Saudi Aramco Inspection Checklist: Selection of Welds For NDE (On-Plot Piping & Structures) SAIC-W-2015 Weld

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

SAUDI ARAMCO INSPECTION CHECKLIST
Selection of Welds for NDE (On-Plot Piping & Structures) SAIC-W-2015 WELD-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.
LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.
SCHEDULED INSPECTION DATE & TIME ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?
SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
A General Requirements for SAEP-1160 Database (Selection of Welds for NDT shall meet SAEP-1160 Reqmts)
Weld Selection for NDT shall be identified in design along with the
Project NDE
Welding specification per line class & per line (SAES-L-310, Sect 7) This
Spec
is set forth in a proposed project NDE specification for owner Inspector
A1 Reqmt,
approval (PID responsibility per ASME B31.3 & CSD).
SAES-L-310,
Follow the NDE SATIP & NDE Process Control Procedure
Section 7
Weld Selection for NDT shall be identified (collected, linked, &

SAEP-1160,
maintained for each weld applicable) on an SAEP-1160 Database.
A2 Section
When UT is used in lieu of RT the tracking & reporting requirements shall
6.1
remain the same. See also SAIC-W-2008 Checklist.
Weld Selection for NDT ... See Attachment 1

A) Sequence of Process & NDT is critical. (NDT of PWHT
welds for P-Nos 3, 4 & 5 materials prior to PWHT should be considered
for information only & not final acceptance. The intent is to evaluate the
weld quality prior to PWHT so any unacceptable discontinuities can SAEP-1160,
A3 be repaired prior to PWHT. (Spec shall state sequence of NDE) Section
B) NDE 6.1
Process Control Procedure is used (SAIC-NDT-2010 Series)
C) Design Information & Code Criteria (Based on Service)
... Ex: Severe Cycle Service has
different code acceptance criteria
NDT Control and Identification ... See Attachment 1
This number, once assigned to a weld, shall remain with
weld until final acceptance. Repeated NDT on a weld shall be indicated SAEP-1160,
A4 by adding or modifying the NDT Report Number suffix similar to that Section
used for weld repair as stated below. 6.1
NDT Process Control Procedure is also req'd. See
Notes.
Selection of Tracer Welds ... See Attachment 1

A) Two tracer welds must be selected for each
rejected weld in a 10% RT system. The two welds must have been
welded by the same welder using the same welding process and use the SAEP-1160,
A5 NDT method as the initial weld for evaluation. Section
B) Progressive sampling of welds 6.1
(tracer welds) shall follow the progressive sampling method as stated in
governing SAES. Tracer welds are not to be counted in the 10%
sampling process.
Results of RT Film Evaluation by Saudi Aramco
A) Welds rejected for weld quality requiring repair
have their original weld id numbers modified by suffix & progression
(R1, R2, T1, T2, T1R1, T1R2,
T2R1, T2R2, etc) B) Welds SAEP-1160,
A6 rejected for film quality (error exists in SAEP-1160) require reshoot Section
as follows: 6.1
W-01 (Reshoot) ... using lead letter ID
See also SAIC-RT-2010 Checklist
Page 1 of 23
Initial production work of contractor welders shall be monitored by SAEP-324,
A7
the project inspector to determine their ability to make sound welds. Para. 6.2.6
Page 2 of 23
ITEM
No.
For progressive examination requirements, a lot shall be defined as all of

the same kind of welds made since the last acceptable weld, excluding SAES-W-011,
A8
"penalty" examinations, for a given welder from any previous production Para. 17.1.9
on a specific line classification.
The progressive examination shall be limited to the specific welder with SAES-W-011,
A9
the defective welds. Para. 17.1.9
The last acceptable weld is defined as a weld that has been examined
SAES-W-011,
A10 and accepted by both RT (or UT) and all other specified NDT methods
Para. 17.1.9
(visual, PT, MT).
The "same kind" of weld is defined as: the same process or

combination of processes, same type of joint (groove vs. fillet), and SAES-W-011,
A11
same P-Number. Different diameters and wall thicknesses may be Para. 17.1.9
classified within the "same kind" of weld.
CONTRACTOR DATABASE MAKES EVERY ATTEMPT TO MINIMIZE

EXCESSIVE NDE ON 10% LINES BY UTILIZING AN NDE DATABASE SAES-W-011,
PER WELDER WEEKLY PRODUCTION. This requires "lot & kind" be Para. 17.1.9 &
established by agreement at the start of the project. Using an "ISO- Para.
A12
based" lot and kind results in excessive NDE exceeding 10% reqmt. 17.5.2 &
Note: Where less than 100% radiographic coverage is reqd, BEST
random selection of welds is based on the weekly weld production. PRACTICE
Initial Testing of Newly Certified Welders (JCC cards have been issued) ... Selection shall be based as follows:
1) Welders shall prove themselves capable of quality welding at the start of production.
B 2) Quality welding is clearly defined below as related to the start of a Project.
3) Project NDE Specs (Notes) or Process Control Procedure
shall specify initial quality to maintain qualifications.
Initial 3* butt welds of each welder are selected for RT.

SAEP-324,
B1 *Other numbers exceeding 3 may be tested per Contractor.
Para. 6.2.1
*List amount tested ____________.
Initial 3* socket welds for each welder are selected for RT.
SAEP-324,
B2 Welders shall meet all requirements listed in
Para. 6.2.6
SAIC-W-2037.
INITIAL WELD QUALITY & WELDER STATUS SHALL BE THAT

WELDERS PASS ALL THREE WELDS (INITIAL PRODUCTION).
SAEP-324,
Note: Welder proceeds with Production subject to the NDE spec.
Para. 6.2.6 &
Welder shall maintain an acceptable repair rate as
SAES-W-
agreed upon FAILURE OF ANY OR
011, Para. 8.4 &
ALL OF FIRST THREE WELDS SHALL: A) Result in
SAES-
welder disqualification (Pull JCC, Return to SA)
W-011, Para
B3 B) Result in welder close monitoring and retraining and:
17.1.3
1) Additional 100% RT for 1 entire week's production
See
after the initial three welds were tested (RT) to determine if a welder can
make Quality Welds 0.50% Linear, 10% Joint Basis per SAIC-W-2016.
SAIC-W-2016
2) Welder shall be
(Pre-
given a maximum of 2 full week's production, each evaluated separately
Job Agreement)
(weekly) or 10 joints minimum to demonstrate his ability to Saudi Aramco
to make sound welds.
C SAES-W-011, Section 17.5 (NDT Coverage) & ASME B31.3 NDE Selection Requirements
Page 3 of 23
ITEM
No.
NDT Coverage
All welds are inspected per ASME B31.3 & SAES-W-011.
SERVICE CATEGORY IS DESIGNATED &
KNOWN: A) CATEGORY D = D
B) CATEGORY M = M
C) NORMAL SAES-W-011,
C1
SERV = N Para. 17.5
D) SEVERE CYCLE = S
NEVER SELECT OR EVALUATE NDE WITHOUT USING THE
CORRECT SERVICE CATEGORY AND CODE CRITERIA!
SEE ATTACHMENT 2 (ASME TABLE 341.3.2)
Visual Examination: (Table 341.3.2 Criteria)

A) All welds shall be visually examined. Visual exam shall be performed
(and accepted) prior to other NDT.
B) Where accessible, welds shall be visually examined from root side to Visual Exams
ensure that proper penetration & fusion have been achieved SAES-W-
C2
C) Service & Category (Normal, D, M, Severe 011,
Cycle) must be known Verify SAIC-W- Para. 17.5.1
2007 Final Inspection Checklist is covered thoroughly & understood
by Inspectors performing visuals. Those supervising NDE ensure
techs understand the criteria.
Butt welds in piping shall be RT'd as required below and:

A) If a weld falls under multiple classifications, the
most stringent requirement is applicable.
B) Minimum percent coverage of specified
RT Exams
NDT method may be increased (at any level up to 100%) if, in the
SAES-
C3 opinion of authorized SA inspector, welds are of questionable
W-011,
workmanship or if NDT indicates an excessive number of defects.
Para. 17.5.2
C) Additional or alternative
NDT methods may be used at the discretion of the authorized Saudi
Aramco inspector in order to assist in determining the type or extent of
defects.
RT Exams
For welds below 100% RT requirements, selection of welds is based on
SAES-
C4 the weekly weld production at a minimum. The detailed requirements of
W-011,
SAEP-1160 apply. (Backlog basis = 7 days)
Para. 17.5.2
Weld joints selected due to progressive examination requirements (after

RT Exams,
weld defects are found) shall not count toward the required overall exam
SAES-W-011,
C5 frequency (%). Tracer shot is the correct term per SAEP-1160. Many
Para. 17.1.9
still refer to the term Penalty* shot. *This implies just what it is, a
Penalty requiring extra work
Onshore Piping RT & Offshore Piping RT Reqmts:

RT Exams
See Attachment 3 Tables & Notes. SAES-
C6
Note: Error in Note 2. It W-011,
should read P-3, P-4, & P-5. These P-Nos are for Low & Intermediate Para. 17.5.2.1
Alloys. P-6 is not used at S.A.
For on-shore piping, at least 10% of the each week's production weld
(circumferential girth welds), are radiographed for:
a. Carbon steel & low alloy steel for general & hydrocarbon Serv. RT Exams
b. Firewater systems (Interpreted to "normal fluid service") SAES-
C7
c. Shop fabricated pipe matls for low temp service below -18°C W-011,
d. Shop fabricated alloy steel, Stainless steel nonferrous materials for all Para. 17.5.2.1
services except Category D fluids.
Shop is an indoor facility approved by SA Insp per SAIC-L-2031.
Page 4 of 23
ITEM
No.
For on-shore piping, 100% RT is performed on the following:

a. Field welds of piping in low temp service below -18°C.
b. Shop fabricated alloy steel, P-No. 3, 4, and 5 materials. RT Exams
c. For field & yard welds of all alloy steel materials (P4 & above), SAES-
C8
stainless, & nonferrous matls for all services except Cat D fluids. W-011,
d. Hydrocarbon service at road crossings (carrier pipe only). Para. 17.5.2.1
e. Piping with severe cyclic conditions (as defined in B31.3).
f. Category M fluid service (as defined in B31.3).
For off-shore piping top side piping in Category D fluid service above
0°C (includes all lines over water, over tidal flats, or within 30 m of the
shoreline), 10% of the weekly production welds are random selected for
radiography. These are:
a. Firewater systems SAES-W-011,
C9
b. Raw water system Para. 17.5.2.2
c. Pressure sewer system
d. All open non-pressure vents and drains
(NOTES: a. Stainless steel in chlorinated sea water is excluded.
b. Results are interpreted to "normal fluid service".)
For off-shore top side piping (includes all lines over water, over tidal flats,
or within 30 m of the shoreline), 100% of the welds of piping systems
SAES-W-011,
C10 listed below are selected for radiography:
Para. 17.5.2.2
a. All services other than Category D fluids
b. Stainless steel in chlorinated sea water service.
Selection of welds for 10% RT is strictly controlled by procedure.

C11 RT Process Control Procedure details all SAIC-RT-2010
aspects of Weld Selection for NDE. Refer to SAIC-RT-2010 for details.
Selection of welds for 10% RT includes welds completed by each welder.

C12 as referenced
{ASME B31.3, Para. 341.4.1 (b) (1)}
Weld joints completed by the welder each day are recorded per SAEP- SAEP-1160,
C13
1160 requirements, Section 6. Section 6
Where multiple welders are used to weld a particular joint, daily weld
SAEP-1160,
C14 record shall indicate the weld area covered by each welder, ie: Root
Section 6
weld, hot pass, capping etc.
Magnetic Particle Testing & Liquid Penetrant Testing
Magnetic particle testing (MT) for ferromagnetic materials. MT/PT Exams
Liquid penetrant testing (PT) for non-ferromagnetic materials.
C16
Exception: PT shall be allowed for small SAES-W-011,
diameters where MT (yoke) is cumbersome & impractical. This Para. 17.5.3
includes SW
Pressure containing welds, other than butts, 100% MT/PT. MT/PT Exams
Includes Branch
C17
Connections, Weldolets, Sockolets, & Welding Bosses ... Any other SAES-W-011,
Groove welded fittings. Para. 17.5.3.1
MT/PT Exams
All attachment welds on pressurized components that are not
C18 hydrotested after making the attachment weld shall be 100%
SAES-W-011,
examined.
Para. 17.5.3.2
D WELD MODIFICATIONS AFTER FINAL ACCEPTANCE (SEE ALSO SAIC-W-2036, SAIC-W-2013 & SAIC-W-2015)
Engineering Change Notice Procedure* covers such work.
D1 ID, Numbering, NDE & Special Processes are Sch Q, Att. VI
controlled. Tables
NDE Process Control Procedure was followed. Database was used to Special
D2 record NDE results. NDE sequence was followed relative to any special Process
process such as PWHT. SA Inspector witnessed the NDE.
E AWS D1.1 Structural Steel Welding, Repairs & NDE (All Applications of AWS D1.1)
Page 5 of 23
ITEM
No.
See
Welding & Selection of NDE meets AWS D1.1 requirements:
SAIC-M-2012
A) Visual Examination Criteria
12-
E1 B) Repair Methods &
SAMSS-007,
Required Selection of NDE See
Para.
Attachment 4 for AWS D1.1 Required NDT.
6.1.6
REMARKS:
NOTES: 1) Contractor's NDE Specification (Based on Line Class Tables & Design) & NDE Process Control Procedure shall cover elements
of this checklist and provide clear direction for NDE Service Provider Companies, along with close supervision. This requires training and
coordination between the Prime Contractor supervising the work, any Subcontractor (also supervises work) & the NDE Service Provider.
DO NOT BYPASS THIS CHECKLIST IN LIEU OF A PROJECT NDE SPECIFICATION. USE APPLICABLE ELEMENTS & ATTACHMENTS.
Attachments:
Attachment 1 - SAEP-1160 DATABASE, PROCESS CONTROL TRACKING (By Weld)
Attachment 2 - ASME B31.3 Process Piping Welding Acceptance Criteria (Table 341.3.2)
Attachment 3 - SAES-W-011 Onshore & OffShore NDE Requirements
Attachment 4 - Structural Steel Welding Requirements, Repairs & NDE (AWS D1.1)
REFERENCE DOCUMENTS:
1. SAES-W-011, Welding Requirements for On-Plot Piping, 30 th March, 2005
2. SAEP-324, Certification Review and Registration of Project Welders and Brazers, (30 June, 2003)
3. SAEP-1160, Tracking & Reporting of Welding, NDT and Pressure Testing for Capital Projects (17 July 2006)
4. 12-SAMSS-007, Fabrication of Structural and Miscellaneous Steel (30 April 2005)
5. American Welding Society (AWS) D1.1 Structural Steel Welding Code (Latest Edition)
6. ASME B31.3, Process Piping, (Latest Edition)
Contractor / Third-Party Saudi Aramco

Construction Representative* PMT Representative
Work is Complete and Ready for Inspection: T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:
QC Inspector PID Representative

Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:
QC Supervisor Proponent and Others

Quality Record Approved: T&I Witnessed QC Record Reviewed Work Verified
Name, Organization,
Name, Sign and Date:
Initials and Date:
*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FAILED
Page 6 of 23
Attachment 1 - SAEP-1160 DATABASE, PROCESS CONTROL TRACKING (By Weld)

ASME B31.3 EQUAL LEG FILLET WELD (Fig 328.5.2A) - Acceptable Fillet Weld Shape & Contour
Note: Leg Size shall be determined by Fillet Gage* (Properly Used Depending upon the weld contour)
Attachment 3 - SAES-W-011 Onshore & OffShore NDE Requirements
NOTE TO INSPECTORS: Note 2 above (typo error) ... Should read P3, P4 and P5. No P6 applications at SA.
MT & PT REQUIREMENTS
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)
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.
12-SAMMS-007 WELDING INSPECTION REQMTS
12-SAMMS-008 CORRECTION OF ERRORS (REPAIR PROCEDURE SHALL COPY & PASTE ELEMENTS)
PIP STS05130 CORRECTION OF ERRORS (REPAIR PROCEDURE TO INCLUDE)

Saudi Aramco Inspection Checklist: Selection of Welds For NDE (On-Plot Piping & Structures) SAIC-W-2015 Weld

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Saudi Aramco Inspection Checklist: Selection of Welds For NDE (On-Plot Piping & Structures) SAIC-W-2015 Weld

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

SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

Weld Selection for NDT shall be identified (collected, linked, &

Weld Selection for NDT ... See Attachment 1

Selection of Tracer Welds ... See Attachment 1

For progressive examination requirements, a lot shall be defined as all of

The "same kind" of weld is defined as: the same process or

CONTRACTOR DATABASE MAKES EVERY ATTEMPT TO MINIMIZE

Initial 3* butt welds of each welder are selected for RT.

INITIAL WELD QUALITY & WELDER STATUS SHALL BE THAT

Visual Examination: (Table 341.3.2 Criteria)

Butt welds in piping shall be RT'd as required below and:

Weld joints selected due to progressive examination requirements (after

Onshore Piping RT & Offshore Piping RT Reqmts:

For on-shore piping, 100% RT is performed on the following:

Selection of welds for 10% RT is strictly controlled by procedure.

Selection of welds for 10% RT includes welds completed by each welder.

Contractor / Third-Party Saudi Aramco

QC Inspector PID Representative

QC Supervisor Proponent and Others

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

Attachment 1 - SAEP-1160 DATABASE, PROCESS CONTROL TRACKING (By Weld)

Attachment 3 - SAES-W-011 Onshore & OffShore NDE Requirements

AWS D1.1 Allowable Repairs (Note NDE Required)

AWS NDT Specs (Section 6, Part C)

PIP STS05130 CORRECTION OF ERRORS (REPAIR PROCEDURE TO INCLUDE)

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