saic-w-2038

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Review & Submittal of Existing WPS (CSD Previously Approved) ... Quality Manager Checklist (Action & Review)

Procedure Variables to be checked in detail:

SAES-W-012, Para. 7.2.6

For all automatic welding & any process with pulsing, the WPS shall include all applicable equipment and controller parameter settings.

C

B2Welding Procedure Qualification Hardness testing is required (sour service applications) with maximum allowable hardness VHN 250 per SASD AB-036386. Use Attachment 5 as a review aid.

SAES-W-012, Para. 7.5.1

C1

After approval by CSD, the package of welding procedures,qualification test records, & weld maps/tables may be approved for additional jobs by Inspection Dept. Project assigned Inspector will authorize the use of existing CSD-approved welding procedures if scope & essential variables are acceptable for the new application. Follow directions below for Existing WPS Package approval.

SAES-W-012, Para. 7.1.1

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

SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER30-Jun-08

PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

Review of WPS & Process Control Procedure (Pipelines) SAIC-W-2038 WELD-

EQPT CODE SYSTEM ID.

LAYOUT DRAWING NUMBER

PLANT NO.EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION

SCHEDULED INSPECTION DATE & TIME MH's SPENTQUANTITY INSP.ACTUAL INSPECTION DATE & TIME

SAUDI ARAMCO USE ONLYTRAVEL TIME

EC / PMCC / MCC NO.REV. NO. PURCHASE ORDER NUMBER

SAUDI ARAMCO INSPECTION LEVEL

SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?

CONTRACTOR INSPECTION LEVEL

ITEM No. ACCEPTANCE CRITERIA RE-INSP DATEN/APASSREFERENCE FAIL

A

A1

For shop and all field fabrication IK, NEW WPSs & PQRs are prepared* and submitted using the correct SA Welding Forms: A) Attachment 1 - SAES-W-011/012 WELDING PROCEDURE SPECIFICATION (ATTACHMENT A, PAGES A1, A2, A3, A4, A5) B) Attachment 2 - SAES-W-011/012 WELD & LINE DESCRIPTION TABLE (ATTACHMENT B). For New Procedures (Master Set), follow Attachment 3 rules. C) If previous CSD-approved WPS is reused. See Section C.

SAES-W-012, Para. 7.2.1

SAES-W-012, Para. 7.1.10

SAES-W-012, Para. 7.2.5 a)

SAES-W-012, Para. 7.1.11

All WPSs & PQRs shall conform to the latest edition of the relevantCode (API STD 1104 or ASME SEC IX, as appropriate).

SAES-W-012, Para. 7.1.3 & 4

SAES-W-012, Para. 7.1.2

Instructions for Approval (Responsibilities) ... Quality Managers shall see Notes 1 & 2 at end of this checklist

A2

A6Welding of qualification test coupons shall be monitored by either an approved independent test laboratory or independent TPI. Monitoring shall include verification of accuracy of the recorded parameters.

A5 Originals of all test records, mill certificates, etc. including records from independent test laboratory are available for review by SA.

Complete Weld Table (Attachment B) listing all mat'ls, thicknesses, & weld joint types for individual line designations, shall be submitted along with the WPS & PQR documents for each job.

A3

A4PQRs shall include certified copies/facsimiles of all test records for IK qualification, (the TPI testing agency that issued the test record shall certify the copies).

B1 Procedure Variables meet the detailed reqmts of SAES-W-012, Section 7.4 & 7.5. Use Attachment 5 as a thorough review aid.

SAES-W-012, Section 7.4

A7PQR mechanical tests and examinations shall be performed by approved independent test laboratory, unless Fabricator is specifically approved by OID to perform their own tests.

SAES-W-012, Para. 7.2.5 b)

B

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Check for Charpy Impact requirements, comparing old and new applications, carefully checking test temperature and impact test values ... Ranges often vary & require requalification.


CONTRACTOR / SUBCONTRACTORPROJECT TITLE WBS / BI / JO NUMBER

DATE APPROVED

Review of WPS & Process Control Procedure (Pipelines) SAIC-W-2038 5-Nov-08 WELD-

QR NUMBERSAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER

RE-INSP DATE

C Review & Submittal of Existing WPS (CSD Previously Approved) ... Quality Manager Checklist (Action & Review)

C8 Check Service & Materials (scope) for Hardness Reqmts, comparing the old and new application.

ITEM No. ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A

Existing P-No. 1 WPS (GTAW/SMAW) without Heat Input reqmt: Revise without requalification of procedure, follow request below: A) Specify in WPS Technique Section (QW 410), under Maximum weave width, the following: 3 x electrode diameter. Note 1: Revisions are legibly handwritten or typed, signed & dated. Note 2: Bead widths over 5 x electrode diam. (excess weave width) can adversely affect weld quality (poor technique). Instruct welders to follow 3 x electrode diameter, & never exceed 5 x electrode dia. Note 3: If Heat Input measurement is req'd , Heat Input reqmts will control weave width (technique). Ensure that travel speeds are closely monitored along with proper bead width for good HI values. Note 4: Weave widths exceeding 5 x dia. result in quite significant reduction in notch toughness test results. (This is unacceptable).

SAES-W-012, Para. 7.1.1

SAES-W-012, Para. 7.1.1C9

C10

C11

NOTICE: ERRORS EXIST IN SAES-W-012 PREHEAT TABLES. NEW & EXISTING WPS SHALL BE REVISED PER ATTACHMENT 6. Background: The 28 February 1998 edition was revised and the following "copy and paste error" was made in welding standards. Preheat Values of Table 4A/4B (Vertical Down SMAW Butt Welds) are identical to Table 3A/3B (Vertical Up SMAW Butt Welds).This is incorrect as higher preheat is needed for vertical down position. Utilize February 1998 Table 4A/4B immediately on project . See Attachment 3 of this Checklist for correct table values. This will result in higher preheats. Train welders accordingly.

As referenced, Attachment 3,

Contact CSD as needed to verify SAES-W-012,

Para. 7.1.1

The following revisions apply to all existing WPS. QA/QC Mgrs. shall take immediate action for revision as needed.

C2

Note:

As referenced, Contact CSD on

any welding technical questions

SAES-W-012, Para. 7.1.1

SAES-W-012, Para. 7.1.1

CSD APPROVAL COVER SHEET LISTS APPROVAL STATUS & CONDITIONS WITH ALL CSD COMMENTS. SUBMIT THIS COVER SHEET ALONG WITH DETAILS OF THE INTENDED APPLICATION: A) Complete Page A1, Request Welding Procedure Approval It must be complete in entirety (Design Details) & Project Specific. B) Complete Attachment B, Weld & Line Description Table Service description & line class information details are provided. Note 1: New Application is compared against CSD-approved docs. Note 2: If the CSD approval cover sheet is not available, the WPS cannot* be approved by PID. Request a copy from CSD providing the CSD Log Number on all requests. * CSD Notes are mandatory . C) All existing WPS, PQR, Attachments (A1, B) are submitted as one package (Incl. NEW Attachment A1, B) for approval.

SAES-W-012, Para. 7.1.1

C5 Per QW 403 & 450, Check Thickness range, comparing the old and new application.

SAES-W-012, Para. 7.1.1

SAES-W-012, Para. 7.1.1

C3Each Weld and Line Description Table (Att. B) must be complete and show line designations (service), materials, joints, & WPS used forthe NEW APPLICATION.

C4 Check Material requirements (compare old & new application), using ASME IX, WPS (QW-403) for P-No, Group No., Spec & Grade

Note: CSD HAS IDENTIFIED 6 SELECTED VARIABLES FOR CLOSE REVIEW OF WPS (MOST COMMON CAUSE OF WPS REJECTION)

SAES-W-012, Para. 7.1.4

Per QW 403, Check Pipe Diameter range, comparing the old and new application.

30-Jun-08

C7

SAES-W-012, Para. 7.1.1

Per QW 407 & Service Application (Form Page A1), Check PWHT, comparing the old and new application.

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DATE APPROVED


QR NUMBERSAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER30-Jun-08

C15

CSD approved WPS with essential variables that include the restriction of electrodes (Per Attachment 5) are "noted": A) G Designated Electrodes are restricted to the exact brand & type specified on the PQR & WPS. B) WPS & PQR with Impact Toughness Reqmts use the same brand name & type GMAW electrode, SAW flux & FCAW electrode. C) Change in filler metal or deposit chemistry from A-No. 1 to A-No. 2 (ASME SECT IX) Note: Requalify Sour Service Procedures WPS Notes shall specify that substitutions are not allowed and exact brand name and type consumable shall be used. Plan Consumable substitution approvals by CSD. Do not wait until designated & required consumables are gone.

SAES-W-012, Section 7

D3 Review of Welder & Welding Operator Certs (Pipelines) & Review of welder performance. See SAIC-W-2039 Att. 2

SAIC-W-2039

D6 Welding Machine Calibration per BS7500 for Pipelines

D4 Weld Repair Procedure (Including WPS) SAIC-W-2040

SAIC-W-2045, SATR-W-2011

D5Weld Joint ID & Database (Status, Reporting) per SAEP-1160* SATR-W-2008, SATR-W-2013, SATR-W-2018, SATR-W-2019 can be eliminated if Database gives an acceptable report format

SAIC-W-2008

D8 Procedure for Buttering and/or Weld Buildup SAIC-W-2047

D9 Pre-Welding & Fit-Up Inspection (& How WPS is monitored) Disposition for Repairs - Alignment Tolerances. See Note 3.

SAIC-W-2048 SATR-W-2006

D7

Welding Consumable Control (Pipelines) A) Receiving Inspection (SAIC-W-2044) (SATR-W-2020)B) Storage & Handling (SAIC-W-2046) C) Consumable Issuance & Control (SAIC-W-2055) (SATR-W-2010)D) Calibration of Electrode Oven, Baking & Portable (SAIC-W-2055) Note: Use SATR-W-2009 for Report Form (Calibration)E) GTAW Tungsten Electrode use, care, restoration (SAIC-W-2049) F) GTAW Purging Consumables (Gas, Purge Dams) (SAIC-W-2049) SAIC-W-2049 Attachment 1 covers GTAW Consumables

SAIC-W-2055

D2 WPS & PQR (Review) for Welding Master Sets SAIC-W-2038

WPS using ER70S-6 filler mat'l (GTAW, GMAW Process) are revised without WPS requalification (unless impact tests are req'd) as directed below (CSD has approved this direction): A) Substitute ER70S-2 for ER70S-6 (GTAW Process) B) Substitute ER70S-3 for ER70S-6 (GMAW Process) See Attachment 4.

D1

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

Schedule Q, Attachment VI,

Special Process Tables

C14

WPS using Internal & External Field applied FBE Coatings shall be CSD approved. The process shall be GMAW STT or GTAW to assure the following criteria: All weld joints including adjacent areas to be FBE coated either Internal or External shall be ground smooth and free from burrs, weld spatter, sharp edges. Weld toes shall be merged smoothly and rounded with no sharp undercuts. Weld cap or internal root protrusion shall not be more than 1.5 mm. WPS provides adequate field instruction.

SAES-H-201, Para. 7.2.2

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

C12

This exists for every type welding joint covered by a WPS. A) See SAIC-W-2037 for socket welding requirements. B) See SAIC-L-2015, SAIC-W-2037 for seal welded thread jts C) See SAIC-L-2013 for welding of branch connections. D) See SAIC-L-2144 for Pipeline repair sleeve applications. 1) Instructions are available at all sites where welding is done. 2) Instructions can be written in or attached to WPS or may be in a Welding Process Control Procedure covering all welding activity. 3) Those responsible for implementation are adequately trained.



Para. 7.1.1

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Para. 7.1.1

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DATE APPROVED


QR NUMBERSAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER30-Jun-08

Attachment 6 - SAES-W-012 TABLE 4A/4B - PREHEAT TEMPS. VERTICAL DOWN SMAW BUTT WELDS (NOTICE OF ERROR IN SA STDS)

REFERENCE DOCUMENTS: 1. SAES-W-012, Welding Requirements for Pipelines, (31 December 2002)2. SAEP-352, Welding Procedures Review and Approval, (31 May, 2003)

Attachment 2 - SAES-W-011/012 WELD & LINE DESCRIPTION TABLE (ATTACHMENT B)

Attachment 3 - SAEP-352 Welding Master Set Preparation & Approval (Instructions)

Attachment 4 - NACE RP-0472 Table 2: Process/Filler Material Combinations Exempt from Weld Deposit Hardness Testing

Attachment 5 - WPS PROCEDURE VARIABLES (SAES-W-012, Section 7.4)

Certain procedure elements (heat input, wps monitoring, associated forms, etc) are also provided as applicable to scope.

3) Alignment Tolerances & Disposition of Repairs shall be addressed during Pipe Stringing. See SAIC-W-2048.

4) Structural steel welding (AWS D1.1 related) on Pipelines shall utilize SAIC-M-2012. See SAIC-M-2012.

ATTACHMENTS: 1 - SAES-W-011/012 WELDING PROCEDURE SPECIFICATION (ATTACHMENT A, PAGES A1, A2, A3, A4, A5)

Remarks:

NOTES: 1) See Section "C" regarding Existing WPS (whether approved or not). Follow all specifics. Contact CSD on any technical matter

related to Welding. Contact your Project Inspection Representative on any checklist question for Welding. QA/QC Mgr. Action Required!

2) QA/QC Mgr shall ensure a detailed Welding Process Control Procedure per Section D is established. See item D1.

D13

D14 Temperature Tie-In Welding SAIC-W-2057, SATR-W-2014

Production Weld & Welder Repair Rate Assessment SAIC-W-2056

D12 Inspection of Weld Repairs (Repair Verification) SAIC-W-2051

Post-Welding Visual Inspection

D10 In-Process Welding Inspection (Heat Input Measurement) SAIC-W-2049

D11 SAIC-W-2050 SATR-W-2007

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

Name, Initials and Date:T&I Witnessed

Work Verified Quality Record Approved:Name, Sign and Date:

Performed InspectionName, Initials and Date:

Name, Organization,Initials and Date:

T&I Witnessed QC Record Reviewed

QC Record Reviewed

Proponent and Others

Work Verified

Work VerifiedT&I Witnessed QC Record Reviewed

Work / Rework May Proceed

QC Supervisor

QC Inspector PID Representative

Name, Initials and Date:Name, Initials and Date:Work is Complete and Ready for Inspection:

Contractor / Third-Party Saudi AramcoConstruction Representative* PMT Representative

saic-w-2038

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