (Alloy Steel)
5 2 ¼ % Cr – 1 % Mo, 5 Cr. (Alloy Steel)
6 High Alloy Martensitic stainless steel.
7 High Alloy Ferritic stainless steel
8 Austenitic stainless steel.
9 Nickel steel.
10 & 11 Quenched & Tempered Steel.
21 – 25 Al & Al base Alloys
31 – 35 Cu & Cu base Alloys
41 – 47 Ni & Ni base Alloys
51 – 53 Ti & Ti base Alloys
61 – 62 Zr & Zr base Alloys.
OD & WT
Outer Diameter Circumference
Diameter (ID)
(OD) Length
½” 22mm 69.10 mm (3)
1” 33.4mm 103.65 mm (2)
1½” 42 mm 131.92 mm (2)
2” 60.3 mm 188.46 mm (1)
3” 90 mm --
4” 114 mm --
6” 168 mm --
8” 219 mm --
10” 273 mm --
12” 324 mm --
A – Numbers:
A – Numbers are used to identify the weld metal chemical composition of ferrous metals.
Table QW-442
A-Numbers
Classification of Ferrous Weld Metal Analysis for Procedure Qualification
(For PQR / WPS)
A.
Types of weld deposit C Cr Mo Ni Mn Si
NO.
1 Mild steel 0.20 --- --- --- 1.60 1.00
2 Carbon-Molybdenum 0.15 0.50 0.4-0.65 --- 1.60 1.00
3 Chrome (0.4% to 2%)-Mo 0.15 0.4-2.0 0.4-0.65 --- 1.60 1.00
4 Chrome (2% to 6%)-Mo 0.15 2.0 –6.0 0.4-1.50 --- 1.60 2.00
5 Chrome (6% to 10.5%)-Mo 0.15 6.0-10.5 0.4-1.50 --- 1.20 2.00
6 Chrome-Martensitic 0.15 11-15 0.70 --- 2.0 1.00
7 Chrome-Ferritic 0.15 11-30 1.0 --- 1.0 3.00
8 Chrome-Nickle 0.15 14.5-30 4.0 7.5-15 2.50 1.00
9 Chrome-Nickle 0.30 25-30 4.0 15-37 2.50 1.00
10 Nickle to 4% (Low Temp) 0.15 --- 0.55 0.80-4.0 1.70 1.00
11 Mn-Mo 0.17 --- 0.25-0.75 0.85 1.25-2.25 1.00
12 Ni-Cr-Mo 0.15 1.50 0.25-0.80 1.25-2.80 0.75-2.25 1.00
F – Numbers:
F – Numbers are used for filler metal designation & grouping of electrodes & welding rods.
It is based essentially on their usability characteristics.
The main purpose of F – Numbers grouping is to reduce the number of welding procedure and performance
qualifications, where this can logically be done.
F No Class. Of Filler Metals F Nos. Class. Of Filler Metals

1 Heavy Rutile Consumable (E7024) 21 – 25 Al & Al base alloys.
2 Most Rutile Consumable (E6013) 31 – 37 Cu & Cu base alloys.
3 Cellulosic Electrode (E6010-6011) 41 –45 Ni & Ni base alloys.
(43-ER-NiCr-3)
4 Low hydrogen electrode. 51 –54 Ti & Ti alloys.
(E7016, E7018, E8018)
5 All stainless steel Electrode. (SMAW) 61 Zr & Zr alloys.
6 Bare wires/Core wires of CS, SS &LAS 71 – 72 Hard-facing weld metal.
QW-433
ALTERNATE F-NUMBERS FOR WELDER PERFORMANCE QUALIFICATION
If one welder is qualified on F4 (i.e E7018) without backing than he is qualified on all below F1, F2, F3
with backing.
Consumable Insert:
Filler metal that is placed at the joint root before welding and is intended to be completely fused in
the joint root to become part of world.
Filler metal Product Form i.e. a-Bare to b-Flux cored to a flux coated c- via-versa
What are the different types of Base Material w i t h Grade?
Material GTAW Interpass

SMAW
with Grade Filler Pre Heat Temp PWHT
P No. Electrode
Wire Max
A106 Gr. A – 0.25 %
A106 Gr. B – 0.30 % o
ER-70S-2 <25mm : 10 C
CS A106 Gr. C – 0.35 % o
See PWHT
to 6 can 7018,7018 -1 >25mm: 80 C 250°C
P No.1 Page No.
API-5L Gr- B use on CS (ASME 31.3 Ed 2014)
A-53 Gr-B
ER-80SNi1 E8018-C3 <20mm Thickness o
o 600 C
CS ( LTCS) ER-80SNi2 E8018-C1 >20mm Thickness Max 10 C 150°C o
200 C-2Hr
A 316
ER-316L E-316
A 316L
A 316H
SS P No.8 A 304
(ASTM-312) ER 308 L E 308 L
A 304L
10°C 177 ºC NA
304,308,310,
A 308L
316,317,321,
347,348 A 321L
ER 347 & E 347
A 321M
347 L
A 347 (L,H,M)
ER 347
Dissimilar CS A-53 to SS-304L ERNiCr-3 10°C 177 ºC NA
Material (BM T=<12mm)
ER-309
CSA-53 to SS-304L See 6.1.6 SAES-W-12
13 mm>
Pll -
o 704°C to 760°
A335-P-11 P-11 = 150 C 260°C
Alloy o High Alloy
A335-P-22 P-22=149 C P22 -
730°C to
300°C
790°C
Aluminum
SB 241 Gr 5083
P No.21 to
25
ASME SA335 / ASTM A335 , Chrome-Moly pipe is a seamless ferritic Alloy-Steel Pipe produced in
nominal or minimum wall thickness for high temperature service. ... Sometimes referred to as “P
Grade” materials, chrome moly pipe comes in more than 17 grades with the most widely used P-
Grades being P5, P9, P11, P22 and P91.
QW-400 VARIABLES (ASME SEC-IX)
Definitions:
Essential Variables as PQR, WPS (QW-401.1)

A change in a welding condition which will affect the mechanical properties (other than notch toughness) of
the weldment (e.g., change in P-Number, welding process, filler metal, electrode, preheat or postweld heat
treatment).
Essential Variables as WQT - Performance (QW-401.2)

A change in a welding condition which will affect the ability of a welder to deposit sound weld metal (such as a
change in welding process, deletion of backing, electrode, F-Number, technique, etc.).
Supplementary Essential Variable (Procedure) (QW-401.3)

A change in a welding condition which will affect the notch-toughness properties of a weldment (for example,
change in welding process, uphill or down vertical welding, heat input, preheat or PWHT, etc.). Supplementary
essential variables are in addition to the essential variables for each welding process.
Nonessential Variable (Procedure) (QW-401.4)

A change in a welding condition which will not affect the mechanical properties of a weldment (such as joint
design, method of back gouging or cleaning, etc.)
What is the difference between Pipe and Tube?

Pipe is identified by NB (Inner Dia) and thickness is defined by Schedule.
Whereas Tube is identified by OD.
From which size onwards NB of pipe is equal to OD of Pipe?

From the size 14” and onwards NB = OD of pipe.
What is the difference between machine bolt and stud bolt?

Machine bolt has a head on one side and nut on other side but stud bolt have nuts on both sides.
What is the thumb rule to calculate spanner size for given bolt? Answer:
1.5 x diameter of Bolt
What is the thumb rule to calculate Current required for Welding? Answer:
Current (Amp) = [Diameter of Electrode (mm) X 40] + 20
What should be the radius of long radius elbow? Answer:

1.5D (Where “D” is the diameter of the pipe)
What is the min. distance to be maintained between two welds in a pipe

Minimum spacing of circumferential welds between centre lines shall not be less than 3-times
the pipe wall thickness or 25 mm whichever is greater.
Position Qualification:
QW-452.3
Groove Weld Diameter Limits
OD Qualified, in (mm)
OD of Test Coupon in (mm)
Min Max
½" ½" Welded Test Unlimited
¾" ¾" Welded Test Unlimited
1" to 2⅞ " (73mm) 1" Unlimited
2⅞ " (73mm) to above 2⅞ " (73mm) Unlimited
Welder Qualification:-
ASME Sec-IX & SAEP-324 must be qualified
JCC's shall be returned to PID 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.
Table QW-451
Procedure Qualification Thickness Limits and Test Specimens (PQR, WPS)
Range of Thickness T of Base Max Thickness t of Deposited Weld

Thickness T of Test
Metal Qualified (mm) Metal Qualified (mm)
Coupon, Welded (mm)
Min Max Max Tensile R F
Less than 1.5mm T 2T 2t 2 2 2
1.5mm to 10mm 1.5 mm 2T 2t 2 2 2
10mm to <19mm 5mm 2T 2t 2 2 2
>19mm to <38mm 5mm 2T 2t 2 4-Side
>38mm to 150mm 5mm 200mm 2t 2 4-Side
Note: 2* change Tension from 25mm.
Thickness Range Qualification for WQT
OD Qualified, in (mm)
Test Coupon in (mm)
Min Max
<10mm 1.5 mm 2 T Deposit Thickness
>10mm to <13mm 1/2 t 2 T Deposit Thickness
>13mm 1/2 t Unlimited
Minimum thickness that applies to welders qualified is it 1/2 t thickness. If the coupon's thickness is
more than 13mm and he deposits a minimum of 3 layers, he is qualified unlimited.
QW-452.1 (a) WQT
Test Coupon in (mm) Side Bend Face Bend Root Bend
<10mm - 1 1
>10mm to <19mm 2 - -
>19mm 2 - -
Note: One face & Root bend may be substituted for the two side bends.
As per ASME B31.3, what is the maximum weld reinforcement allowed?
Wall thickness Max. Weld Reinforcement

Less than 6 mm 1.5 mm
6 ~ 12.5 mm 3 mm
12.5 ~ 25 mm 4 mm
Above 25 mm 5 mm
Process Used on base of Material Thickness:

SMAW = All above 3mm
GTAW = Thin Section <10mm
GMAW/FCAW= Typically 3 to 30mm
SAW = 15 to 150mm or above
GTAW process is mandatory for all Lines that will be less than 24” in Dia.
Contract Welders and Welder Operators performance criteria
to meet 0.2% Linear and 5% joint basis, with linear being the over-riding factor. From the
performance data the welders shall be categorized from the linear WRR criteria as follows:
A. 0 - 0.2% Level A
B. >0.2% - 0.4% Level B
C. >0.4% - 0.5% Level C
D. > 0.5% Level D, Revoke
(Length) = RT Rejected / RT Done x 100

Joint (Qty) = RT Rejected / RT Done x 100
Level A, B & C Welders
In all cases, Welder performance should target “A” Classification results with the lowest possible Linear &
Joint Repair Rates achievable.
Continuing Process Improvement, Cost Effectiveness is acceptable for Cat. A & B welders.
Cat. C welders are not cost effective and require close supervision)
Level D Welders
Welders may exceed the 7.5% joint WRR weekly for a maximum period of 2-3 weeks with close
surveillance on all repairs.
Additional supervision / additional NDT (to 100%) is required until consistent results of 7.5% WRR or less
(joint repair rate) are achieved.
If WRR target is not achieved within 2-3 weeks, the options are: (i) welder may be considered candidate
for re-training and retesting or (ii) revoke qualification and remove from production work.
Tack Weld:
Thickness = 3.2 to 4.8
Length = 12.5 to 25.4
Upto 4” Dia = Use 3-Nos Tacking

Above to 4” Dia = Use 4-Nos Tacking
Tack Weld: Less then 10” Dia Tacking without Clit
Bridging: Use of Clit
PREHEAT:
To reduce the cooling rate of weld area and HAZ.

Improving ductility with great resistance of cracking
Provides the opportunity for H2 that may be present to defuse out.
To reduce the shrinkage stress in weld and base metal.
Reducing the potential of cracking.
Preheat Temperature not be less than 10°C

Preheat Temperature shall be established over a minimum distance 75mm of each side.
Temperature Equalization 1mint = For 25mm Thickness
When we required more than 93°C Temperature in Preheat so we use Electrical Coil.
For (CS) P-1 Material: (ASME 31.3 Table 330.1.1)

10°C < 25mm Thickness
80°C > 25mm Thickness
Maximum Interpass Temperature: (SAES-W-11)

P-1,3,4,5 315°C
P-3x, P-4x, P-8 177°C
Maximum Interpass Temperature: (SAES-W-12)

P-1 315°C
P-4x, P-8 177°C
Preheat employ as per (SAES-W-11 31.3) & (SAES-W-12 31.4, 31.8)

For More Details:
SAES-W-012
Welding Requirements for Pipelines
Appendix 3 – Preheat Temperatures Tables - Tables 3A and 3B:
Pre-heat
For CS
Flange = 52oC
Pipe, Reducer, Elbo, Tee = 25 oC
ASME D 1.1
Structural = 10 oC
Post Weld Heat Treatment Requirements and Exemption
Only for P-1 Material
ASME 31.8 ASME 31.3 Edition 2014
Required:
Required: PWHT required if
PWHT required if Material Thickness > 25mm and Preheat apply
Material Thickness ≥ 32mm Less than 95°C
Not Required: (Exemption) Not Required: (Exemption)

Less than 32mm no need PWHT Material Thickness > 5mm to
And > 25mm if minimum Preheat apply 95°C
PWHT
To reduce the residual stress and hardness.

To improve the ductility
To regain the mechanical properties.
To refine the grain size.
1- PWHT selected by Material P No. wise i.e P3, P4-Gr-1, P5A, P5B, P6, P11, P12
2- P-6 (High Alloy Steel All thickness Required PWHT)
3- P No. 7 (High Alloy Ferritic Stainless Steel) – Not allowed PWHT in Saudi Aramco.
4- P No. 8 (Austenitic Stainless Steel ) – Not allowed PWHT in Saudi Aramco.
5- 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%.
ASME 31.3 Table 331.1.1

Sr # Material Thickness Temp C Soak Time
1 CS <25mm Not required
2 CS >25mm 595-650* 1-Hr
3 Alloy Steel (P-4 & 5) >13mm 704-746* 2-Hr
4 High Alloy Steel (P-6) All Thickness 732-788 2-Hr
5 Nickel Alloy (P-9 A &B) >20mm 595-650 1-Hr
* 620 °C ± 20 * 720°C ± 20
Note: P No. 7 (High Alloy Ferritic stainless steel) & 8 (Austenitic stainless steel.) Not Done PWHT
Heating & Cooling Rate in PWHT is :- 222oC/Hr/In after 316oC
Example:
19mm
19/25 for Convert in Inch : 0.76
0.76 x 222 = 168.72 oC/Hr
Insulation shall be applied a minimum of 300 mm on either side of the weld that is to be PWHTed. The
insulation shall not be removed before the temperature has cooled to below 150°C. The ends of open lines
shall be closed off in order to eliminate drafts or air circulation that could lower the temperature on the
inside surface of the joint unless the internal surface is also insulated.
Thermocouple Requirement: (J & K Types)
Pipe Dia = 305mm (12”) or Less = 1 No.
Pipe Dia = 305 to 610 = 2 No.
Pipe Dia = 610 and above = 4 No.
In this chart,
X-axis represents temperature and Y-axis represents Time.
In X-axis each line to line distance represents 10Deg C
In Y-axis each line to line distance represents half an hour. That means the time between 2 and 3
represents one hour.
The graph contains several lines, AB, BC, CD, AE
1 ) AB is RATE OF HEATING curve 3) CD is RATE OF COOLING curve

2) BC is SOAKING TEMPERATURE 4) AE is ROOM TEMPERATURE curve
When you check the WPS you can see the required values for each of these.
WELDING POSITIONS:
Procedure: A Main Line Procedure: B Tie-in Weld

(Cross Country Line) (After Main Line the Tie-in Weld)
4-Pass = Down Hill Root Pass = Up Hill 3-Pass = Down Hill
Procedure: C Tie-in Weld Procedure: D Tie-in Weld
(For Repair Weld) (For Fabrication Weld)
Root Pass = Up Hill 2-Pass = Down Hill Root Pass = Up Hill 2-Pass = Down Hill
Capping = Up or Down Capping = Up Hill
Types of Bead:
1- Wider / Weaving Bead 2- Narrow / Stringer Bead
Note: Included and Bevel angle of Aluminum is larger then CS.
Welding Imperfections
Definitions:
Imperfection / Discontinuity: Any deviation from the ideal weld.
Defect: An unacceptable imperfection.
Important:
Planner, 2-Dimension and Linear one thing means same.
Non-Planner & Volumetric are one thing
Full Thickness Defects = Volumetric Defects
Planner (Linear) Non-Planner (Volumetric)

Lack of Side Wall Fusion Gas Pore
Inter Run Fusion Porosity / Cluster Porosity
Burn Through Root Concavity
Cracks Crater Pipe, Undercut
Slag Inclusion
Classification of imperfections according to BS EN ISO 6520-1:
Group Type Cause /Location

1-Cracks Solidification (Hot) Impurities Centerline (Weld Metal)
HICC (Cold) Hydrogen Induce (Toe to HAZ)
Lamellar Tearing Lamination (Base Metal)
Weld Decay Bead to HAZ
2- Cavities Porosity (Cluster Porosity) Damp Electrode Weld Bead

Gas Pore ≤ 1.5mm ∅ Un-cleaned Weld Bead
Blow Hole >1.6mm ∅ Parent Metal Weld Bead
Loss of Gas
Shield
3- Solid Slag (MMA,SAW) Poor Inter-run Cleaning

Silica (MAG) (TIG) Dipping Tungsten / TIP in Weld Pool
Inclusion Tungsten (TIG)
Copper (MIG/MAG)
4-Lack of Lack of Side wall Fusion Slag Not Proper Cleaning

(Can be Surface Breaking) High Travel Speed
Fusion Gas Inclusion
Lack of Roof Fusion Same to Incomplete Root Fusion
Cold Lap / Over Lap Positional Welding Technique
Lack of Fusion= (Cold Laps(Laps), Lack of Side Wall Fusion, Lack of Inter run Fusion)
Lack of Side wall Fusion occur cause of ARC Blow
5- Surface & Poor Toe Blend Incorrect Welding Technique
Profile Arc Strike Poor Welding Technique
Incomplete Penetration Root Face too Large
Incomplete Root Penetration Root Gap too Small
Current Setting being too low
Linear Misalignment
Under-fill Incorrect Welding Technique
(incomplete Fillet Groove)
Spatter Damp Consumables
High Current
Undercut High Current / Poor Welding Technique
Slow Travel Speed
Root Concavity • Excessive back purge pressure during TIG
welding
• Excessive root bead grinding before the
application of the second pass
• welding current too high for 2nd pass
overhead welding
• root gap too large - excessive ‘weaving’
Excess Penetration Too Large Root Gap / Amp
Burn through Too Small a root Face
Crater pipe (Mainly TIG) Incorrect Current Slope-out
6-Mechanical Hammer/Grinding marks Poor Work man ship

Damage
Welding of Tie-in Joint (Normal & Temperature Tie In)

All tie-ins shall be done in accordance with SAES-L-450. Tie-in shall be carried out as per approved
procedure. QC Inspector shall maintain a permanent record of all actual tie-ins performed. Minimum
tie-in temp, shall be 70 -deg. F. or as given in the Safety Instruction Sheets (SIS).
A tie-in welds is a weld that connects the pipeline string to another or the pipeline under construction
or to an anchor. The segment of the pipeline between the tie-in points remains fully restrained at the
tie-in temp., if shrinkage of the segment is prevented by adequate anchorage at both ends. For normal
daily temp., variations during construction, one of the following will provide adequate:
• Full Thrust Anchor

• Intermediate anchor with a full string of pipe welded to each side of the anchor; or
• Frictional forces along the tail: at least 450 m. of buried pipeline; a 900 to 1200 or long string
on wooden skids or sand; or 1800 to 2400 of pipe, a double string resting on steel supports.
The pipes to be tied-in shall be kept near to each other. During the peak temperature of the day, the
pipe shall be marked and cut. The bevel end shall be brought together and aligned using an external
clamp. The joint shall be welded using dolly mix procedure.
The pipe string shall not be lifted to take the slack in the string. The tie-in temperature shall be equal
to or greater than the highest mean temperature of the previous three days.
Notice of inspection shall be issued to Project Inspection 24 hours in advance for witnessing tie ins.
Tie-In to Existing Facilities
All tie-ins to existing facilities as indicated in construction drawings shall be verified with regards
to location, orientation and dimension prior to final fabrication.
Detailed Tie-in Procedure will be submitted to Company Representative, Tie-in Package shall be
submitted for approval by Saudi Aramco PMT and Project Inspection.
SAIC-W-2057
SATR-W-2014
Welding On SS (Austenitic Stainless steel)
Only 300 series SS brushes are used on austenitic & nickel alloys.
Where 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)
Austenitic & nickel alloy material fabrication areas are separated from CS areas (upwind to
prevent cross contamination).
Wind velocity in the weld area for GTAW, GMAW, or gas shielded FCAW shall not exceed 8 kph
(2.2 m/s)
Oil, moisture, scale, rust, paint (except approved weld-able primers), metallic coatings (e.g. zinc)
or other foreign matter, has been removed from weld surfaces at least 25mm adjacent to weld
joint.
PIKOTEK
Pickling and Passivation:-

Both are chemical treatments applied to the surface of stainless steel to remove contaminants which
assist the formation of a continuous chromium-oxide, passive film. Both are acid treatments and
neither will remove grease or oil.
Back Purging:
Purging is applied on P-5 and Greater materials, For process GTAW & GMAW root passes single
sided grove welds, Purging shall be maintained until at least 10mm of the weld deposit thickness has
been completed.
Not use of Nitrogen as purging gas in Austenitic Stainless steel.
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. (ppm=Parts Per Millions)
12 ppm O2 = No oxide tint ... ACCEPTABLE
Oxygen level reduce by Purging:

In Low Alloy Steel = 1%
In SS & Ni = 0.05%
Weld Repair:
For Crack defect first evaluated by CSD
Crater Crack do not required special repair and shall be ground out only.
During production do not require a separate repair procedure except for crack
Replacement weld (Cut Out) shall be examined as repair.
After Welding Re-Cutting & Modification
After Receiving NTI
Raise the RFI of Modification (Only Cutting and Beveling)
After Re-Cutting and Beveling, (Joint PT will be Done) than Fit-up will done.
Now again Raise the RFI for Pre-welding/ Fit-up , In Process Welding
Note: If required Drawing Will be Change / Modification, for Addition Joint or Joint No. Changing
Gap Control Procedure & Inspection

Check all Individual Axial gaps on socket-welded joints before welding.
Fit-up follows an approved Gap Control procedure!
Pre-Welding = 1.5 - 3 mm gap exists
SA CSD recommends 3 mm target gap on fit-ups.
After welding: Maximum gap of 50% engagement is acceptable.
Note: At a minimum, 50% engagement is obtained, this easily verified
If SMAW welding is used for socket welding, the largest size of electrode permitted is 3.2mm Dia.
The axial gap between male and female component, shall be maximum of 3 mm and minimum of 1.5
mm. This gap is required prior to welding. (It does not apply to piping already installed and welding
was completed successfully)
Butt joint Internal misalignment shall not exceed 1.5 mm.
NOTE: Internal tapering (ASME B31.3) by machining, back welding, 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).
For Socket Welding:-
For steel piping in hazardous services, threaded and socket welding fittings shall conform to ASME
B16.11 Class 3000, Class 6000 or higher and Pipe unions shall be limited to Class 3000 threaded or
socket welding forged steel unions in accordance with MSS SP-83
Welding Procedure used is approved & socket weld 2-pass minimum welding sequence (tacking
method, root pass, weld profile/form detail) is available to provide the welder adequate instruction in
the field.
Welder has been qualified for socket welding by passing RT on the first three production welds.
Buttering / Weld buildup:-

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 CSD.
Permanent backing rings or strips shall not be used.
Full penetration groove joint included angles < 30 degrees, except portions of compound bevels, shall
not be used without approval.
Minimum distance between parallel butt welds shall be 25 mm or three times the wall thickness of the
joint, whichever is greater.
Line Class:- (SAES-L-105)
3CS1P11
First = Pressure rating
Second = Pipe Material
Third = Corrosion Allowance
Forth = Service
Fifth = Modification Suffix – Optional
An example of a complete piping line class designator is "3CS1P11". This designator specifies an
ASME pressure class 300, carbon steel piping system with 1.6 mm corrosion allowance designed for
general process service & fifth field is optional Project Specific requirements.
Exceptions, modification, or additions may be made to the base piping line class to meet specific
requirements through the use of the fifth field location, i.e., modification suffix. Line classes with listed
fields shall be approved the Chairman of the Piping Standards Committee.
1. CB (Chilled Carbon Steel).

2. CC (Low Carbon Steel)
3. SX (Duplex Stainless Steel).
SATIP-W-012-01
Electrode & Maximum Size can be used:- SAIC-W-2005
Electrode type Maximum Size

5mm for 1G/1F Position
Low Hydrogen Electrode
4mm for other Position
Non-Low Hydrogen Electrode 5mm for All Position
Welding Sequence & Pipe Handling meets SA workmanship requirements. Prevent any associated
NDE penalty (RT) with the process:
• For pipelines greater than 16 inch, two welders are used, operating simultaneously and in
opposite quadrants
• Second or hot pass is added ASAP after completing root pass.
• Time shall not exceed 5 minutes (Vertical down, Cellulose electrode)
• Time shall not exceed 15 minutes for vertical up welding.
• Hot pass was made while pipe was fully supported (tractor, etc)
• The pipe shall not be lifted or moved during welding.
• Partially welded joints shall not be lifted or lowered into the ditch.
• The weld joint shall be completed within 24 hours of starting.
Fluid Services: (B 31.1)
Applies to all fluids where steam vapor is generated at 15 psig or higher. Steam condensate (liquids)
where water is 160 psig or temperatures exceed 250F.
SAES-W-11
17.5.2.1
Radiography Fluid Class basis
Fluid Services: (B 31.3)
Normal Fluid Service
Fluid service that is covered by 31.3 but not subject to the rules for Category D, Category M or High
Pressure Fluid definitions.
10% Not subjected to D,M or High Pressure Fluid Service.
Category D Fluid Class Fluid Services (Non-Toxic, Non-Flammable) –No changes to human Tissues
(Temp -29 oC ~ 186 oC)
Shop = 10%
Site = 100%
• Design Gauge pressure is below 150 psi (1,035 kPa)
• Design Temperature is between -20F to 366F (-29C to 186C)
An example of Category D fluid might be utility water in a plant or low pressure steam condensate.
Category M Fluid Class Fluid Services (Toxic & Flammable Fluid)

Shop = 100%
Site = 100%
An example of Category M fluid could be Hydrogen Sulfide gas, high concentrations of HydroChloric
Acid or high pressure steam.
P4, P5, P6 = 100%
AWS D 1.1
Structural
SATIP-M-001-01
SAIC-M-2012
Pre Welding: 3.11
In Process 3.12
Post Weld 3.13
I = 100% Contactor Inspection
AWS A2.4
In Fillet Weld In a Butt Weld
Size of the weld is the Leg Length Size of the weld is based on the depth of Joint
(Z=Leg Length) preparation
Only write 6 mean leg length is 6mm S= Depth of Penetration (ATT)
DTT= Leg Length x 0.7

Leg Length = DTT x 1.4
Pre Qualified WPS as per AWS D 1.1 Sec-3
Joint Design Backing Only For Material Fillet Size As Per

B-U2 TC-U4a P 1 Gr. 1 & 2 Base Metal Thickness
B-U4b C-U2a ASTM
TC-U4b B-U2a A36 T≤ 6.40 = 3
TC-L1b A516 6.40 < T ≥ 12.7 = 5
C-U2 A53-Gr B 12.7 < T ≥ 19.0 = 6
BTC-P4 A106-Gr B T > 19.7 = 8
API 5L Gr-B
A 572 Gr-55
PRE HEAT Interpass Temp
T 3 to 38 mm = 10 oC 315 oC
T 39 ~ 63mm = 66 oC
T 63> = 107 oC
When the bas metal temp is below 0 oC, the base metal shall
be preheated to minimum of 20 oC.
Single V-groove Weld (2)

Corner Joint (C) C-U2
Square groove weld (1)

T-Joint (T), Corner Joint (C) TC-L1B
Single V-groove Weld (2)

Butt Joint (B) B-U2a
Single Bevel -groove Weld (4)

T-Joint (T), Corner Joint (C) TC-U4b
In Fillet Weld Convexity:-
Width of weld face Maximum convexity
W < 8mm 2mm
W > 8 to < 25mm 3mm
W ≥ 25mm 5mm

Experience Base - QA/QC Standards

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Experience Base - QA/QC Standards

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Experience Base - 2019

With ARAMCO Engineering

What are the basic responsibilities of a QA/QC personal?

Welder: (ASME Sec-IX)

Welding Operator: (ASME Sec-IX)

What are QA/QC’s ITP’s?

What is RFI? When an RFI will be raised?

ASME 31.1 (Pressure Piping, Power Piping)

Welding Consumable Control Room

Monitor & Fulfill the Requirements:

Available trained ROD Issuer

*(SFA = Specification of filler analysis)

M = Military requirements (Greater toughness and lower Moisture Contents)

C1 = Improved toughness (due to presence of Ni)

R = Electrode meets the requirements of the absorbed Moisture Test.

E6010 or E6011 has = 3% to 7% Moisture Level

B2 = Moisture Resist Pickup Coating

2- SFA-5.4 SS Electrodes (SMAW)

3- SFA-5.5 Low-Alloy Electrodes (SMAW)

5- SFA-5.6 Copper & Alloy Electrode

6- SFA-5.7 Copper & Alloy Rods & Electrodes

7- SFA-5.9 Bare SS Electrodes & Rods

8- SFA-5.11 Nickel & Alloy Electrodes (SMAW)

9- SFA-5.12 Tungsten & Alloy Electrodes

10- SFA-5.13 Surfacing Electrode (SMAW)

11- SFA-5.14 Nickel & Alloy Bare Electrodes & Rods

12- SFA-5.17 SAW Solid Wire – i.e EM12K

13- SFA-5.18 GTAW Wire

14- SFA-5.21 Bare Electrodes & Rods, Surfacing

15- SFA-5.22 SS Electrodes (FCAW) & SS Flux Cored Rods (GTAW)

16- SFA-5.23 Low-Alloy Electrodes & Fluxes (SAW)

18- SFA-5.29 Low-Alloy Electrodes (FCAW) ``

19- SFA- 5.36 FCAW = E81T8 6

ER70S-6: Not Use is Saudi ARAMCO without prior Approval:

(Weld Metal VS Base Metal = 10% Variation accepted)

(Consumable = ±12.5% Variation accepted)

Covered Electrodes (C1, C2, C3, C4, C5)

Electrodes may be re-dried only once.

A 5.1 (Carbon Steel) A 5.5 (Low Alloy Steel)

Stainless Steel & Non Ferrous Electrodes:-

Electrode Shelf Life = 2-Year maximum

2. Argon (Ar): Compressed Gas Association CGA G-11.1, Grade A.

DUTIES DURING WELDING (CHECK ACTION)

DUTIES AFTER WELDINGCHECK ACTION

SECTION-1 Rules for Construction of Power Boilers

ASME B16.1 Cast iron pipes flanges & flanged fittings

P – Numbers Types of Material

F No Class. Of Filler Metals F Nos. Class. Of Filler Metals

Material GTAW Interpass

Essential Variables as PQR, WPS (QW-401.1)

Essential Variables as WQT - Performance (QW-401.2)

Supplementary Essential Variable (Procedure) (QW-401.3)

Nonessential Variable (Procedure) (QW-401.4)

What is the difference between Pipe and Tube?

From which size onwards NB of pipe is equal to OD of Pipe?

What is the difference between machine bolt and stud bolt?

What should be the radius of long radius elbow? Answer:

What is the min. distance to be maintained between two welds in a pipe

Range of Thickness T of Base Max Thickness t of Deposited Weld

Thickness Range Qualification for WQT

QW-452.1 (a) WQT

Test Coupon in (mm) Side Bend Face Bend Root Bend

As per ASME B31.3, what is the maximum weld reinforcement allowed?