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ARAMCO Interview 2015 PDF
ARAMCO Interview 2015 PDF
ARAMCO Interview 2015 PDF
Quality Control is the operational techniques i.e (Inspection, Testing & Examination) that are used
to fulfill requirement for quality.
What is ITPs?
ITP: ITP means Inspection and Test Plan.
Details of work scope and required types of inspections
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 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 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
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
ASME SECTIONS
Page : 3/15 Written By: Shahid Ali
(ASME - American Society of Mechanical Engineers)
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
P – Numbers:-
To reduce the number of welding procedure qualification required, BASE METALS have been assigned
P – Numbers. These assignments are based essentially on comparable base metal characteristics, such as
Chemical composition, Weld ability and Mechanical properties. (P No.2 is not applied)
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.
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.
Position Qualification:
Pipe — Groove
1G F
2G F,H
5G F,V,O
6G All
2G and 5G All
Thickness:
Qualification based on 2T formula
GTAW process is mandatory for all Lines that will be less than 24” in Dia.
Page : 6/15 Written By: Shahid Ali
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
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.
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.
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.
Page : 7/15 Written By: Shahid Ali
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.
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.
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
Contractor shall assure electrode issue control follows a "First In, First Out" Rule.
Check E6010 storage closely.
Zirconated (Brown) or Pure (Green) Use for AC (Cooper / Alloy, Mg, Mi, Plain Carbon, SS)
Thoriated (Red) Use for DC-ve (Steel & Most Metals)
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)
Tack Weld:
Thickness = 3.2 to 4.8
Length = 12.5 to 25.4
Important:
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).
PMI (Hand Held Spectrometer) results showing Copper Content greater than 0.7% indicate
unacceptable "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.
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%.
Note: P No. 7 (High Alloy Ferritic stainless steel) & 8 (Austenitic stainless steel.) Not Done PWHT
For PWHTs that are not performed in a furnace, 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.
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.
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.
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)
NOTE: Internal tapering (ASME B31.3) by machining, backwelding, 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).
For steel piping in hazardous services, threaded and socket welding fittings shall conform to ASME
B16.11 Class 3000, Class 6000 or higher and
Pipe unions shall be limited to Class 3000 threaded or socket welding forged steel unions in
accordance with MSS SP-83
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.
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.
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
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 mins (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.
Welds are completed before welding
3CS1P
First = Pressure rating
Second = Pipe Material
Third = Corrosion Allowance
Forth = Service
An example of a complete piping line class designator is "3CS1P". This designator specifies an ASME
pressure class 300, carbon steel piping system with 1.6 mm corrosion allowance designed for general
process service with no changes to the base piping line class material specification.
2. Tee Used to make a Branch Line at Right Angle to the Main line
Equal Tee
Reducing Tee
3. Reducer Normally where do we use the following?
i. Eccentric reducers
Pump suction to avoid Cavitations, To maintain elevation (BOP) in rack.
ii. Concentric reducers = Pump discharge, vertical pipeline etc.
What are Weld olet and Sock olet, and where they are used?
Ans: Weld olet and Sock olet are basically self reinforced fittings.
Weld olet is used for Butt weld branch connection where standard tee is not
available due to size restrictions and the piping is of critical / high pressure
service .
Sock olet is used for socket welding branch connection, which require
reinforcing pad.
Which piping items will you drop down before conducting Flushing and Hydro-test?
Items like Control Valve, Orifice plates, Rota meters, safety valves, Thermo wells are dropped or
replaced with temporary spools before hydro test.
What is the normal upstream and downstream straight length of orifice flow meter?
Upstream - 15D Downstream - 5D