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
Review WPS & Process Control Procedure (Plant Piping) SAIC-W-2001 15-Dec-09 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 Instructions for Approval (Responsibilities) ... Quality Managers see Notes 1 & 2 at end of this checklist
CSD previously approved WPS(s) & any new or proposed WPS(s)
intended for project use are compiled into a Welding Master Set (WMS)
SAES-W-011,
for IK Projects.
Para. 7.1.1 &
A1 Follow SAEP-352, Appendix 1 instruction. See Attachment 1.
SAEP-352
Allow
Appendix 1
adequate time (in weeks) for CSD review & approval stage.
Individual WPS & PQR are prepared using correct SA Forms:
A)
Attachment A - SAES-W-011/012 Welding Procedure Spec (See
attachment A, PAGES A1, A2, A3, A4, A5)
B) Attachment B - SAES-W-011/012,
Weld & Line Description Table (See ATTACHMENT B). SAES-W-011,
Note: SA CSD performs Para. 7.1.1 &
A2
technical approval of all WPS & indicates such approval on each and SAEP-352
every page of the WPS (requirement). SA PID performs Appendix 1
approval based on the intended WPS application. See Section C for
specific checks relative to the WPS application.

All WPSs & PQRs conform to the latest edition of ASME IX.
SAES-W-011,
CAUTION: WPS intended for re-use previously
Para. 7.1.2 &
A3 approved before 2003 & 1st Edition of SAEP-352 shall be resubmitted in
Para.
a Welding Master Set. Revise & requalify older WPS as req'd per ASME
7.2.1
code
Weld & Line Description Table (Attach. B) lists:
A) Matls, thickness, & weld joint type for
individual line designations. B) A welding procedure shall be
listed for each different weld type and line designation.
C) All base SAES-W-011,
A4
materials (by spec, grade, P-No, Piping Diameter range) and wall Para. 7.1.3
thicknesses to be used shall be included in the Weld Table.
D) Weld Table shall only be reviewed with WPSs and
PQRs and and vice-versa.

Each Weld Table shall be completed & show all line designations to be
used for the entire complete job or contract.
Note : Line Service designation ("sour", non-sour, Internal FBE
SAES-W-011,
A5 Coated, Impact tested CS, Severe Cycle or Category M service, & other
Para. 7.1.4
special service considerations such as Hardness Testing & PWHT shall
be so designated in the Attachment B. Utilize the Remarks Section as
needed.

Welding shall not commence until the welding package has been
approved for application by Saudi Aramco Inspector & returned to
the fabricator. Any welding prior to the approval of the welding SAES-W-011,
A6
package is subject to rejection at the sole option of Saudi Aramco Para. 7.1.5
Inspector. Any rework required as a result of this rejection shall be at the
fabricator's expense.

After approval by SA Inspector, fabricator shall issue copies of the

approved Welding Procedures & Weld Table to SA Inspection and PMT SAES-W-011,
A7
prior to the start of fabrication. Para. 7.1.6

Page 1 of 27
 Approval of welding procedures shall not be construed as authority for
deviation from listed specifications or requirements of relevant SAES-W-011,
A8
codes and standards and shall not relieve the contractor, fabricator, or Para. 7.1.7
vendor from correcting any deviations.

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SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review WPS & Process Control Procedure (Plant Piping) SAIC-W-2001 15-Dec-09 WELD-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
All WPSs, PQRs, & Weld Table shall be available at work site for SAES-W-011,
A9
verification at any time by the authorized Saudi Aramco inspector. Para. 7.1.8

All Welding Procedure Specifications and Welding Procedure SAES-W-011,

A10
Qualification Records shall be written in English. Para. 7.1.9

PQRs shall include certified copies/facsimiles of all test records

(for In-Kingdom qualification, the independent testing agency that SAES-W-011,
A11
issued the test record shall certify the copies), which may be Para. 7.1.10
permanently retained by Saudi Aramco*. *CSD shall retain these.

Originals of all test records, mill certificates, etc. including records from SAES-W-011,
A12
independent test laboratory are available for review by SA. Para. 7.1.11

For In-Kingdom qualifications:

a) The welding of all qualification test coupons shall be monitored
by either an approved independent test lab, an independent third party
approved by Saudi Aramco, or SA Inspection. The monitoring shall
SAES-W-011,
A13 include verification of accuracy of the recorded parameters.
Para. 7.2.5
b) All procedure qualification mechanical tests and examinations
shall be performed by an approved independent test laboratory
unless the fabricator is specifically approved by Saudi Aramco
Inspection to perform their own tests.

For all automatic welding and any process with pulsing, welding
SAES-W-011,
A14 procedures shall include all applicable equipment and controller
Para. 7.2.6
parameter settings.

Special applications determined by CSD, such as but not limited to

severe corrosion service (e.g., chlorinated seawater) or high temp
service, special qualification tests (stress corrosion cracking or SAES-W-011,
A15
embrittlement tests for low alloy steels) may be specified by CSD. Para. 7.3
Confirm : Review job & contract specs or purchase order for
same

B Procedure Variables to be checked in detail (Procedure Qualification & Intended Application Checks):

Welding Procedure Variables meet SA reqmts for the new

application including:
A) Procedure Variable Restrictions (Section 7.4)
B) Impact Testing (Charpy) Requirements (Section 7.4.13 & 7.4.4) SAES-W-011,
B1
C) Hardness Tests (Section 7.5) & PWHT Section 7
(Section 7.5, 13.3 & 13.8) D)
Preparation of Test Coupons (Section 7.6) See
Attachment 2 for detailed text.

C Review & Submittal of Existing WPS to PID (CSD Previously Approved)

After approval by CSD, the package of welding procedures,

SAES-W-011,
qualification test records, & weld maps/tables may be approved for
Para.
additional jobs by Inspection Dept. Project assigned Inspector will
C1 7.1.1 &
authorize the use of existing CSD-approved welding procedures if scope
SAEP-352,
& essential variables are acceptable for the new application.
Para. 5.1 a)

Submit CSD approved cover sheet showing approval status &

conditions/comments along with the details listed below for PID approval.
A) Request
Welding Procedure Approval (Complete Page A1), It
must be complete in entirety (Design Details) & Project Specific.
B) Weld & Line Description Table (Complete
Attachment B,) Service description & line SAES-W-011,
C2 class information details are provided. Para.
Note 1: New Application is compared against CSD-approved 7.1.1
docs. Note 2: CSD approval cover sheet is an requirement
& no WPS can be approved with out the same(CSD Log Number &
approval shall be indicated in all pages of the WPS).
Note : C) All existing WPS, PQR,
Attachments (A1, B) are submitted as one package (Incl. NEW
Attachment A1, B) for approval.

D WELDING PROCESS CONTROL PROCEDURE (COVERS ALL WELDING RELATED ACTIVITY OTHER THAN THE WPS)

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

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER

Review WPS & Process Control Procedure (Plant Piping) SAIC-W-2001 15-Dec-09 WELD-
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

Welding related activities other than the actual WPS are identified and
controlled (Special Construction Process) by Procedure. Option exists for Schedule Q,
a single procedure (Welding Process Control) or multiple procedures
covering the remaining elements in Section D below. Attachment VI,
D1
A single Procedure is recommended for efficiency. All
SAIC are referenced in this procedure. Use the specific checklists. Special Process
SAEP-1160 Weld ID & Tracking System (Database) Tables
required.

D2 WPS & PQR (Review) for Welding Master Sets SAIC-W-2001

D3 Review of Welder & Welding Operator Certs (Plant Piping) SAIC-W-2035

SAIC-W-2002
D4 Weld Repair Procedure (Including WPS)

Weld Joint ID & Database (Status, Reporting) per SAEP-1160*

SATR-W-2008, SATR-W-2013, SATR-W-
D5 SAIC-W-2008
2018, SATR-W-2019 can be eliminated if Database gives an
acceptable report format
SAIC-W-2011,
D6 Welding Machine Calibration per BS7500 for Plant Piping
SATR-W-2011

Welding Consumable Control (Plant Piping)

A) Receiving Inspection (SAIC-W-2010) (SATR-W-2020)
B) Storage & Handling (SAIC-W-2032)
C) Consumable Issuance & Control (SAIC-W-2032) (SATR-W-2010)
D) Calibration of Electrode Oven, Baking & Portable (SAIC-W-2009) SAIC-W-2009
D7 Note: Use SATR-W-2009 for Report Form
(Calibration)
E) GTAW Tungsten Electrode use, care, restoration (SAIC-W-2006)
F) GTAW Purging Consumables (Gas, Purge Dams)
(SAIC-W-2006) SAIC-W-2006 Attachment 1
covers GTAW Consumables

D8 Procedure for Buttering and/or Weld Buildup (Plant Piping) SAIC-W-2033

SAIC-W-2005
Pre-Welding & Fit-Up Inspection (& How WPS is monitored)
D9 SATR-
Disposition for Repairs - Alignment Tolerances. See Note 2.
W-2006

D10 In-Process Welding Inspection (Heat Input Measurement) SAIC-W-2006

SAIC-W-2007
D11 Post-Welding Visual Inspection
SATR-W-2007
D12 Inspection of Weld Repairs (Repair Verification) SAIC-W-2013

D13 Production Weld & Welder Repair Rate Assessment SAIC-W-2016

Remarks:

NOTES:
1) Structural steel welding (AWS D1.1 related) on Pipelines shall utilize SAIC-M-2012. See SAIC-M-2012.
ATTACHMENTS:
Attachment 1 - SAEP-352 Welding Master Set Preparation & Approval (Instructions)
Attachment A - SAES-W-011/012 WELDING PROCEDURE SPECIFICATION (ATTACHMENT A, PAGES A1, A2, A3, A4, A5)
Attachment B - SAES-W-011/012 WELD & LINE DESCRIPTION TABLE (ATTACHMENT B)
Attachment 2 - WPS PROCEDURE VARIABLES (SAES-W-011, Section 7.4, 7.5 & 7.6)
Attachment 3 - NACE SP-0472 Table 2: Process/Filler Material Combinations Exempt from Weld Deposit Hardness Testing, 2008
REFERENCE DOCUMENTS: 1. SAES-W-011, Welding Requirements for On-Plot Piping, 30 March 2005
2. SAEP-352, Welding Procedures Review and Approval, 31 May, 2003

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 4 of 27
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
Review WPS & Process Control Procedure (Plant Piping) SAIC-W-2001 15-Dec-09 WELD-

Attachment 1 - SAEP-352 Welding Master Set Preparation & Approval (Instructions)

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
Review WPS & Process Control Procedure (Plant Piping) SAIC-W-2001 15-Dec-09 WELD-

SAES-W-011/012 WELDING PROCEDURE SPECIFICATION (ATTACHMENT A, PAGES A1, A2, A3, A4, A5)
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
Review WPS & Process Control Procedure (Plant Piping) SAIC-W-2001 15-Dec-09 WELD-
SAES-W-011/012 WELD & LINE DESCRIPTION TABLE (ATTACHMENT B)
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
Review WPS & Process Control Procedure (Plant Piping) SAIC-W-2001 15-Dec-09 WELD-

Attachment 2 - WPS PROCEDURE VARIABLES (SAES-W-011, Section 7.4, 7.5 & 7.6)
Attachment 2 - WPS PROCEDURE VARIABLES (SAES-W-011, Section 7.4, 7.5 & 7.6)
Attachment 2 - WPS PROCEDURE VARIABLES (SAES-W-011, Section 7.4, 7.5 & 7.6)
Attachment 2 - WPS PROCEDURE VARIABLES (SAES-W-011, Section 7.4, 7.5 & 7.6)
Attachment 2 - WPS PROCEDURE VARIABLES (SAES-W-011, Section 7.4, 7.5 & 7.6)
Attachment 2 - WPS PROCEDURE VARIABLES (SAES-W-011, Section 7.4, 7.5 & 7.6)
Attachment 2 - WPS PROCEDURE VARIABLES (SAES-W-011, Section 7.4, 7.5 & 7.6)
SEE ASME B31.3 PWHT TABLE 331.1.1 … P-No 4 / 5 Code Exemptions do not apply
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
Review WPS & Process Control Procedure (Plant Piping) SAIC-W-2001 15-Dec-09 WELD-
Attachment 3 - NACE SP-0472 Table 2:
Process/Filler Material Combinations Exempt from Weld Deposit Hardness Testing
ASME SEC II C (SFA 5.18) & ER70S-6 "Description" below.
A7. Description and Intended Use of Electrodes and Rods
A7.4 ER70S-6: Electrodes and rods of the ER70S-6 classification are intended for both single and multiple-pass
welding. They are especially suited for sheet metal applications, where smooth weld beads are desired,
and structural and plate steels that have moderate amounts of rust or mill scale.
A7.1 ER70S-2: Electrodes and rods of the ER70S-2 classification are primarily used for single-pass welding of killed,
semi-killed, and rimmed steels, but may be used for some multipass applications.
ER70S-2 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. (GTAW, for sure = ER-70S-2)
A7.2 ER70S-3: Electrodes and rods of the ER70S-3 classification are intended for welding single-pass & multi-pass
welds. Typical base metal specifications are often the same as those for the ER70S-2 classification. Electrodes of
ER70S-3 classification are the most widely used of GMAW electrodes classified under this specification.
SAES-W-012, Section 6 (Welding Consumables)
Para. 6.1 Electrodes, filler wires, and fluxes shall conform to ASME SEC IIC. What does "conform" mean?
WELDING APPLICATIONS
Simply, ER70S-6 runs smooth (it's great for sheet metal per ASME/AWS), but clearly we don't have many
sheet metal pipelines in Saudi Aramco. So choose an application ER70S-2 (GTAW) or ER70S-3 (GMAW)
that conforms to ASME SEC II C. Don't allow hardness values to fall above minimum reqmts causing PWHT repair.
ASME SEC II C & NACE SP0472

SAES-W-11 : 14 Production Weld Hardness Testing

14.1 Testing shall be in accordance with NACE SP0472 and the requirements listed below. Exemptions with respect to welding process and
consumables are not allowed.