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

SAIC NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST
Review of Positive Material Identification Program and
SAIC-L-2004 11-Dec-13 PIPING-
Testing Procedure
PROJECT TITLE CONTRACT NUMBER CONTRACTOR

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 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 PMI Program & Testing procedure shall contain the elements listed below as minimum: See Notes & Attachments
Procedure is identified and traceable to the project's updated list of
quality documents. This is a Special Construction Process.
Sch. Q,
A1
Detailed requirement for document identification shall be listed as Para. 3.1
addition or supplementary to this checkpoint upon approval of the
Project Document Control Procedure.

Procedure identifies S-PM-G000-1520-0006 requirements for Weld ID & S-PM-G000-

Database and ties PMI activities into a trackable reporting format. 1520-0006,
A2 PMI results are entered Section 8
into an approved Weld Database as a critical element for
completion of systems prior to testing. (Database)

B PMI program identifies the following, conforming to Sec. 7 of S-PM-G000-1520-0008 as follows: See Notes & Attachments

S-PM-G000-
B1 Pre-approval of the PMI operators. 1520-0008,
Para. 10.6
S-PM-G000-
B2 Alloy Materials and components 1520-0008,
Para. 7.1
S-PM-G000-
B3 Required Number of PMI tests (Per Application) based on Scope. 1520-0008,
Section 7
S-PM-G000-
B4 Elements of the basic alloy materials to be verified. 1520-0008,
Table 7.5
S-PM-G000-
B5 PMI testing of Welding Consumables (See Consumable Control also) 1520-0008,
Section 9
S-PM-G000-
B6 Acceptance Criteria (S-PM-G000-1520-0006 Database element) 1520-0008,
Sec. 12
S-PM-G000-
Rejection Procedures (S-PM-G000-1520-0006 Database element) See
B7 1520-0008,
Sect. D.
Sec. 13
S-PM-G000-
B8 Records and Reports (S-PM-G000-1520-0006 Database element) 1520-0008,
Sec. 14
S-PM-G000-
B9 Inspection requirements 1520-0008,
Sec. 15
Marking and color coding. Procedure details disposition for PMI when
piping material is received with MISSING/FADED/UNCERTAIN color S-PM-G000-
B10 code markings. Repainting stripes (cause for NCR/EDR) is never 1520-0008,
permitted unless Company Inspection is notified & approves. Sec. 16

C The PMI Test Method shall contain the following as minimum: See Notes & Attachments

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 S-PM-G000-
Identified the instrument and method to be used suitable to test the 1520-0008,
C1
applicable material specification. Para 11.2 to
11.4
S-PM-G000-
C2 Verification of operator's qualification prior to PMI testing. 1520-0008,
Para. 11.5
S-PM-G000-
C3 Calibration/verification of equipment performance. 1520-0008,
Para. 11.6
S-PM-G000-
Specified frequency interval & calibration procedure for
C4 1520-0008,
calibration/verification of the test equipment.
Para. 11.6
S-PM-G000-
C5 Location of test on welds. 1520-0008,
Para. 11.8
S-PM-G000-
C6 Surface Preparation of material to be tested. 1520-0008,
Para. 11.9

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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 3 (Standards Cutoff - June 2008) REV 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review of Positive Material Identification Program and
SAIC-L-2004 12/11/2013 PIPING-
Testing Procedure
PROJECT TITLE CONTRACT NUMBER CONTRACTOR

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

D Reject Resolution ... See Attachment 3 (PMI Failures, Inspection Tips, & Prevention (Lessons Learned)

As a condition of procedure approval, unacceptable PMI results shall be

addressed as follows to prevent widespread problems:
A) Welds found unacceptable shall require full investigation
and involvement by none other than the Quality Manager & Welding
Eng. B) COMPANY shall be full witness
and in full participation of any investigations/assessments to determine
the extent of PMI problems C) Welders making such Sch. Q,
welds shall be evaluated for consumable control practices along with the Att. VI
D1
entire consumable control practice. D) Where
consumables can be easily mixed, adequate segregation practices and Tables
controls shall be verified to be in place and effective. E)
Where deficiencies have been found, documented retraining and
corrective measures shall be taken by the Quality Manager. NCR!
F) Special Proactive measures are taken to assure
"TACKING" operations do not allow inadvertent mixture of welding
metallurgies.

Also, unacceptable PMI result investigations shall rule out the possibility
of defective Welding Consumable Lots immediately.
Random matls of same lot shall be welded & PMI
examined. Note: This can be a proactive
Sch. Q,
quality effort that occurs on initial use of welding consumables,
Att. VI
D2 especially alloys. Further proactive measures can include ordering one
type of electrode with alloying element or marking the ends (unique color
Tables
code) to prevent the inadvertent mixing of electrodes during welding.
After review of Form SATR-W-2010, it is easy to see that similar
electrodes can be easily mistaken if such precautions do not exist in the
field.
Relative to Item D1 (b), COMPANY shall be immediately notified Sch. Q,
of any PMI Test result that fails in order to rule out the Att. VI
D3
possibility of dilution of welds (Most common CuNi welding, utility
service). Tables
REMARKS:

NOTES: 1) See Attachment 1 for S-PM-G000-1520-0006 PMI Reqmts. PMI is tracked on a Per weld Basis and reported as per S-PM-G000-
1520-0008. This shall include Repairs, that receive a Unique ID Number or designation. Also, Reporting status & backlog reporting is required.
2) See Attachment 2 for S-PM-G000-1520-0008 PMI PROGRAM REQMTS, ELEMENT TABLE & SA Form 175
3) See Attachment 3 for PMI FAILURES, INSPECTION TIPS, & PREVENTION (LESSONS LEARNED)
4) QC Forms SATR-A-2012 & SATR-A-2013 or approved equivalency shall be utilized with the work
5) DEFINITION SECTION SHALL DEFINE BASIC ALLOYS IN TABLE 1. ASSURE ENGINEER & INSPECTORS KNOW CRITICAL DETAILS
ATTACHMENTS: Attachment 1 - S-PM-G000-1520-0006 DATABASE, PROCESS CONTROL TRACKING (By Weld)
Attachment 2 - S-PM-G000-1520-0008 PMI PROGRAM REQMTS, ELEMENT TABLE & SA Form 175
Attachment 3 - COMMON PMI FAILURES, ROOT CAUSES & RESOLUTIONS THAT EVERY INSPECTOR MUST KNOW
REFERENCE DOCUMENTS: 1. S-PM-G000-1520-0008, Positive Material Identification

Contractor / Subcontractor Saudi Aramco

Subcontractor QC Inspector COMPANY PMT Representative
Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:

Contractor QC Inspector COMPANY Inspector

Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:

Contractor QC Supervisor Proponent and Others

Quality Record Approved: T&I Witnessed QC Record Reviewed Work Verified
Name, Organization,
Name, Initials and Date:
Initials and Date:

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

Page 3 of 18
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 3 (Standards Cutoff - June 2008) REV 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review of Positive Material Identification Program and
SAIC-L-2004 11-Dec-13 PIPING-
Testing Procedure
Attachment 1 - S-PM-G000-1520-0006 DATABASE, PROCESS CONTROL TRACKING (By Weld)

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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 3 (Standards Cutoff - June 2008) REV 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review of Positive Material Identification Program and
SAIC-L-2004 11-Dec-13 PIPING-
Testing Procedure
Attachment 2 - S-PM-G000-1520-0008 PMI PROGRAM REQMTS & ELEMENT TABLE

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Attachment 2 - S-PM-G000-1520-0008 PMI PROGRAM REQMTS & ELEMENT TABLE

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Attachment 2 - S-PM-G000-1520-0008 PMI PROGRAM REQMTS & ELEMENT TABLE

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Attachment 2 - S-PM-G000-1520-0008 PMI PROGRAM REQMTS & ELEMENT TABLE

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Attachment 2 - S-PM-G000-1520-0008 PMI PROGRAM REQMTS & ELEMENT TABLE

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Attachment 2 - SA Form-175 PMI PROGRAM REQMTS & ELEMENT TABLE

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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 3 (Standards Cutoff - June 2008) REV 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review of Positive Material Identification Program and
SAIC-L-2004 11-Dec-13 PIPING-
Testing Procedure

Attachment 3 - PMI FAILURES, INSPECTION TIPS, & PREVENTION (LESSONS LEARNED)

1. NEVER ALLOW CuNi & SS (316, etc) to be done in same shop without careful consumable segregation.

2. CONSUMABLES & GRINDERS/BRUSHES/FILES MUST BE "COLOR CODED" FOR EACH DIFFERENT MATL

3. NEVER ALLOW grinders used on CuNi to be used on SS (316, etc). This can cause PMI failures/cracks.

4. ALWAYS VERIFY Cu (Copper) content in SS when performing PMI … If ANY possibility of mixing exists.

5. Cu (Copper) content in SS (316, etc) SHOULD NEVER EXCEED 0.7% IN ANY CASE. Lessons Learned.

6. ALWAYS USE A MAGNET TO CHECK RECEIVED SS HARWARE & SS MATERIALS & WELDS
7. 300 SERIES STAINLESS STEEL (High % Cr & Ni) DOES NOT ATTRACT A MAGNET (NON-MAGNETIC)

8. 400 SERIES STAINLESS STEEL (High % Cr & 1% or Low % Nickel) IS "VERY SLIGHTLY" MAGNETIC

9. Electroplated CS (Counterfeits substituted for SS) are strongly magnetic along with zinc plated items.

10. MARKINGS ON MATERIALS / HARDWARE / BOLTING ARE OFTEN WRONG (COUNTERFEIT ITEMS)

11. COUNTERFEIT HARDWARE IS COMMON NOW IN SAUDI ARAMCO IN ALL CONSTRUCTION DISCIPLINES

12. NEVER "ASSUME" VENDOR PMI TESTS ARE CORRECT, AS MOST PMI IS "VERIFIED" NOT WITNESSED.

13. PMI SHOULD BE DONE ON 100% OF ALL FITTINGS & PIPE "BEFORE FABRICATION" (TEST WELD ONLY)

14. IF MATERIALS ARRIVE WITHOUT REQD "PMI OK" MARKINGS PER SAES-A-206, REJECT THEM/VERIFY.

MAGNET TO FIND MIXED SS HARDWARE.

15. ON VESSEL INTERNAL INSTALLATIONS, USE A

16. ON SKID MOUNTED EQUIPMENT, USE A MAGNET TO FIND MIXED SS MATLS / HARDWARE.

17. ON RECEIVED FABRICATED PIPING, MAGNETS CAN IDENTIFY MIXED CONSUMABLES.

18. NEVER "ASSUME" VENDOR PMI TESTS ARE CORRECT, USE A MAGNET ANYWAY.

19. ALWAYS KNOW THE MATERIAL SPECIFICATION REQUIRED BEFORE INSPECTING IT.

20. ALWAYS KNOW THE MATERIAL SPECIFICATION MARKINGS REQUIRED BEFORE INSPECTING IT.

21. ALWAYS KNOW THE MATERIAL SPECIFICATION MAGNETIC PROPERTIES BEFORE INSPECTING IT.

22. ALWAYS KNOW YOUR CHEMICAL COMPOSITION REQUIREMENTS BEFORE REVIEWING RESULTS.

23. WHEN WELDING WITH 1% Ni or OTHER ALLOY ELECTRODES, PMI MUST BE DONE.

24. WHEN ANY POSSIBILITY OF CONSUMABLE MIXING EXISTS, EVALUATE / REVIEW OTHER ELEMENTS

25. THE # 1 CAUSE OF PMI FAILURES = CS CONSUMABLE (P-1) MIXING WITH LOW ALLOY STEEL (P-3/4/5)

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