Engineering Procedure

SAEP-324 12 October 2015

Certification Review and Registration of Project Welders
Document Responsibility: Project Quality Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope..................................................................... 2
2 Conflicts and Deviations......................................... 2
3 Applicable Documents............................................ 2
4 Definitions and Acronyms....................................... 4
5 Responsibilities....................................................... 6
6 Instructions............................................................. 7

Appendix I - Table for Welder Criteria......................... 11

Appendix II - Template Job Clearance Card............... 13
Appendix III - Flow Diagram of NDE Requirement
for 1st Three Production Welds....................... 14
Appendix IV - Sample of Welder Registration
and Tracking Record………….…...............…. 15

Previous Issue: 27 September 2009 Next Planned Update: 12 October 2018

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Primary contact: Ghamdi, Khalid S (ghamks0k) on +966-13-8801775

Copyright©Saudi Aramco 2015. All rights reserved.

Document Responsibility: Project Quality Standards Committee SAEP-324
Issue Date: 12 October 2015
Next Planned Update: 12 October 2018 Certification Review and Registration of Project Welders

1 Scope

1.1 This engineering procedure specifies the minimum requirements for certification
review and registration of contractor welders working on In-Kingdom
construction and fabrication projects.

This engineering procedure specifies the minimum requirements for certification

review and registration of welders working on In-Kingdom construction projects
including affiliated in-kingdom and out-of-kingdom contractor’s fabrication.

1.2 This engineering procedure does not apply to Manufacturer Fabrication Facilities
as defined in Section 4.

1.3 This engineering procedure does not apply to Maintenance Projects as defined in
Section 4.

2 Conflicts and Deviations

2.1 Conflicts

Any conflicts between this SAEP and other applicable Mandatory Saudi Aramco
Engineering Requirement (MSAER) shall be resolved in writing by the
Company through the Chairman, Project Quality Standards Committee.

2.2 Deviations and Waivers

Direct and process all requests to deviate or waive the requirements of this
SAEP according to the internal company procedure SAEP-302, Instructions for
Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement.

3 Applicable Documents

Unless stated otherwise, all codes and standards referenced shall be the latest issue
(including Revisions and Addenda). When industry codes and standards, or Saudi
Aramco standards are required for use by project specifications, they shall become a
part of this Engineering Procedure.

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-302 Instructions for Obtaining a Waiver of a Mandatory
Saudi Aramco Engineering Requirement

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Document Responsibility: Project Quality Standards Committee SAEP-324
Issue Date: 12 October 2015
Next Planned Update: 12 October 2018 Certification Review and Registration of Project Welders

SAEP-321 Performance Qualification Testing and Certification

of Saudi Aramco Welders
SAEP-1141 Radiation Protection for Industrial Radiography
SAEP-1150 Inspection Coverage on Projects
SAEP-1160 Tracking and Reporting of Welding, NDT and
Pressure Testing for Capital Projects

Saudi Aramco Engineering Standards

SAES-W-010 Welding Requirements for Pressure Vessels
SAES-W-011 Welding Requirements for On-Plot Piping
SAES-W-012 Welding Requirements for Pipelines
SAES-W-013 Welding Requirements for Offshore Structures
SAES-W-017 Welding Requirements for API Tanks
SAES-W-019 Girth Welding Requirements for Clad Pipes

Saudi Aramco Form

SA-4758-ENG Job Clearance Card

3.2 Industry Codes and Standards

American Petroleum Institute

API STD 1104 Welding of Pipelines & Related Facilities
API STD 620 Design and Construction of Large, Welded, Low-
Pressure Storage Tanks
API STD 650 Welded Steel Tanks for Oil Storage

American Society of Mechanical Engineers/Boiler & Pressure Vessels Code

ASME B31.1 Power Piping
ASME B31.3 Process Piping
ASME B31.4 Pipeline Transportation Systems for Liquid
Hydrocarbons and Other Liquids
ASME B31.8 Gas Transmission and Distribution Piping Systems
ASME SEC I Boiler and Pressure Vessel
ASME SEC VIII Rules for Construction of Pressure Vessels
ASME SEC IIC Welding Rods, Electrodes and Filler Metals

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Document Responsibility: Project Quality Standards Committee SAEP-324
Issue Date: 12 October 2015
Next Planned Update: 12 October 2018 Certification Review and Registration of Project Welders

ASME SEC V Nondestructive Examination

ASME SEC IX Welding and Brazing Qualifications

American Welding Society

AWS D1.1 Structural Welding Code – Steel
AWS D1.6 Structural Welding Code – Stainless Steel
AWS D1.8 Structural Welding Code-Seismic Supplement

4 Definitions and Acronyms

Certified Welder: A welder that has a valid welder certification and approved agency
qualification card. A certified welder is only qualified to weld with those welding
processes, and within the essential variables, of the valid certification according to the
qualification governing code. Unless specified otherwise, the term welder shall also
mean welding operator.

Contractor Project Welder Tracking Coordinator (PWTC): Welding Inspector who

oversees the performance of all Project Welders and accepted by Project Inspector.

Contractor Welder: A welder working directly for, and under the supervision of a
contractor.

Fabrication Shop: A facility with a controlled environment used for the fabrication
and/or assembly of equipment and structures such as pipe spools, pressure vessel, etc.
Controlled environment refers to atmospheric weather condition, established quality
system, and welder’s accessibility to welds joints. Fabrication Shop requires
pre-approval by Saudi Aramco Inspection Agency.

Fabrication Yard: A large open outdoor area used for the fabrication and/or assembly
of very large structures such as offshore platforms, etc.

Field Fabrication Shop: A temporary fabrication shop set up in the field near a
construction project by a contractor to fabricate piping, fittings and/or structural
components.

IEU: Inspection Engineering Unit

OID: Operation Inspection Department

Welder Job Clearance Card (JCC): An identification card (Form SA-4758-ENG)

issued by Saudi Aramco Inspection Agency to contractor’s welders after verification of
their qualification card or certificate issued by a Saudi Aramco approved Welder
Testing Agency. The Welder Job Clearance Card will allow the welder to start welding

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Document Responsibility: Project Quality Standards Committee SAEP-324
Issue Date: 12 October 2015
Next Planned Update: 12 October 2018 Certification Review and Registration of Project Welders

in the specified project within the limits of their qualification (See Appendix II).
The JCC contains the welder’s name, symbol, photograph, limits of the qualification,
project reference (i.e., BI Number/JO Number or Work Order Number), name of
Contractor Company and Saudi Aramco Inspector’s name and signature.

Maintenance Project: A project to perform maintenance work under a short form

contract with the maintenance department as the proponent.

Manufacturer’s Fabrication Facility: A facility engaged in fabrication of assembled or

sub-assembled products under a Purchase Order and monitored by Vendor Inspection.

PMT: Project Management Team

Project Inspector: Refers to Saudi Aramco Project Inspection who verifies project
quality, integrity and compliance with industry and international codes/standards.

Qualification: See preferred term Welder Performance Qualification.

Qualification Card: A photo identity card issued by an approved Welder Testing

Agency to a welder passing a certification test that lists all the welder essential variables
and limitations in welding. Qualification Cards must be carried at all times by the
welder, and must be presented for review upon request.

Qualified Welder: See preferred term Certified Welder.

Registered Welder: A welder whose certification has been reviewed, found to be

acceptable, and is listed in the Welder Registration and Tracking System established for
specific project.

Retraining: As used in this procedure, a welder shall require a minimum of 40 hours

of practice and instruction on the applicable welding process.

Renewal: A process of the reinstating the welder qualification certificate after the
expiration period or approval revoke.

Saudi Aramco Approved Welder Testing Agencies: Any agency approved by IEU to
qualify as an approved agency for qualifying welders/welding operators for Saudi
Aramco.

Uncertified Welder: A welder that does not have a valid welder certification from an
approved Welder Testing Agency.

Unqualified Welder: See preferred term Uncertified Welder.

Welder Certification: Certification in writing that a welder has produced a test weld
meeting a defined standard.

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Document Responsibility: Project Quality Standards Committee SAEP-324
Issue Date: 12 October 2015
Next Planned Update: 12 October 2018 Certification Review and Registration of Project Welders

Welder Performance Continuity Record: A record maintained to document welder’s

qualifications and his continuity of production welds.

Welder Performance Qualification: The demonstration of a welder’s ability to

produce test welds meeting a defined standard.

Welder Testing Agency (WTA): It is an agency approved by Saudi Aramco.

WPS: Welding Procedure Specification

WTA: Welder Testing Agency

WTS: Welder Tracking System

WRR: Weld Rejection Rate

5 Responsibilities

5.1. Saudi Aramco

5.1.1 The IEU supervisor under OID is responsible for maintaining the
approved list of Welder Testing Agencies (WTA).

5.1.2 The Project Inspector is responsible for:

a) Reviewing welder certifications and issuance of Job Clearance
Cards prior to start of welding.
b) Monitoring the initial production welds of welders to determine
their ability to make sound welds in accordance with the approved
welder performance guidelines criteria per Appendix I.
c) Monitoring the contractor’s quality control program to ensure
welder certifications, registration and performance are being
maintained in accordance with the governing codes and standards of
the project or as referenced in Section 3.
d) Reviewing weekly welders’ performance assessment and revoking
JCC’s card for poor welding performance, as per Appendix I,
through PMT.

5.2 Contractor

5.2.1 Contractor’s QA/QC Manager is responsible for:

a) Ensuring all Welders are certified by Saudi Aramco Approved
Welder Testing Agencies.

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Document Responsibility: Project Quality Standards Committee SAEP-324
Issue Date: 12 October 2015
Next Planned Update: 12 October 2018 Certification Review and Registration of Project Welders

b) Developing and maintaining a Welder/Welding Operator

Registration and Tracking Record to list all project approved
welders (Appendix IV). This record will serve as the Master List of
welder qualification and performance status.
c) Reviewing welder qualification to see if it meets project requirements
before submission to Project Inspector for issuance of JCC.
d) Monitoring the initial production work of welders to determine their
ability to make sound welds in accordance with the approved welder
performance criteria per Appendix I.
e) Designating a Contractor’s Project Welder Tracking Coordinator
(PWTC).
f) Revoke JCCs in conjunction with Project Inspector and PMT.
g) Performing monthly review on JCC status and availability to ensure
all welders working in the project are available and tracked.
h) Rating the performance of welders as identified in Appendix I,
Welder Performance Guidelines.

5.2.2 The Contractor’s Project Welder Tracking Coordinator (PWTC) is

responsible for the following:
a) Registering welders and tracking issued JCC’s, welder performance
and revoked JCC’s during project.
b) Maintaining a welder identification system and welder registration
records by utilizing Appendix IV.
c) Conducting weekly welder performance assessment and report poor
performing welders to Welding supervisor /foreman and QA/QC
Manager.

6 Instructions

6.1 General Requirements

6.1.1 Welders working in construction projects and contractor’s fabrication

shops, In-Kingdom and/or Out-of-Kingdom, shall be tested and certified
by approved Third Party WTA.

6.1.2 WTA is not allowed to qualify their own welders and welding operators
working in the same project.

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Document Responsibility: Project Quality Standards Committee SAEP-324
Issue Date: 12 October 2015
Next Planned Update: 12 October 2018 Certification Review and Registration of Project Welders

6.1.3 Prior to start of welding activities, Contractor shall submit a Welder

Registration and Tracking System to Project Inspector. Contractor shall
establish a welders performance monitoring system or welder Data
tracking system to be used throughout the life of the project consistent
with SAEP-1160 requirements.

6.1.4 Prior to start of production welding, Contractor shall submit welder’s

valid qualification certificate and/or Welder’s Performance Continuity
Record to project inspector. Project Inspector will review all essential
variables to ensure welder’s qualification meet project requirements and
then issue a Job Clearance Card (JCC) as provided in Appendix II of this
procedure.
Commentary Note:

The project welders in the field must carry on their original JCC cards
with PID original signatures, no scans or copies will be allowed.

6.1.5 The project inspector shall be authorized to retest or remove any welder
at any time due to unsatisfactory work or poor performance as identified
in Appendix I, Welder Performance Guidelines.

6.1.6 The Project Inspector shall regularly audit welder certifications to ensure
fabricator compliance with the Codes, standards and approved Quality
Plan.

6.1.7 All welders shall be qualified in accordance with ASME IX, AWS D1.1,
D1.6, D1.8, or API STD 1104, this SAEP as required and additional
requirements in the design code if required, for all types of welds
including tack, temporary and repair welds.

6.1.8 The first three (3) production butt welds made by each new welder,
regardless of welding process, shall be 100% examined by the applicable
NDE method. NDE acceptance shall be as specified by the applicable
Code. Decision path for evaluation of the first three (3) production welds
is illustrated in Appendix III.

6.1.9 The first three production butt welds will not be included in the project
welding statistics or weld repair rates for daily welding production
percentage. The percentage radiography requirement is as listed in the
applicable SAES-W-011, Section 17 and SAES-W-012, Section 16.
Each welder and Welding operator’s work shall be represented in the
required selection.
Commentary Note:

Percentage coverage of welders may extend to higher percentage to

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Document Responsibility: Project Quality Standards Committee SAEP-324
Issue Date: 12 October 2015
Next Planned Update: 12 October 2018 Certification Review and Registration of Project Welders

cover welder's weekly weld production, if number of joints welded in a

week are less than 10.

6.1.10 For tank welding, the first three (3) production butt welds to be
radiographed shall be the first three shots of 6” length of each weld.

6.1.11 Targeted performance criteria on Weld Rejection Rate (WRR) for

Welder and Welding Operator is 0.2% on linear method and 5% on weld
joint method, with linear method being the over-riding factor.
From the performance data the welders shall be categorized based on the
linear Weld Repair Rate (WRR) as detailed in Appendix I.

6.2 Construction and Fabrication Shop/Yard

6.2.1 Structural welders for structures in seismic conditions defined by

AWS D1.8 shall meet the qualification requirements of AWS D1.1 and
the Supplemental Welder Qualification for Restricted Access Welding
Test as prescribed in Annex D of AWS D1.8. Weld joints are identified
to be in seismic condition when production weld involves all of the
following:
a) The weld is Demand Critical
b) The weld joins the bottom beam flange to the column flange
c) The weld must be made through a weld access hole in the beam web

The qualification of welders in accordance with Annex C is only

required when all three of these preceding conditions are part of the
production weld. If anyone is not present (i.e., a production weld that is
not made through a weld access hole) this qualification is not required,
even though such a weld may be Demand Critical. (See D1.8, clause
5.1.1).

6.2.2 The qualification of a welder who has taken the Annex D Supplemental
Welder Qualification test is valid for 36 months, providing the D1.1
continuity requirements are also met (i.e., the process is used at least
every six months). (See D1.8, clause 5.2).

6.2.3 Welder’s Performance Continuity Records shall contain welder

certifications and previous performance history supported by a
permanent NDT report (RT or UT) confirming that welder has been
welding within the past 6 months.

6.2.4 In the absence of a valid Welder’s Performance Continuity Record, the

welder shall be subjected to requalification test and certification by
approved Welding Testing Agency.

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Document Responsibility: Project Quality Standards Committee SAEP-324
Issue Date: 12 October 2015
Next Planned Update: 12 October 2018 Certification Review and Registration of Project Welders

6.2.5 Upon issuance of JCC, the welder shall be registered in the project’s
Welder Registration & Tracking System. Welders that have not been
properly certified and registered shall not be permitted to weld.

6.2.6 For offshore pipelines and structures, all welders shall be qualified per
applicable code and this SAEP.

6.2.7 Job Clearance Card (JCC) is only valid for the job or project it is issued
for. With approval of the project inspector, job clearance cards may be
issued per contract number of the contractor which may involve work
activities with numerous BI or JO.

6.2.8 Job Clearance Cards can be withdrawn by the Project Inspector at any
time for cause if the contractor welder is not producing work of
acceptable quality. Withdrawal of JCC shall be done through Project
Management and once withdrawn, JCC will only be reinstated upon
receipt of written proof of training, and the successful completion of a
recertification test by approved Welder Testing Agency.

6.2.9 When the welder leaves or terminated, Job Clearance Cards shall be
returned to Welder Tracking Coordinator to update the Welder
Registration and Tracking System. Welders returning to work within six
(6) months (to the same project) may be reinstated without retesting.

6.3 Sub-Contractor Fabrication Yard/Shop

6.3.1 All requirements listed in Section 6.2 apply to sub-contractor fabrication

yards or shops that are located In-Kingdom or Out-of-Kingdom.

6.3.2 The fabricator shall maintain a welder identification system and welder
registration and tracking system acceptable to the Project Inspector
utilizing Appendix IV as minimum to follow. Welders shall carry an
identification card that includes a photo, welders name, company
identification number, and welder’s symbol.

Revision Summary
12 October 2015 Major revision to include the technical responsibility of conducting Welder Testing Agency
Assessment by Inspection Engineering Unit (IEU) to have high levels of project quality.

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Document Responsibility: Project Quality Standards Committee SAEP-324
Issue Date: 12 October 2015
Next Planned Update: 12 October 2018 Certification Review and Registration of Project Welders

Appendix I - Table for Welder Criteria

Welder Performance1 Guideline (Contractor Welders)

(On-Plot & Pipeline Manual / Semi-automatic Processes6)
2 2 3, 4, 5, 6
Linear Joint Qualification & Performance
Welder (Weekly & overall) - Weld Rejection
JCC Status Repair Rate Repair Rate
Classification Rate, WRR
(Lr / Lw) (Jr / Jw)
7
Level A Welder , achieves both
Maximum maximum 0.2% Linear and 5% Joint
A Acceptable 5%
0.2% Repair Rates
7
Level B Welder , achieves up to
Maximum maximum 0.4% Linear and up to
B Acceptable 7.5%
0.4% 7.5% Joint Repair Rate
7
Level C Welder , borderline, always
Maximum meets maximum 0.5% Linear and
C See Note 7 See Notes regularly meets 7.5% maximum
0.5%
allowed Joint Repair Rate
8
Level D Welder , consistently
(weekly) exceeds above 0.5% linear
Not Above Above and 7.5% joint rate.
D
Acceptable 0.5% 7.5% Pipe welding qualification to be
Revoked. Note 8

Notes:
1. Contractor’s Welding Process Control Procedure (Company approved) shall clearly state acceptable
Welding Performance parameters for initial and weekly production.
2. Procedure shall define Linear & Joint method performance targets and these quality targets shall be
acceptable to COMPANY and approved before welding begins where Lr is the welder's total length of
repairs in one week, Lw is the welder's total length of weld radiographed in one week, Jr is total rejected
welds and Jw is the total joint welds radiographed.
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.
b. Welders shall not make additional initial production welds until their “initial performance” has been
verified and NDT results are acceptable per the procedure.
c. First three joints shall not be counted as routine daily production for project WRR.
4. Procedure states maximum number of consecutive weeks when a welder exceeds performance targets.
Severe weather or other factors beyond welder control may be considered.
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.
6. Pipeline Projects using Semi-automatic / Automatic / Combination Processes may utilize even more
stringent Weld Quality Guidelines than those listed above for Manual process.

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Document Responsibility: Project Quality Standards Committee SAEP-324
Issue Date: 12 October 2015
Next Planned Update: 12 October 2018 Certification Review and Registration of Project Welders

7. Level A, B & C Welders

a) In all cases, Welder performance should target “A” Classification results with the lowest possible
Linear & Joint Repair Rates achievable.
b) Continuing Process Improvement, Cost Effectiveness is acceptable for Cat. A & B welders.
c) Cat. C welders are not cost effective and require close supervision
8. Level D Welders
a) Welders may exceed the 7.5% joint WRR weekly for a maximum period of 2-3 weeks with close
surveillance on all repairs.
b) Additional supervision / additional NDT (to 100%) is required until consistent results of 7.5% WRR or
less (joint repair rate) are achieved.
c) 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.

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Document Responsibility: Project Quality Standards Committee SAEP-324
Issue Date: 12 October 2015
Next Planned Update: 12 October 2018 Certification Review and Registration of Project Welders

Appendix II - Template Job Clearance Card

Welder Job Clearance Card

Saudi Aramco SA-4758-ENG (9/15) Required by SAEP-324

WBS
Photo
Project

Contractor

Welder Name Symbol Cert. Ref No.

Note: This clearance card is for welding on the above mentioned project
only, and may be revoked if welder's performance is not satisfactory.
Card must be returned when welder is removed from this project.

PID Inspector Issuing Card JCC No. Date

Welder Job Clearance Card (Back)

PID Section

Cleared for Welding On

Material P-No's
Process
Electrodes/F-No's
Position/Progression
Min/Max Thickness
Diameter Range
(Backing/Inert Backing)
WPS No.
JCC-No.

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Document Responsibility: Project Quality Standards Committee SAEP-324
Issue Date: 12 October 2015
Next Planned Update: 12 October 2018 Certification Review and Registration of Project Welders

Appendix III - Flow Diagram of Radiographic Requirement

for 1st Three Production Welds

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 Document Responsibility: Project Quality Standards Committee SAEP-324
Issue Date: 12 October 2015
Next Planned Update: 12 October 2018 Certification Review and Registration of Project Welders

Appendix IV - Sample of Welder Registration and Tracking Record

(SAEP 324 Appendix IV- Sample of Welder Registration and Tracking Record)
WELDER REGISTRATION AND TRACKING RECORD
PROJECT NAME:
BI: JO: CONTRACT No.:
CONTRACTOR: LOCATION:
WELDER REGISTRATION DETAILS OF QUALIFICATIONS
Recording the
Serial No. Date of Last STATUS/REMARKS
Continuity Date of PID
OR Welder's Name Symbol ID Number Date of Test Continuity Record PID Inspector PID Signature Welding Process Material (P-No) Electrodes Position Thickness Range Diameter Range
Record (i.e. NDT Approval
JCC No. Verificied
Report No.)

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