Experience Base

With ARAMCO Engineering

Standard & Procedure

SHAHID ALI
CSWIP 3.1 (Instructor)
Cell#: 00966-599-807084
Cell#: 0092-334-7497876
Email: ss_aakash@yahoo.com
Web: www.qctrainer.com
What is QA/QC?
Quality Assurance is the system of action and planning needed to
provide maximum confidence for quality requirements.

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 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
proceeded 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.

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.

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 schedule Q?
Schedule Q is an attachment to the contract, which is the provision of quality assurance and control,
Inspection and test plan.

What is WPS?
WPS is Welding Procedure Specification, It is a written document that provides direction to the
welder or welding operator for making production welds.

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?
Specifications clearly and accurately describe 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

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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
ASTM - American Society of Testing Materials
A WS D 1.1 - American Welding Society (Structural Welding)
A WS D l.6 - American Welding Society (Structure SS Welding)

Received NTI from Construction Team:-

Internally Checking and Not Proceed the Next Step Before RFI time
With NTI (ISO Drawing, MTC, SATR-W-2006 etc),
Raise the RFI in QMIS System (Pre, In-process, Post) before the 24-Hr.
According to (SATIP-W-12-01) activity No. 3.7, 3.8, 3.9 etc

For NDT
SAEP-1141 (RPP)
SAEP-1143 (RT)
SAEP-1144 (MT)
SAEP-1145 (PT)
SAEP-1146 (UT)
SAEP-1150 Inspection Coverage on Projects

Raise (Issue), Replied (Action) Open & Closed

NCR (Non-Conformance Report)
PAR (Preventive Action Request)
Surveillance Report

After Two Contactor Internal NCR for Same Violation: Escalate to raise the ARAMCO NCR
ARAMCO NCR Mean Log Book Entry
Before getting MCC should be close the all open NCRs.

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 PQP (Project Quality Plan) or
QCP (Quality Control Procedure) Standard: ASME-XI
Construction Scope of Work Design Code: 31.1, 31.3
IFC Package Project specifications

Material Arrival

MTO, MTC, Outboud Certificate

(As per Drawing)

NTI For Heat No.

Material Receiving Inspection Grade
(QC Mechanical /Piping Inspector) Specification
Class
SAP No.
Dimensional
Inspected & Release for Construction

Construction / Execution Department

Fabrication
Preparation
(ISO Drawing, MTO, Outbound)
Consumable
NTI for Cutting & Fitup to WPS
QC Piping Inspector Calibration
Welders
Pre / Inprocess / Post Weld Inspection
By QC Welding Inspector

NDT Coordinator
(Selection of Weld as per ITP, Drawing
10%, 100%)

IF Repair
(Repair Procedure (PQP), MT, Pre Heat, RT)

If Specified
(PWHT, Chart, Procedure)

Send to (NTI)
Sand Blasting, Paining & Coating

Final Inspection
Site Release (IRC)

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Daily Using SAIC & STAR as Per SATIP-W-011-01
Welding of On Plot Piping (ASME 31.1 & 31.3)

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Daily Using SAIC & STAR as Per SATIP-W-012-01
Welding of On Plot Piping (ASME 31.4, 31.8 & API-1104)

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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.

Pickling and Passivation:-

Both are chemical treatments applied to the surface of stainless steel to remove contaminants and
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%

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

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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),

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".

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Welding Consumable:
(Receiving, Handling & Storage)
Welding Consumable Control Room
Non Stop electricity should be available.
Humidity: 40 oc to 50 oc
Temperature: 5-60 oc o o
(Ideal Temp 25 c to 30 c)

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 Consumables Issuance Report

Welding Rod Oven Calibration/Verification Report

Welding Consumable Receiving Inspection Report

Electrode Test Certificate

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:

SFA-5.4 SS Electrodes (SMAW)

SFA-5.5 Low-Alloy Electrodes (SMAW)
SFA-5.6 Copper & Alloy Electrodes
SFA-5.7 Copper & Alloy Rods & Electrodes
SFA-5.9 Bare SS Electrodes & Rods
SFA-5.11 Nickel & Alloy Electrodes (SMAW)
SFA-5.12 Tungsten & Alloy Electrodes
SFA-5.13 Surfacing Electrode (SMAW)
SFA-5.14 Nickel & Alloy Bare Electrodes & Rods
SFA-5.21 Bare Electrodes & Rods, Surfacing
SFA-5.22 SS Electrodes (FCAW) & SS Flux Cored Rods (GTAW)
SFA-5.23 Low-Alloy Electrodes & Fluxes (SAW)
SFA-5.28 Low-Alloy Electrodes & Rods (GMAW)
SFA-5.29 Low-Alloy Electrodes (FCAW)

*(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

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 Major Inspection of Material Receiving

Size
Lot No.

Condition
Consumable Certificate

Type & Specification
P.O

Storage
DN

Heat Number
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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.
Drying & Re-Drying

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.

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 A 5.5
Alloy Low Hydrogen Electrode Alloy 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.

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

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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.

Tungsten Electrode: (Non-Consumable)

Zirconated (Brown) or Pure (Green) Use for AC (Cooper / Alloy, Mg, Mi, Plain Carbon, SS)
Thoriated (Red) 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)

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.

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 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 Inn accordance with WPS and being controlled as Procedure
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

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ASME SECTIONS
(ASME - American Society of Mechanical Engineers)
SECTION-1 Rules for Construction of Power Boilers
SECTION II Materials
Part A - Ferrous Material Specifications
Part B - Nonferrous Material Specifications
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
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 Ta n k s .

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

As per ASME Sec-IX: All weld passes thickness less then <13mm
Weld Bead Thickness: 3-Times of Dia of filler wire or Electrode

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

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A – Numbers:

A – Numbers are used to identify the weld metal chemical composition of ferrous metals.

ANALYSIS
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% 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 – Numbers Class. Of Filler Metals F – Nos. Class. Of Filler Metals

1 - 21 – 25 Al & Al base alloys.
2 - 31 – 37 Cu & Cu base alloys.
3 - 41 –45 Ni & Ni base alloys.
4 Low hydrogen electrode. 51 –54 Ti & Ti alloys.
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.

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.

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 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 %
A106 Gr. C – 0.35 % ER-70S-2 o
CS <20mm : 10 C 19>593°C
to 6 can 7018,7018 -1 o 250°C
P No.1 >20mm: 80-100 C to 647° C
API-5L Gr- B use on CS
A-53 Gr-B
o
ER-80S- o 600 C
CS ( LTCS) A-333 Gr-6 LTCS E-8018-1 Max 10 C 150°C o
B2 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)

CSA-53 to SS-304L
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
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.

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

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 Procedure Qualification Thickness Limits and Test Specimens

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

Thickness T of Test Coupon,
Metal Qualified (mm) Metal Qualified (mm)
Welded (mm)
Min Max Max
Less than 1.5mm T 2T 2t
1.5mm to 10mm 1.5 mm 2T 2t
10mm to <19mm 5mm 2T 2t
>19mm to <38mm 5mm 2T 2t

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.

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.

Position Qualification:

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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

7. 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)

8. 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.

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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).

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Page : 20/25 Complied By: Shahid Ali 0092-334-7497876 – 00966-599-7080-84
 Different Services Of Lines

A (Air). H (Hydrogen).
BBD (Boiler Blow down). HCL (Hydrochloric Acid).
BD (Blow Down). HO (Hydraulic Oil).
BFW (Boiler Feed Water). HSG (Hydrogen Sulfide Gas).
C (Chemical). IA (Instrument Air).
CA (Caustic). LO (Lube Oil).
CAS (Caustic sewer). PA (Process Air).
CS (Chemical Sewer). RL (Relief Line).
CW (Chilled Water). RW (Raw Water).
CWR (Cooling water return) S (Steam).
CWS (Cooling water supply) SA (Sulfuric Acid).
DMW (Dematerialized Water) SF (Sulfur).
DSW (Distilled water). SR (Sewer Storm).
DW (Drinking water). SW (Salt Water).
EIA (Emergency Instrument Air) SWS (Sanitary Sewer).
FG (Fuel Gas). TW (Treated Water).
HGH (High Pressure Fuel Gas) UA (Utility Air).
FGL (Low Pressure Fuel Gas). UW (Utility Water).
FLO (Flushing Oil). W (Water).
FW (Fire Water). WW (Waste Water).

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

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

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Preheat:
Preheat Temperature not be less than 10C
Preheat Temperature shall be established over a minimum distance 75mm of each side.
Temperature Equalization 1mint = For 25mm Thickness
When we required more than 93C Temperature in Preheat so we use Electrical Coil.

For (CS) P-1 Material:

10C < 25mm Thickness Pre-heat
79C > 25mm Thickness For CS
Flange = 52oC
Maximum Interpass Temperature: Pipe, Reducer, Elbo, Tee = 25 oC
P-1,3,4,5 315C Structural = 10 oC
P-3x, P-4x, P-8 177C

PWHT
Code exemptions for PWHT for P-No. 7 & P-No. 8 materials are not allowed at Saudi Aramco.
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%.

Sr # Material Thickness Temp C Soak Time

1 CS <20mm Not required
2 CS >20mm 593-649 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 593-635 1-Hr

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.

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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

Socket Welding:

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).

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.

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TIE-IN WORKS:-
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 & SATR

SAIC-W-2057 and SATR-W-2014

In Fillet Weld Convexity:-

Width of weld face Maximum convexity
W < 8mm 2mm
W > 8 to < 25mm 3mm
W ≥ 25mm 5mm

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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.

Essential Variable Supplementary Variable Non-Essential Variable

Parent Metal Vertical Position – 5G Groove Design
T-Qualified (Down hill / Uphill) Root Spacing
T>13mm
P No. Increase Preheat >55oC Size of Filler Metal in GTAW
PWHT (Time & Temp Range)
Filler Metal Heat Input Dia of Electrode SMAW,
F No. Dia of SMAW Electrode GMAW, SAW
A No.
Consumable Insert (GTAW)
Preheat decrease > 55oC Position
PWHT & Thickness Limits Gas Shielding Flow
Shielding Gas (GTAW, GMAW) Type of Fuel Gas
Transfer Mode (GMAW)
Tungsten Electrode
Stringer / Weave Technique
Gouging / Cleaning

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