SAUDI ARAMCO ID/PID - 24-Mar-2016 - REV. 2015.09.01 (Standards Cutoff - September 6, 2015) Rev. 2015.09.

01 6-Sep-15
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Supplemental Procedure - Method Statements
SAIC-W-2018 24-Mar-16 MECH-
related to Overlay Welding, Cladding Restoration, Repair
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
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

Welding procedures for corrosion resistant weld overlay have been

SAES-W-014,
A1 prepared & qualified in accordance with ASME SECTION IX & SAES-W-
Para. 5.1
014 and CSD has approved the Welding Package. (Refer SAIC-W-2017)

All corrosion-resistant weld overlays, including clad restoration, shall

conform with ASME SEC VIII reqts (Div. 1 or Div. 2) & W-014. SAES-W-014,
A2
Commentary Note: Refer to ASME SEC VIII D1, Part UCL and ASME Para. 4.1
SEC VIII D2, Article F-5 for specific requirements.

Repairs to integrally clad material shall not be done without the specific
SAES-W-014,
A3 approval of CSD. Any weld repairs to the cladding shall meet the
Para. 4.7
requirements for weld overlays.

The required deposit thickness of overlay as required by specific design

requirement is known and procedure relates how it shall be accomplished SAES-W-014,
A4
(for all surfaces & types of overlay).The deposited overlay thickness shall Para. 4.2
not be less than 3 mm for corrosion-resistant overlays.

Single layer overlays require prior approval by CSD. Additional

SAES-W-014,
A5 qualification and production tests may be required, as determined by
Para. 4.9
CSD.

Weld deposit chemistry shall be specified in engineering design. Where a

nominal alloy designation for overlay or cladding is listed (e.g., 316L), then SAES-W-014,
A6
overlay deposit shall meet equivalent filler metal composition reqmts Para. 4.4
unless otherwise specified or exempted.

The direction of overlay deposition shall be circumferential unless

otherwise approved by CSD. (Some components and geometries, such SAES-W-014
A7
as small diameter nozzles, or special applications may not permit welding Para. 4.3
in a circumferential direction.)

The WPS shall indicate the minimum deposit thickness qualified and the
minimum number of layers required. The number of layers used for the SAES-W-014,
A9
Procedure Qualification Record (PQR) shall be recorded and shall be the Para. 5.2
minimum number of layers specified on the WPS and used in production.

Method of Weld Overlay identification (to be supplemented by the weld SAES-W-010,

A10
map - see SAES-W-010, Para. 7.1.2). MARKING METHODS! Para. 15.1/15.2

Saudi Aramco: Company General Use

SAUDI ARAMCO ID/PID - 24-Mar-2016 - REV. 2015.09.01 (Standards Cutoff - September 6, 2015) Rev. 2015.09.01 6-Sep-15
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Supplemental Procedure - Method Statements
SAIC-W-2018 24-Mar-16 MECH-
related to Overlay Welding, Cladding Restoration, Repair
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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

B Requirements for production welding inspection and testing

Production welding shall conform to the WPS, including all supplementary

SAES-W-014,
B1 essential variables and restrictions specified in this standard, such as heat
Para. 6.1
input restrictions , flux brand , and bead overlap (Also refer SAIC-W-2017)

Base metal shall be cleaned and this requires removal of the mill scale
SAES-W-014,
B2 and any adherent corrosion products. Caution: Repairs may require
Para. 6.2
special cleaning such as grit blasting or mechanical cleaning

Cladding restoration portion of weld joints between clad materials or

SAES-W-014,
B3 attaching clad materials to other materialsls shall meet requirements for
Para. 4.5
weld overlays.

Joint preparation & details for weld joints in clad vessels (incl weld SAES-W-014,
B4
overlays) shall be per SASD AB-036367. Para. 4.6

Ferrite measurements are per AWS A4.2.

Note: Calculation of the ferrite content using Schaeffler or DeLong
SAES-W-014,
B5 diagrams based on the chemical composition is not sufficient for critical
Para. 4.8
applications (CSD to determine). Actual measurements using methods
specified in AWS A4.2 are required. (SAIC-W-2030)

Actual overlay thickness achieved, after any machining, shall be

measured by ultrasonic methods or by physical measurement.
SAES-W-014,
B6 Note: A detailed procedure shall be submiited to
Para. 6.3
Inspection for review and approval. Minimum final thickness shall not be
less than thickness specified in the engineering design.

Final weld overlay surface shall have the chemical composition checked
prior to final PWHT or hydrotest. Chemistry is tested as described below.
All elements specified for deposit chemistry shall be analyzed and
reported (except for carbon when using the X-ray fluorescence method) :

A) Physical sample (drillings) removed for quantitative analysis OR

B) Portable spectrograph. With the specific approval of SA Insp, a SAES-W-014,

B7
portable X-ray fluorescence machine may be used instead of a Para. 6.4
spectrograph.
Note:
1) Analysis method & accuracy limits for each element shall be submitted
to Inspection for review & approval.
2) Repair method for
areas where samples have been removed shall be submitted to
Inspection for review and approval.

Frequency of chemical composition analyses shall be as follows:

A) Automatic welding - One analysis for each overlay
area or clad joint. Separate analyses shall be made for each heat/batch of SAES-W-014,
B8
filler metal or electrode. Para. 6.5
B) Manual - One analysis for each 1 m sq. of area or one analysis at
intervals of 2 m or less for overlay restoration of clad joints.

Saudi Aramco: Company General Use

SAUDI ARAMCO ID/PID - 24-Mar-2016 - REV. 2015.09.01 (Standards Cutoff - September 6, 2015) Rev. 2015.09.01 6-Sep-15
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Supplemental Procedure - Method Statements
SAIC-W-2018 24-Mar-16 MECH-
related to Overlay Welding, Cladding Restoration, Repair
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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

Ferrite measurements shall be made for austenitic SS welds when the

design temp exceeds 427°C: A) Ferrite
SAES-W-014,
content shall be checked in the as-welded condition.
Para. 6.6
B9 B) Ferrite Number shall be between 3 and 10
FN. C) Ferrite number
(SAIC-W-2030)
checks shall be performed at the same frequency as specified above
(Item B8) for chemical composition analyses.

For service temperatures below 427°C, the chemical analysis results shall
SAES-W-014,
be used to calculate the ferrite content using the DeLong diagram. If
Para. 6.6
B10 calculated ferrite content is not between 3 & 10 FN, then actual ferrite
measurements shall be taken on production piece. The measured Ferrite
(SAIC-W-2030)
Number shall be between 3 and 10 FN.

First layer of multi-layer overlays shall be PT examined per ASME SEC

SAES-W-014,
VIII D1, App 8 (equivalent to ASME SEC VIII D2, Art 9-2). Area examined
B11 Para. 6.7.1
shall be a 10 percent random coverage. If rejectable indications are found,
then the entire area shall be 100% examined.

Final layer, incl. single layer overlays shall be PT'd, over the entire area
(100%) per the same code criteria above (item B11).
The examination shall be conducted on the surface in its
SAES-W-014,
final
B12 Para. 6.7.2
condition, i.e., as-welded or machined. The examination shall be
conducted after the final PWHT, if PWHT is specified.
Notes: Perform an additional examination prior to
PWHT in order to find and repair any defects prior to PWHT.

SAES-W-014,
Ferroxyl test, shall be performed to determine the extent and nature of the
B13 Para. 6.7.2
cracking if determined that extensive cracking or fissuring has occurred.

Requirement for Repair Disposition (Ferroxyl Test)

A ferroxyl or ferricyanide test is an iron contamination test to determine if
SAES-W-014,
the cracking extends to the base metal. If iron contamination is found,
Para. 6.7.2
then the overlay shall be repaired by complete removal of the overlay to
B14
base metal in the area of fissuring prior to rewelding. If iron contamination
(SAIC-W-2026)
is not found, then only localized repairs are required (i.e., the excavations
only need to be large enough to completely remove the defect
indications).

REPAIRS TO OVERLAYS:
Repairs to overlays shall be performed by removing the defect by
machining or grinding (thermal methods are not permitted). Removal of SAES-W-014,
B15 the overlay defect shall not reduce the base metal thickness below the Para. 6.8
minimum design thickness. The repair area shall be welded using an
approved overlay procedure with a nominal composition that shall match
the original overlay composition.

VISUAL INSPECTION CRITERIA:

Finished overlay surface shall be free of overlaps, SAES-W-014,
B16 undercutting, & notches & shall be relatively smooth. All flux & slag are Para. 6.9
removed completel. Only SS brushes, ceramic (glass) beads, iron-free
grit, or SS grit shall be used to mechanically clean the overlay surfaces.

Saudi Aramco: Company General Use

SAUDI ARAMCO ID/PID - 24-Mar-2016 - REV. 2015.09.01 (Standards Cutoff - September 6, 2015) Rev. 2015.09.01 6-Sep-15
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Supplemental Procedure - Method Statements
SAIC-W-2018 24-Mar-16 MECH-
related to Overlay Welding, Cladding Restoration, Repair
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

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

Base Metal cladding or Overlay shall be stripped back 10 mm from each

side of weld joint prior to welding base metal portion of weld. Complete
SAES-W-014,
removal of the cladding/overlay shall be verified by a suitable etching test
B17 Para. 6.10
or chemical analysis of stripped back surface.
Note: Suitable etchants incl nitric acid or nital.

SAES-W-014,
After welding base metal portion of the joint, the side of the weld to be
B18 Para. 6.10
overlaid shall be ground flush using mechanical methods.

Hardness Testing shall be in accordance with standard drawing AB-

036386.The amximum allowable hardness is VHN 250 for the base metal.
For sour service, SAES-A-301 reqmts for weld metal overlay (Production
Hardness Testing) must be met. SAES-W-014,
Hardness testing is required for weld overlays in: Para
B19 A) Hydrogen service components of any wall thickness. 5.11.2
B) Sour service components of any wall thickness. (SAIC-W-
C) For pressure vessels in any service if the base metal wall thickness is 2012)
greater than 38 mm.
Only CSD may waive Production Hardness Testing Reqmts

Hydrogen Disbonding Test Supplement:

In high temperature, high pressure hydrogen service, the SAES-W-014,
B20 special requirements of SAES-W-014, Section 7 shall be met Section 7
REFER TO SAIC-W-2020 for Details.

REMARKS:

REFERENCE DOCUMENT: 1. SAES-W-010, Welding Requirements for Pressure Vessels, (08 September 2012)
2. SAES-W-014, Weld Overlays and Welding of Clad Materials, (11 March 2013)
3. ASME SEC VIII D1 Pressure Vessels (2013 Edition)
4. ASME SEC VIII D2 Pressure Vessels, Alternative Rules (2013 Edition)
5. ASME SEC IX Welding and Brazing Qualifications (2013 Edition)
6. AWS A4.2 Std Proc for Calibrating Magnetic Instr to Measure Delta Ferrite Content of Austenitic & Duplex Austenitic-Ferritic SS Weld Metal

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

Saudi Aramco: Company General Use